Ford Mustang V8 1964 thru 1973. Automotive Repair Manual

Citation preview

36048 (357)

• •

•

Ьу

J

Н

Haynes

Member of the Guild of Motoring Writers

Вгисе Gilmour аnd Мarcus S

Daniels

Models covered: AII Mustang va models •

ISBN

О

85696 357 7 •

©

Haynes North Ameгica, 'пс. 1979 With permlssion

•

'roт

J.

Н . Науп еs

& Со. Ltd .

All rlghts reselVed. No part of this book тау ье reproduced ог transmlned '" апу form ог Ьу апу meenl, elec:tronlc ог mechenlcal, Includlng photocopylng, recordlng ог bv апу information Itorвge ог retrlвvaJ .уяет. wlthout permllllon 1" wrltlng from the copyrlght holder. Pгinted

in the USA "СОЕ

(10Z3 - 36048) (357)

'OНU

ю.мNO РО

,

•

Haynes PubIishing Group Spaгkfoгd Nr Yeovil Someгset ВА22 7JJ

England

Haynes North America, Inc. Lawгence Dгive Newbuгy Paгk Califoгnia 91320 USA

861

•

Acknowledgements Thanks аге due to the Ford Motor Сатрапу in the USA 10г the supply of technical iпfОП11аtiоп and certain iIIustrations. Тhe bodywork

repair photographs used in this

Мапиаl

were provided

Ьу

Lloyd's

Industries Umited who suppJy "Turtle Wax", "Dupli-color Holts", and other Holts range products.

Special thanks аге al50 due to all those people at Sparkford and in the USA who helped in the ргoduсtiоп of this Manual. Par1icular1y, these аге Brian Horsfall and Les Brazier who carried out the mechaniсаl work and took the photogгaphs respectively, Pete Ward who edited the text and Stanley Randolf who planned the page layout.

About this manual Its aims The aim of this Мапиаl i5 to help you get the best value from your саг. It сап do за in sеуегаl ways. It сап help you decide what work mU5t Ье done (еуеп should you choose to get it done Ьу а repair statlon), provide "in10rmation оп routine maintenance and servicing, and give а logical course 01 action and diagnosis when random 1ault5 occur. However, It is hoped that you will use the Manual Ьу tackling the work yoursel1. Оп 5impler jobs it тау вувп Ье quicker than booking the саг Into а гераlг station, and яо1пя there twlce to 'еауе and collect It. Perhaps most impOr1ant, а lot of money сап Ье saved Ьу avoiding the costs the garage must charge to соувг it5 lаЬог and overheads. The manual has drawings and descriptions to show the function of the varlous components so that their layout сап Ье understood. Then the tasks аге described and photographed in а step-by-step sequence 50 that еуеп а поУlсе сап do the work.

Its arrangement The Мапиа' Is divlded Into twelve Chapters, еас" covering а logical sub-dlvislon 01 the vehicle. The Chapters аге each dlvided Into

Sections, numbered with single ligures, ео 5; and the Sections into paragraphs (ог sub-sесtiопsJ, wlth decimal numbers 10Howing оп Irom the Section they аге in, ео 5.1, 5.2, 5.3 etc. It is 1гее1у illustrated, езресiаllу in those par1s where there Is а detailed sequence 01 operations to Ье carried out. There аге two 10гms 01 illustгation: figuгes and photographs. The figures аге numbered in 5equence with decimal пumЬегз, accordlng to their position in the Chapter: eg Fig. 6.4 is the 4th drawing!i1Iustration in Chapter 6. Photographs аге numbered (either individually ог in related groups) the same as the Section ог 5ub-section 01 the te)(t where the operation they show 15 de5cribed. There Is ап alphabetical inde)( at the back 01 the manual as well as а contents 11st at the front. References to the 'left' ог 'rlght' 01 the vehicle аге in the sense 01 а регзоп in the driver's seat 1acing 10rwards. Whilst every саге i8 taken to еП8иГ8 that the Informatlon in thi8 manual i8 correct по liabIlity сап Ьв 8ccepted Ьу the 8uthors ог pubIishers for 1088. damage ог injury caused Ьу апу еггов in. ог omissions from. the information given,

Introduction to the Ford Mustang The orlginal Mustang design was created Ьу Ford's chie1 stylist Joseph Огоз and when the finished саг was introduced to the market 1п April 1964 it caused еуеп тоге interest and e)(citement amongst the Amerlcan motoring 1raternity than Its predecessor the Thunderbird. With its гасу and definitely masculine арреагапсе , the low price t8g and not least the e)(cellent cholce 01 name, the Mustang was а phenomenal success. 'П fact, Ьу 1966, the sales ligures were nearing the two million ligure. When lirst introduced, the Mustang was available with ап option 01 1оиг engine capacities. For the owner with good gas mileage иррег­ mозt in mind, Ford offered the 170 си in ог 200 си in six-cylinder engines, while the 260 си in and 289 си in V8 engines were available to the customer whose prime consideration was acceleration. For those who required еуеп тоге power beneath the hood, а tuned version 01 the 289 cu in engine was obtainabIe which developed 271

brake horsepower at 6000 грт. Beneath the attractive bodyshell the mechanical layout 01 the Mustang was quite conventional, comprising а Iront-mounted engine driving the геаг wheels via the transmission unit, driveshaft and differential unit. А choice of either three- ог 10ur-speed manual transmission, ог three-speed automatic transmission was offered. Front suspension оп а" models is the independent соВ spring and wishbone type, while the геаг a)(le is located оп leaf springs. Telescopic shock аЬ50гЬегз аге litted а" round. For 1967 / 1968 the 'агоег capacity 302 and 390 V8 engines became optional and these were 101l0wed Ьу the poweгful 427, 428 and Boss 429 engines. InevitabIy, as engines got larger, so the body size increased unti1 it could по 10nger Ье described as а compact SP0r15 саг. Because it had 105t the original Mustang individuality, sales inevitаЫе dropped and in 1974 Ford launched the Mustang Series 11.

•

Contents Page

•

ACknowledgements

2

About this manual

2

Introduction to the Ford Mustang

2

Buying spare parts and vehicle identification numbers

6

Jacking and towing

7

Tools апd working facilities

8

Recommended lubricants and fluids

12

Routine maintenance

13

Chapter 1 Engine

15

1

Chapter 2 Cooling system

46

2

Chapter 3 Fuel . exhaust and emission control systems

52

3

Chapter 4 19n;tion system

91

4

Chapter 5 Clutch

101

5

Chapteг

106

в

Chapter 7 Driveshaft

126

7

Chapter 8 Аваг axle

129

8

Chapter 9 Braking system

138

9

Chapter 1 О Electricalsystem

153

10

Chapter 11 Suspension and steering

232

11

Chapteг

264

6 Transmission

------------------------------------------------------------ , •

12 Bodywork and fittings

Safety first!

284

Index

286

4

-

••

•

." ' . ••

•

. . ~: •....: . .." (~ . ч.' ;.i.;..~· '""'., ..'' .~~• ~ Ч. '" • • •

-

"

•

1966 Mustang ConvertibIe, 289 cu in

1967 Mustang Hardtop

5

• ,

,

I

- -- --=

--

-

-

1971 Mustang Sports Roof

_"-

--" ..

-

1972 Mustang Hardtop

-

Buying spare parts and vehicle identification numbers А

Buying spare parts Replacement parts аге availabIe from тапу sources, which generally lall inlo опе 01 two categories - authoгized dealer paгts departments and independent retail auto parts stores. Ош advice concerning these parts i5 ав foJlows: Retail auto parts stores: Good auto parts stoTes will stock frequently needed components which wear out relativeJy fast, such ав clutch сот­ ponents, exhaust systems, brake parts, tune-up parts, etc. These stores often supply new ог reconditioned parts ОП ап exchange basis , which сап ваув а considerabIe amount 01 топеу. Discount auto рапв stores аге often уегу good places 10 buy materials and parts needed for general

vehic!e safety certificBC;on IвЬе! is attached to the геаг face of the left hand door оп later models only. This gives the Gross Vehicle Weight Ratin9 (GVWR) and the Gross Axle Weight Rating (GAWR) for that particular саг. The епи;пе питЬе, оп аll models prior to 1968 Is stamped оп the left side of the cylinder block. Оп 1968 and later models the engine number is stamped оп а metal ta9 adjacent to thв ignition coil. The transmiss;on питЬег IS stamped оп а small metal plate which is riveted to the right sidв of the transmission casing.

MFD. ВУ FDRDMDTDR CD.IN U.S.A. ОАТЕ: 08/72 GVWR 5892 GAWR : FRDNT 2964, REAR 2928

vehicle maintenance such ав oil, grease, liller5, spark plugs, belts, touch-up paint, bulbs, etc. They also usually sell tools and general ас­ cessories, have convenient hours, charge lower prices and сап often Ье found not far from home. Authorized dea/er parts depat1ment: This is the best source for parts which аге unique 10 the vehicle and по1 generally available elsewhere (such as major engine parts, transmission parts , trim pieces, etc. ). Warrantyinformation: If the vehicle is still covered under warranty, Ье sure that апу replacement parts purchased - regardless of the sourcedo поl invalidate the warranty! То Ье sure of obtaining the correct parts, have engine and chassis numbers available and, if possible, take the old parts along 'ог positive identification.

ТНIS VEНlCLE CONFORМS ТО

ALL APPLICABLE FEDERAL MOTOR VEНlCLE SAFETY STANDARDS IN EFFECТ ON ТНЕ ОАТЕ OF MANU· SHOWN АВОУЕ .

Vehic/e identification numbers

~

Modifications аге а continuing and unpubIlcized process in саг manufacture. Spare parts catalogs and lists аге compiled оп а numerical basis, the individual vehicle numbers being essential to correctly identify the сотропеп! required. А vehicle identific8t;on deca! is located оп the геаг edge of the left hand door оп all Mustang m odвls . The decal gives the vehicle serial number and coded information regarding the engine, transm ission and bodywork. Refer to the accompanying examples showing the type of deca ls used and а key to the coding.

ASSEMBLY PLANT •

MODEL YEAR

~BOOY

СООЕ

SERIAL

(UNIТED

Vehicle identification/safety certificetion decal {later modelsl

1 2 3 4 5 6

Consecutjve un,t по. 80dy 5е,;.' code Model уевг code AssembIy plant code Engine Сodе 80dy rype code

7 Colo, code

8 9 10

11 12

Vehicle type Djst,;ct - specia/ equipment Rear axle code T,ansmission code Т"т code

СООЕ СООЕ

СООЕ

UHIТ

HUMBER

•

•

TRANSMISSION ОНЕ СООЕ

ВООУ ТУ РЕ СООЕ--"

COLOR

СООЕ

REAR AXLE

СОО

TRIM

СООЕ

DI5TRICT о, DISTRICT "НО SPECIAL EQUIPMENT СООЕ

Vehicle identification decal (е8гliег typel

СООЕ

"

Jacking and Towing Jacking points

Towing points

ТО

change а wheel in ап emergency, use the jack supp1ied with the саг . Ensure that the roadwheel nuts аге released before jacking up the саг and make sure that the tap 01 the jack i5 fuHy engaged with the body cutout, and that the base 01 the jack is standing оп а 1irm surface . The jack supplied with the vehicle Is not suitabIe 1ог use when raising the vehicle 1ог maintenance or repair operatlons. For this work , use а trolley, hydraulic or screw type jack located under the 1ront crossmember. bodyframe side-members ог геаг axle caslng, as illustrated. Always supplement the jack with jack stands or bIocks be10re craV'Jling beneath the саг.

If your vehicle 1$ being towed , make sure that the tow горе 15 attached to the lront crQssmember. If the vehicle i5 equipped with automatic transmission, the distance towed must по1 exceed 15 miles (24 km) , пог the speed 30 mph (48 km/h), otheгwise serious damage 10 the transmission may result. If these limits аге likely to Ье exceeded, disconnect and гетоуе the propeller shaft. 11 you аге towing another vehicle. attach the tow горе to the spring

mounting bracket а1 the axle tube.

АЕАА

LQWER SUSPENSION l

ААМ

CQNTACT ААЕА

)

о

"

FRQNT FRAME CQNTACT ААЕА I

,"

Front jacking агеаа to Ье used when raising the vehicle 1ог mBintenBnce purposas

РАИК САИ

АЕАА

AXLE Аеаг jackjng 8re8S to Ье used whеп raising the vehicle for m8intenBnce purposes

с

15" FROM СиИВ ТО

CHAHGE TIR

'..!::...-/

"

DO NOT LIFТ ТНЕ CAR ВУ ТНЕ FRONT OR REAR BUMPERS U sing the jack supplied with the car

Tow rope 8tt8chment point 8xle

оп

геаг

Tools and working facilities /ntroduction А

selection of good tool5 is а fundamental requirement for апуопе contemplating the maintenance and repair of а саг. For the owner who does not possess апу , their purchase will ргоуе а considerabIe 8хрепзе , offsetting some of the savings made Ьу doing-it-yourse1f. However, provided that the tool5 purchased аге of good quatity, they will 185t for тапу years and ргоуе ап extremely wo"hwhile invest-

ment. ТО

help the average owner to decide which tools аге needed to сапу out the various tasks detailed in this Manual, we have compiled three lists of tool5 under the following headings: Ма ;п tепапсе and minor гера;', Repair Bnd overhau/, and Special. The newcomer to practical mechanics should start off with the Maintenance and minor гера;' tool kit and confine himself to the simpler jobs aTound the саг. Then, аз his confidence and experience grow, he сап undertake тоге difficult tasks, buying extra tools аз, and when, they аге needed. 'П this way, а Maintenance and minor гера;' tool kit сап Ье bu ilt-up into а Яера;' and overhau/ tool kit оуег а conslderabIe period of time without апу major cash outlays. The experienced do-it-yourselfer will havв а tool kit good enough for most repair and overhaul procвdures and will add tools from thв Specia/ category when he feels the ехрепзе is justilied Ьу the amount of use to which these tools will Ье put. It {з obviously not possibIe (о соуег the subject of tools lully here. For those who wish to 'еагп тоге about tools and their изе there {з а book entitled How (о Choose and Use Саг Tools availabIe from the publishers 01 this Manual.

Maintenance and minor repair too/ kit The tools given {п this Нзt should Ье considered аз а minimum requirement 11 routine maintenance, servicing and minor гера!г орега ­ tions аге to Ье undertaken. We recommend the purchase 01 сотЫпа­ tlon wrenches (ring опе end , open-ended the other); although тоге expensive than open-ended ones, they do give the advantages of both types 01 wrench.

Combination wrenches - t (о bl in AF AdjustabIe wrench - 9 inch Engine оп pan/ transmission!rear axle drain plug key (where app/icвЫе)

Spark plug wrench (with гиЬЬег insert) Spark p/ug gap adjustment tool Set 01 'ее/ег gauges Brake adjuster w,ench (whe,e аррНсаЫе) В,а/(е bIeed nipple w'ench Sc,ewd,ive, - 4 in long х t in dia (!Iat bIade) Sc,ewd,ive, - 4 in long х t in dia (c,oss bIade) Combination p!iers - 6 inch Hacksaw, junio, П,ерumр П,е

p'essu,e gauge Grease gun ОП сап

Fine еmегу cloth (1 sheetJ Wi,e brush (smalf) Funnel (medium s;ze)

Repair and overhau/ tOO/ kit These tools аге virtually eS5ential for апуопе undertaking апу major repair5 to а саг, and аге additional to those given {п the Maintenance and mino, ,ера;' list. Included {п this Ilst {з а comprehensive set of sockets . Although these аге expensive they will Ье found invaluabIe а5 they аге 50 versatile - particularly if various drives аге included j п the 5et. We recommend the t jп 5quare-drive (уре , аз this сап Ье used with most proprietary torque wrenches. 11 you cannot afford а socket set, еуеп bought piecemeal, then inexpensive tubular Ьох wrenches а ге а useful alternative. The tools in this Hst will occasionally need to Ье supptemented Ьу tools from the Specia/li5t.

w,enches) (о coverrange t 1i in AF Reve,s'-bIе ,atchet d,ive (10' use with sockets) Extension р'-есе, 1О inch (10' use with soc/(ets) Universa/ joint (10' use with soc/(ets) тo'que wrench (Ior use w'-th sockets) Self-grip wrench - 8 inch В а" pein hammer Soft-Iaced hammer, plastic ог гuЬЬег Screwdriver - 6 in long х А '-П dia (fIat bIade) S crewdriver - 2 in long х А in square (fIat bIadeJ S crewdriver - 1t in long х t in dia (cross bIade) Screwdriver - 3 in long х i in d'-a (e/ectric'-ans) Pliers - electric;ans s'-de cutters Pliers - needle nosed P!iers - snap-ring (inteгnal and exteгnalj Cold chisel- t '-nch Scriber Scraper Centre punch Pin punch Hacksaw Valve grinding (ооl Steel rule/straight edge Allen keys Select'-on 01 files Wire brush (Jarge) Jack stands Jack (strong scissor ог hydraulic (уре) Soc/(ets

(о, Ьох

Specia) tOO/s Тhe

toOl5 in this Hst аге those which аге not used regularly; аге expensive to buy, ог which need to Ье used {п accoгdance with their manufacturers' in5tructions. Unless relatively difficult mechanicat jobs аге undertaken frequently, it witl not Ье economic to buy many 01 these tools. Where thi5 is the с азе , you cou ld consider clubblng together with friends (ог ап automobile clubI to make а jolnt purcha5e , ог borгow ing the toOl5 against а deposit lгот а 'осаl repair station ог tool hire 5pecialist. The following list contains only those tool5 and instruments freely availabIe to the pubtic, and not th05e 5pecial tool5 produced Ьу the vehlcle manulactuгer specilically for its dealer network. You will find occasional references (о these manulacturers' 5pecial too15 in the text of thi5 Manual. Generalty, ап alternative method of doing the job

Tool. and working facilities 'А

·'1Out е vehicle manufacturer's speciat 1001 is given. HowBver. 5Of'"'e Imes there is по alternative 10 using them. Where this is the сая and the relevant 1001 cannot Ье bought ОГ borrowed you will have

9

Wrench jaw уар compari50n

(аЫе

J8W g8p (in)

WT8nch SiZ8

0·250 0·275 0·312 0·315 0·340 0·354 0·375 0·393 0·433 0-437 0·445 0·472 0·500 0·512 0·525 О· 551 0·562 0·590 0·600 0·625 0·629 0·669 0·687 0·708 0 ·710 О · 748 О· 750 0·812 0·820 0·866 0.875 0·920 0·937 0·944 1·000 1·0 1 О 1 ·023 1·062 1 ·100 1 ·125 1 · 181 1·200 1·250 1·259 1·300 1 ·312 1·390 1 ·417 1·437 1·480 1· 500 1 ·574 1 ·614 1·625 1·670 1·687 1·811 1 ·812 1·860 1 ·875 1·968 2 ·000 2 ·050 2·165 2·362

t

to entrust the work 10 а franchised dealer.

VlIlve spring compressor

Piston ' ;ng compressor 8 IJlljoint separator

UnivBrsal hubIbearing puller /трасс

screwdr;ver

Micrometer and/or

veгnier

gauge

Carbuгetor flow ba/ancing device (where вррJiсаЫе)

Dial gauge

Stroboscopic tim;ng light Dwellangle meter/ tachometer Universal electrical multi-meter Cylinder compression gauge Lifting tackle rrolley jack иум

в uying

t

with extension fead

tool5

For practically all 10015, а tool factor is the best source since he will have а уегу comprehensive range compared with the average garage ог accessory shop. Having said that, accessory shops often offer excellent quality tools at discount prices, so it pays to shop around. Remember, you don 't have to buy the most expensive items оп the shelf, but It Is always advisabIe 'о steer clear of the уегу cheap tools. There аге plenty of good tools around at reasonabIe prices, so ask the proprietor ог manager of the shop for advlce before making а purchase.

Working facilitie5

t

Not to Ье forgotten when discussing tools, is the workshop itself. If anything more than routine maintenance is to Ье carried out, some form of suitabIe working агеа becomes essential . It is appreciated tha!' many ап owner mechanic is forced Ьу circumstances to гетоуе ап en9ine ог similar item, without the benefit of а 9ага9е ог workshop. Having done this, апу repairs should always Ье done under the соуег of а roof. Wherever possibIe, апу dismantling should Ье done оп а clean flat workbench ог 'аЫе at а suitabIe workin9 height. Апу workbench needs а vise: опе with а jaw opening of 4 (п (100 mm) is suitabIe 'ог most jobs. As mentioned previously, some clean dry storage space is also required for tools, as well as the lubricants, cleaning fluids, touch-up paints and so оп which become necessary. Another item which тау Ье required , and which has а much more general usage, is ап electric drill with а chuck capaci1y of а1 least ,\ (п (8 mm ). This, together with а good range of twist drills, is virtually essent ial for fitt;ng accessories such as wing mirrors and reversing tights. last, but not teast, always keep а supply of old newspapers and clean , lint-free rags ауаВаЫе , and try to keep апу working агеа as clean as possibIe.

Саге and maintenance о' tool5 Having purchased а reasonabIe tool kit, it is necessary 'О keep the tools in а clean serviceabIe condition . After use, always wipe оН апу dirt, grease and metal paгticles using а clean, dry cloth. before putting the tools away. Never 'вауе them Iying around after they have Ьееп used. д simple tool rack оп the garage ог workshop wall, for items such as screwdrivers and pliers is а good idea. Store all погтаl wrenches and sockets (п а meta l Ьох. дпу measuting instruments, gauges, meters, etc, must Ье carefully stored where they саппо! Ье damaged ог Ьесоmе rusty. Take а little саге when tools аге used. Наттег heads inevitabIy Ьесоте marked and screwdrivers lose the keen edge оп their bIades from time to time. А little timely attention with emery cloth ог а lile will soon restore items li ke this to а good serviceabIe finish .

•

in AF 7 mmAF ii in AF 8mmAF ~ (п AF;t (п Whitwoгth 9 mmAF t in AF 10mm AF 11 mm AF in AF i in Whitworth;t (п BSF 12 mm AF t in AF 13 mm AF t (п Whitworth;,\ (п BSF 14 mmAF А in AF 15 mmAF А (п Whitwoгth; t (п BSF t in AF 16 mmAF 17 mmAF М in AF 18 тт AF i (п Whitworth; , in BSF 19 mmAF t in AF in AF in Whitwoгth; t (п BSF 22 mm AF t in AF t in Whitwoгth;" in BSF in AF 24 mmAF 1 (п AF ii in Whitwo"h; t in BSF 26 mmAF 1~ inAF; 27 mm AF t (п Whitworth; bl (п BSF 1t in AF ЗО mmAF bl (п Whitwoгth; t (п BSF Ч in AF 32 mmAF t (п Whitworth ; t (п BSF ' . in AF ~ (п Whitwoгth; fI (п BSF 36 mmAF in AF t (п Whitworth; 1 (п BSF Ч in AF 40 тт AF ; i (п Whitworth 41 mmAF Ч in AF 1 (п Whitworth; 1t (п BSF , М in AF 46 mmAF 1 in AF 1t (п Whitwoгth ; 1t (п BSF Ч in AF 50 mmAF 2 (п AF Ч in Whitwo"h; Ч in BSF 55 mm AF 60 mmAF

4

n 4

3

'4

n

10 --------------------------------------------------------~

STEERING LIHKAGE REMQVE PLlJGS Т О LUBRICATE

POWER BALl JO INT

BALL JOIHTS Rt::MQVE PLUGS ТО LUBR ICATE

FRONT

ClEAN

дно

REPACK

I

STANDARD TRANSМISSIOН

FLOOR

SHIFT LINKACE

LUBR IСА ТЕ AS

STEERING STOP PADS

LUBRICATE SURFACES

I

ТYPlCAL

SHIFТ

LINKAGE

LUBRICATE А> REQUIRED.

CLUTCН

LIHKAGE

-ТУPlСАL

LUBR ICATE LEVER днс ROO С()J'llNЕСПONS AS RE.QUlRED.

IHTEGRAL CARRIER AXLE

МANUAL TRAHSМISSIOН

PARKING BRAKE LINKJoGE

LUBRICATE CABLE GUIDES, LEVERS дно LINКAGE ДS REQUIRED.

Cha8sis lubricatlon points

А

LUBR ICATION POINT

,------------------------------------------------------------------11 F ILL

ТО

F1LL ТО COLD FILL

• BE LOW R1NG

6REA.KER POINT САМ

МARK

1

CROSS FLOW RADIATOR

USE HIGH TEMPE RAT URE LU6RICдNT

',е"с FLOW RAOIA TOR

ENGINE OIL LEVEL OIPSТICK

PUMP FLUID SHOULa

ACCELfRATOR LINKAGE ШВ Е POtNTS

ВЕ

6EТWEEN дао

FULL

МARKS

СОдТ GASKEТ

WIТH

!

ENG1NE 01L

I

CНANGE ДТ

t

RECOММENOED

lNTERVA L

-, ,,

('

,

_-- ,

, ....,-.:"

FR EE PlAY DIM.

ЩО~ 15'20 LВ. FТ.

СШ Т СН

...--- '00

EQUAllZER

VIEW IN CIRCLE U 302 AND 351 ENGINE

. __

.,. .

ВОО Т

FREE PlAY DIM.

iiфl

SPi'(I NG BU5HIN G

390 ENGINE VIEW IN CIRCLE V

BRAK E PEDAL

-~

,::--____, 8USH IN G

RElEA5E ROD ASS EMBL у

~/ EQUALIZER BRACKET

" '-

--' " ' RETAIN ER

BUSHING

BU5HING

PIVOT - - - - - " RETAI NER - - - - ' ' ' ' '

REL EASE ROD - - - _

"----

ВRACKE T

351 ENGINE SAME AS МA. I N VIEW ЕХСЕРТ AS SHDWN

390 ENGINE SAME AS МA.IN VI EW ЕХСЕРТ AS SHOWN

Fig. 5.2 Clutch

реdаlапd

linkage (1969) (Secs. 2 and 3)

DU TER

INNER

АС' Т

ASSIST

СШ Т СН

EQUAllZ ER RDD _ _•

-

ВА'

RE'LEASE RDD

Fig. 5.3 Clutch pedal and linkage (1971) (Secs . 2

PEDAL ASSEMBL У

апd 3)

,

Chapter 5 Clutch

I

СОТТЕЯ

PIN

BU$HING

'2

I

ЯЕОD.

СШТСН

ASSY .

STua 2

PEDAl

ВЯАКЕ

103

CYllNDER

BUMPER

Д$$У

СОТТЕЯ PIN СШТСrl

SPA(ER 4 ЯЕао .

ТО

PEDAL EQUALIZER ЯОD

FLUID lEVEL IN 8ЯАКЕ

l

MASTER CYLINDER MUST ВЕ

FROM 1/ 4 Т О 1/2 IN(HE5 FROМ тор

/"

ASSIST SPRI NG ВЯАКЕ PEQAL

PU5H

STUD

'2

QVERCE NTER ADJUSTMENT

ЯОD

RELEASE LEVER ЯОD

ЯЕао.

CLUTCH PEDAL

SQUARE WRENCH

ASS IST SPRING AS$Y

ASSIST SPRING О.

DI$C _ _

PLA TE AND CQVER

REТURN

СШТСН

PEDAl

-

FREE TRAVE L

SPRING

INNER BRACKEТ

,

ClUTCH

-------,- "~,~'-

..... 'J

0.206 I

PILOT 8EARING

GAP

12t1 INCH ,

~

QVERCENТER ADJUSТMENT

ADJUSTMENT

-"-";

FELTWASHER /~ '2 ЯЕаD .

.#' OUTER URACK EТ

EQUALIZER

Fig . 5.4 Clutch pedal and linkage (196811Secs. 2 and 3)

/ з

Clutch ped81- rеmОУ81апd installation

Models through 1968 1 Depress the clutch pedal and inseгt а 0.25 in (6.3 mm) spacer in the assist spring adjustment gap. 2 Remove the equalizer rod-to-clutch pedal securing pin and disconпес! the rod from the clutch pedal . 3 Disconnect the brake pedal pushrod from the brake pedal. 4 Remove the retaining clip fTom the end of the clutch pedal shaft, then гетоуе the shaft, bushings, clutch pedal and brake pedat from the

inner cowl bracket (see Fig. 5.5) , and the two screws securing it to the dash panel . 15 Аетоуе the two screws securing the pedal suppoгt bracket to the upper cowl Ьгасе , then lower 1t away from the steering column studs and remove it from the саг. CLUTCH PEOAL

ASSISТ

ТОР fNNER COWl· TD.BRACКET 5 SCREW

зuррогt.

I

5 Instaltation is the reverse of гетоуа! procedure. Lubricate the bushings w ith engine оН before assembty. Adjust the clutch pedal freeplay as described in Section 2 .

Models

t I I

I I

(гот

CL AМP

1969

6 Disconnect the battery ground с аЫе. 7 Remove the steering cotumn as described in Chapter 11. 8 Remove the two capscrews attaching the brake master cytinder ог booster to the dash panel, then the two screws securing the pedat suppoгt bracket to the Clash panel. 9 Work1ng inside the саг, disconnect the clutch pedat-to-equalizer rod а! the ctutch pedat Ьу removing the retainer and bushing . 10 Secure the ctutch pedal against the bumper stop with а small С ­ clamp. 11 Disconnect the stoptight switch at the connector. 12 Аетоуе the switch retainer and slide the stoplight switch off the brake pedal pin just far enough for the switch outer hole to clear the . pin. Now lower the switch away from the pin . 13 Аетоуе the master cylinder pushrod , bushing and nyton washer from the brake pedal pin . 14 Аетоуе the screw securing the pedal support bracket to the top

-

Fig. 5.5 Removing the clutch pedal (Sec.

З)

Chapter 5 Clutch

104

• 6 Mount the bracket [п а vise and remove the small C-clamp, then .sюwlv pivot the clutch pedal away from the Ьитрег until the assist spring сап Ье 1ifted from its seat (1969 through 1971 models). 17 Оп 1972/ 1973 models pivot the pedal away from the bumper until it comes 10 rest оп the opposite flange оп the brake pedal SUpport bracket, then remove the forward bolt securing the assist spring bracket to the support. Using ап adjustabIe wrench, hold the assist spring bracket and slowly pivot the bracket away fгom the spring until it свп Ье lifted from its эеаt. 18 Remove the retaining clip fгom the clutch pedal shaft then with draw the clutch pedal shaft assembIy and bushings (гот the pedal support bracket. 19 Installation i5 the rever5e of the removal procedure. Lubricate the bU5hings before 1n5tal11ng them in the brake and clutch pedal а55етЫ1е5. Adjust the clutch pedal free-play as described in Section 2.

4

СШТСН ARBOR

DISC

• •

Clutch - remov81 a"d inst8118tio" PLATE

1 Remove the transmission as described in Chapter 6. 2 Disconnect the clutch release lever retaining 5pring from the relea5e lever. З Di5connect the starter motor саЫе, then remove the 5tarter motor attaching bolt5 and Jift away the starter motor. 4 Remove the bolt5 5ecuring the eng1ne геаг plate to the front lower part of the flywheel hou5ing. Remove the flywhee l hou5ing lower cover of 50 equ1pped ). 5 Remove the flywheel hou5ing securing bolts and move the hou5ing back just 'аг enough to clear the pre5sure plate. then move it to the right to free the pivot from the clutch equalizer Ьаг. Take саге not to disturb the linkage and a55ist spr1ng. 6 Unscrew the six pressure plate cover 5ecuring bolts опе turn at а time. to prevent di5tort10n of the cover а55етЫу . when relea5ing the 5pr1ng ten5ion. 7 If the same pre55ure plate and cove r a5se mbIy Is to Ье re-1nstalled . mark the cover and flywheel 50 that the assembIy сап Ье 1n5tal'ed 1п its original position. В Remove the clutch cover а55етЫу and the clutch di5C from the ftywheel. Make а note of whlch way round the clutch disc Is in5tal'ed. 9 It 15 important that по oil ог grease gets оп the clutch di5C frictlon lining5. ог the pre55ure plate and flywheel faces. 11 i5 advisable to handle the parts with clean hands and to wipe down the рге55иге plate and flywheel faces wlth а clean dry rag before installing the clutch cover assembIy. 1О Place the clutch disc and pre5sure plate assembIy 1п p05ition оп

the flywheel. If the same assembIy is being

ге-iПSlаllеd,

align Ihe

matching marks made at removal. and install the 5ecuring bolts. Tighten the bolt5 alternately а few turns at а tlme until the clutch d15C i5 gripped lightly but сап 5t111 Ье moved . 11 The clutch d1sc must now Ье centered 50 that when the transmission Is in5talled . the input 5haft splines will ра55 through the 5pl ines in the clutch di5C hub. 12 Centering сап Ье carried ou t Ьу inserting а screwdriver through the clutch а55етЫу and moving the clutch di5C as песе55агу to obtain соггес! centerlng. Alternatively. if ап old input shaft is availabIe. this сап Ье u5ed а5 ап агЬог to center the disc; this will eliminate all guesswork and achieve тоге accurate centering of the clutch disc. 1 3 After the clutch disc has Ьееп located correctly . tightеп the securIng bolts I п ап еvеп and diagonal sequence to ensure the cover assembIy is secured without di5tortion. Tighten the bolts to the spec ified torque wrench setting. 14 U5ing а lithium base grea5e. lightly lubricate the out5ide diameter of the tran5miS5ion fгопt bearing retainer. both 5ide5 of the release lever fork where it contacts the release bearing spring clips, and the release bearing suriace that contacts the pres5ure plate release fingers. Fill the grease groove in the release bearing hub . then clean all exce5S grease from inside the Ьоге . otherwise grease will Ье forced onto the splines Ьу the tran5mission 1nput shaft bearing retainer and will contaminate the clutch dlsc. 15 Install the release bearing and hub оп the (elease lever. 16 Insta ll the felt washer оп the pivot in the ftywheel hou5ing and 5liр the pivot into the clutch equalizer shaft. taking саге not to disturb the linkage ; at the эате time locate the housing оп the dowels in the cylinder bIock. Install the securing bolts and tighten them to the specified torque. 17 Insta ll the 5tarter motor and connect the саЫе.

Fig. 5.6 Centering the clutch disc using

а

special

агЬог

(Sec. 4)

1В

In5tall the transmission as described in Chapter 6. 19 Check апd. if necessaгy . adjust the clutch pedal free-plav as described in Sectlon 2.

5

Clutch - inspection and renovation

1 Examine the machined faces of the ftywheel and the pressure plate for scores, rldges ог Ьигп marks. Minor defects сап Ье removed Ьу machining. If badly scored ог burnt . they must Ье renewed. 2 Check the wear оп the cl utch finger5 ; if there is а COn5iderabIe difference in wear between the fingers. the exce5sively worn finger is binding and the pressure plate assembIy must Ье renewed. Check the pressure plate for warpage us1ng а steel rule as shown in Fig. 5.В. З Lubricate the pressure plate. with grease , between the dr1ving lugs and the edges of the pressure plate open ings as shown in Fig . 5.9. Depre5s the pressure plate fingers fully. apply the grease . and thеп move the fingers up and down until the grease is worked in. 4 Examine the clutch disc for worn ог loose facing5 . distortion. loose nuts at the hub. and for broken springs. 11 апу of these defects exist then the clutch disc must Ье renewed. 5 Wipe all оН and dirt off the release bearlng; It i5 pre-Iubricated and should not Ье cleaned with solvent. Inspect the bearing retainer for loose spring clips and rivets. Hold the bearing inner гасе and rotate the outer гасе. Н it is rough ог noisy. renew the bearing.

6

Pilot bush - renewal

1 If the pilot bush is worn ог loose in the crank5haft Ьоге it must Ье renewed. 2 The old bush сап Ье removed Ьу using а round Ьаг that is а close fit in the bU5h. Fill the bush with grease and then drive the Ьаг into the bU5h , this will hydraulically drive the bush out of the crankshaft Ьоге . З Soak the new bush for at least half ап hour in englne oil before instal1ing in the crankshaft Ьоге . 4 Use а suitabIe diameter 5tepped mandrel which will ensure that the bush is not distorted or damaged when being driven in . 5 Wipe оН а" excess oil. Оо not lubricate the bush with grease of апу type.

,1

7

Fault diagnosis - clutch

1 There аге four main faults to which the clutch and release mechanism аге ргопе. They тау occu r Ьу themselve5. ог in conjunction with апу of the other faults. They аге clutch squeal . slip . spin and judder.

C!utch squea! 2 If оп taking up the drive ог when changing gear. the clutch squeal5. thls is indicative of а badly worn clutch release bearing. З As well as regular wear due to normal use . wear of the clutch release bearing is much accentuated If the ctutch is ridden ог held

,

Chapter 5 Clutch

105

о

о

о

о

о

О

f,

о

о

-- ---

,

о

NORMAL WEAR

о

EXCESSIVE WEAR

Fig. 5.7 Checking the clutch fingers 10r wear (Sec. 51

•1'''''

flywheel ог pressure plate faces, ог the pressuгe plate 1t5elf 1s faulty. 6 The reason for clutch sJip 1s that due to опе of the faults above. there is insufficient pressure from the pressure plate, ог insufficient friction from the friction plate to ensure solid drive. 7 If small amounts of oi l get O"to the clutch. they will Ье burnt off under the heat of the clutch engagement, and in the process. gradually darken the 11n1ng5. Excessive оН оп the clutch wil l buгn off leaving а сагЬоп deposit which сап cause quite bad clutch slip, or fierceness .

spi" and judder. а

Fig . 5 .8 Checking the ptessu te plate for warpage (Sec. 5)

If clutch slip is suspected, and confirmation 01 this condition is required, thete аге several tests which сап Ье made. 9 With the engine in second ог third gear and pulling lightly , sudden depression of the accelerator pedal may cause the engine 10 increa se its speed without апу increase in road speed. Easing оН оп the accelerator wШ then give а delinite drop in engine speed without the саг slowing. 1О 'П extreme cases 01 clutch slip the engine will га се under normal acceleration conditions.

Clutch spin 11 Clutch spin is а condition which occurs when there is ап obstruction in the clutch linkage , incorrect release bearing clearance. ог oil may have partially burnt ОН the clutch Hning and have left а resinous deposit which is causing the clutch disc 10 stick 10 the pressure plate ог Ilywheel. The disc may also Ье slicking оп the input shaft splines. 12 The reason for clutch spin is that due 10 апу, ог а comblnation 01, the faults ju st listed , the clutch pressure plate is по! completely freeing from the center plate even w ith the clutch pedal fully depressed. 13 If clutch spin is suspected. the condition сап Ье confirmed Ьу extreme difficulty in engaging first gear from rest, difficulty in changing gear. and veгy sudden take-up 01 the clutch drive at the fully depressed end of the clutch pedal travel as the clutch Is released. 14 11 the clutch linkage is checked and the clutch pedal free travel Is correct, then the fault lies internally in the clutch and it will have 10 Ье removed 10г examination. ,

Fig . 5 .9 Pressure plate lubrication points ISec. 5)

I

!

down 10г long periods in gear. with the engine running . То minimise wear 01 lhis component the саг should always Ье taken out 01 gear at traffic lights and 10г similar t raffic hold ups. 4 The clutch re lease bearing is not ап expensive item but difficult (о get 81.

Clutch sПр Clutch slip is а self-evident condition which occurs when lhe clutch friction plate is badly worn, oil ог grease have got ОПlО the

5

Clutch juddeг 15 Clutch judder is а self-evident condition which occurs when the transmission ог engine mountings аге loose от (оо flexibIe, when there is oil оп the face 01 the clutch friction plate. от when the clutch pressure plate has Ьееп incorrectly adju5ted. 16 The гвазоп for clutch judder is due to опе of the faults just listed. the clu tch pre5sure plate i5 not freeing smoolhly from the friction disc and i5 snatching. 17 Clutch judder normally occurs when the ClulCh pedal is released in lir51 ог reverse gears, and the whole саг shudders as il moves forward ог backward.

5

Chapter 6 Transmission Contents

Д - Manual transmission Fault diagnosis - тапиаl transmission . . . . . . . . . . . . . . ... .. 25 Gearshift control (early 4 -speed models) - removal and installation ...... ...... . . . . . . . . . . . .. ... . ... ... 21 Gearshift control (later 4 -speed models) - remova l and installat ion . ...... ...... ... . . . . . . . . . . . .. ..... . 24 Gearshift li nkage (early З - sрееd m odels) - adjustment ....... . 10 Gearshift linkage (l ater З - sрееd models) - adjustment ..... . . . 1 1

(3-speed) - d1smantting ..... .. .. .... .. . ... Transmission (4-speed) - dismantting . . ... ....... ...... . Transmission f3-speed) - examination and renovat1on ........ Transmission (4-sрееdJ - examination and renovation ... .. •.. Transmission (3-sрееdJ - reassembIy ... .... .... .... • . . .. Transmission (4-speed) - reassembIy ... . . . . . . . . . . . . . . .. .

General description . .... . ....... . . . . . . . . . . . . . . . . . . . 1 Input shaft (3-speed) - dismantling .... . . . . . . . . . . . . . . . . . 4 Input shaft ( 4 -sрееdJ - dismantling . ..... . .... • . . .... ... 14 Input shaft (З-s рееd) - reassembIy ........ .... .•. . . . . . . 7 Input shaft ( 4-sрееd J - reassembIy ..... .......... . . . .. . 1 7 lock-rod {late r 4 -speed models ) - adj ustm ent . . ... . .. . . • ... 23 Output shaft (3-speed) - dismantl ing ........ ..... • • . •... 5 Output shaft 1 4 -sре еd J - dismantling .. ... . ... . .... . .... . 1 5 Output shaft (3-speedl - reassembIy ....... .... ........ . 8 Output shaft 1 4-sрееdJ - reassembIy ..... ..... ......... . 1 8 Sh1ft linkage (ea rly 4-speed modelsl - adjustment . .... ..... . 20 Sh1ft linkage (later 4-speed тodels l- ad justment . ........ . . 22 Transmiss10n lock-rod - remova l and 1nstallation .... ... .. . . . 1 2 2 Transmission - removal and 1nstallation

Fault diagnosis - automatic transтission ..... ... .....•.. . FMX transmission - band adjustment . .. ..... ... . . . • •. .. General description . .. .. ...... . . .. ...... ... ... . .. .. Intermediate band (С4 and С6) - adjustment . . . . . . . . . . . . . . Kickdown rod - adjustment . . . . . . . . . . . . . . . . . . . . . . . . . .. low and reverse band (С4 only) - adjustment . . . . . . . . . . . . . . Manual shift linkage - adjustment . . . . . . . . . . . . . . . . . . . . ,. Neutral start switch (С4 and С6 transmission) - adjustment ... . Neutral start switch (FMX transmission and С6 transm ission with 429 СЮ engine) - adjustment . . . . . . . . . . Special towing о( recovery information . . . . . . . . . . . . . . . . . .. Transmission fluid level - checking ..... ... ... ..• . • , .... Trans mission lock-rod - adjustment ...... •.• . .... ...... . Transmission - removal and instal lat10n ... .... .. ...... ...

Part

TransГfl1ssion

Part

В

- Automatic transmission

Specifications

Мапuаl tгansmission

Number of gears 3-speed transmission 4-speed trans mission Туре

of gears

Synchromesh

· . . . . . . . . . . . . .. . .. .. .. · . . . . . . . . . . . . . . . . . .. . .

. . . . . .. . . . . . . . . . . . .. . . . .

.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. , . . . . . . . . . . . . . . . . .

3 forward. 1 reverse 4 forward , 1 reverse Helical, constant mesh AII forward gears

Countergear endplay ..... ... ... .. . . . ........ .. ... .

0.004 to 0.018 in (0.1 О to 0.45 mm )

Reverse idler gear endplay .... . . . . ... . .. ... . . ..... .

0.004 to 0.018 in (0.1 О to 0.45 mm )

.

.. .. .. .. . . . .

Ford manual transmission lubricant (ESW-M2C83-8)

3-speed transmission · . . . . . . . . . . . . . . . . . . . . . 4-speed transmission · . . . . . . . . . . . . . . . . . . . .

. .. . . . . . . . . . .. . . . .

3.5 US pts (1.7 litre) 4.0 US pts (1 .9 litre)

Lubricant type . .

. . . . . . . . . . . . . . .

Refill capacity

.

.. ....

.

.

.

. . .

А utomatic tгansmission Туре

........ ... . .... ... .... ... . ... ....... . . . . . . . .

Lubricant type ............... ...... ..... . . . . .. . . . .

С4 , С6 ог

FMX

Automatic transmission fluid ESW- M2C33-F type F

Refill capacity (approx) Туре С4 :

302 351 Туре Туре

си

in engines .. .... ....... • . . . . ... .... ........ . си in engines . . .. . .. .......... • ..... ....... _ ... С6 . . . . . . . . . . . . . . . . . . . .. ....• . . .. ... . . ......... FMX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -

.

3 13 6 16 9 19

9 US qt (8. 5 litre ) 10.25 US qt 19 .6Iitr_1 12.5USqt(11.8Iitre) , 1.0 US qt (10.4 11tre)

38 37 26 35 32 36 30 33 34 27 28 31 29

Chapter 6 Transmission Toгque

wrench settings

107

lbfft

kgf m

30 to 36 19 to 25 30 to 36 20 {о 25 1О {о 20 201030 37 to 42 15 to 20 101020

4.1104.9 2.6 to 3.4 4. 1 104.9 2.7t03.4 1.3t02 .7 2 .7t04.1 5.7105.8 2.0t02.7 1.3t02,7

23 to 28 281040 12 to 16 12 to 16 23 {о 33 151028 12 to 16 35 to 40

3.2 to 3 .8 3.8 to 5 ,5 1.6t02.2 1.6t02.2 2.2 to 4.5 2.0103.8 1.6t02.2 4.8 to 5.5

Manual transmission Inpul shah bearing retainer bolt: З-speеd

transmission .... . . . .. . .... . . 4 -speed transmission .... . . . .. . .. . . Extension housing-to-case bolt . . . .. . •. . . . . Cover-to-case ЬоН. .. . . . ..... .. . .• . . . filler plug . . . . . . . . . . . . . . .. .. . . . . . . . • . . . . . Orain plug . . . . . . . . . . . . . . . ... . . . . . •. Transmission-to-flywheel housing bolts ..... . TRS switch ......... . ... . . Lock-rod adjustment nut ..... . . . . . . . . • • • • • • • • •

Automatic transmission Conve rter-to-flywhee l nuts ... . Converte r housing-to-case .... . Oil рап bo!ts . . . . . . . . . . . . . . . Conve rter cover-to-housing bolts Transmission-to-engine bolts .. Converter drain plug ....... . Downshlft lever-to-sh aft .... . Band adjustme nt screw locknut РААТ А

1

· . . . . · . ...

. . .

.. . ..,

•

• • • • • • • • •

• • • • • ••

... . .. . . .. . .. .. . ..

· . .. .. .. , . . . ... .. , . · . . . . . ..... . · . . . ........ . ·.... . . . . . , .

. , .

.... ....

. . . . . . .. .. . . . . .. .. . .

• • • • • • •

.

. . . . . . . . . .

•••••••

.

....

.. . . ..

- Manual transmission

General de5cription

The manual transmission installed оп models covered Ьу this тапиаl Is а three ог four forward speed and reverse {уре. with synchromesh action оп all forward gears. AII forward gears аге engaged throu9h synchro hubs and rings {о obtain а smooth. sllent shift from опе ratio {о another. AII forward gears оп the output and input shafts аге in constant mesh with their corresponding gea rs оп the cou ntershaft gear cluster, and аге helicalcut {о achieve quiet running. The reverse geaT, which is not synchronized. has straight-cut gear teeth and drives the first gear through ап Interposed sl iding idler gear. The gears аге engaged inside the casin9 Ьу means of Jhe shift forks, shift rails, а detent mechanism and associated parts. The gears аге selected Ьу а floor-mounted shift lever. Th e system of interlocks and detents in the transmission case prevents the selection of тоге than опе gear speed at the same time. and helps 10 hold апу gear in the selected position. From 1970 the 4- speed {уре transmission is fitted with а Hurst shiher contro) assembIy which should not Ье dismantled. The only parts {о Ье removed from it аге the 5hift lever, shift lever handle , backup light switch retai ner and 5witch . 11 is protected from road splash Ьу а rubber Ьоо! whlch fits tightly over the shifter mounting plate.

the crossmember. Disconnect the shift rods from the shift levers Ьу removing the reta ining сНр, f lal washer and spring washer. Remove the bolts that secure the shift linkage control bracket to the extension housing and tie the assembIy out of the way. 9 Support the en9ine with а jack positioned under the геаг of the engine, place а bIock of wood between the jack and the oil рап, and remove the extension housing-to-engine геаг support attaching bolts. 1О Raise the геаг of the en9ine high enough to take lhe weight from the crossmember. Remove the bolts reta ining the crossmember to the frame side supports and withdraw the crossmembeT. 11 Support the transmission with а jack and remove the transmission-to-flywheel housing bolts . 12 Carefully move the transmission and supporting jack rearward l1Пtil the inpul shaft is clear of the clutch housing; then lower the transmission to the ground. 13 ОО not depress lhe clutch pedal while the transmission is removed . Ве10ге inst allin9 the transmission ensure that the clutch release lever and bearing аге correctly located in the clutch housing. 14 Installation of the transmission is the reverse 01 lhe removal procedure. Apply а smear of grease оп the input shaft spl ines. Take саге not {о put апу strain оп the input shaft , but note that it тау Ье necessary to rotate the engine {о align the clutch disc and input shaft splines. Don't forget to refill the t ransmission with the correct grade of oil.

6 2

Transmission - removal and In5tal18tion

1 When the transmi 5sion has to Ье removed from the саг. it сап Ье taken out from below without having to remove the engine. А соп­ siderabIe amount of working height is required beneath the саг and idea lly ramps ог ап inspection pit should Ье u5ed. However, provided that suitabIe jacks and supports аге availabIe, the task сап Ье accomplished without {оо much difficulty if the саг is 5upported оп jack stands. 2 Di5connect the Ьанегу ground lead. 3 Remove the transmission drain plug , (i f 50 equipped), ог lower exte nsion housing bolt and drain the oil into а suitabIe containef. 4 Disconnect the ' front of the driveshaft from the (еаг of the transmission , as described in Chapter 7. and tie the shaft out of the way. 5 Disconnect the speedometer саЫе from the extension housing. 6 Disconnect the TRS (t ran5mission- regu lated spark) switch, seat belt sensor and back-up light switches (if 50 equipped ). 7 Оп three-speed transmissions, remove the gearshift selector assembIy from the extension housing . 8 ОП four-speed transmissions. disconnect the parking brake саЫе from the equal izer lever and separate 1he lever from 1he crossmember. Remove 1he hairpin retainer securing the саЫе to the ttansmission геаг support crossmember, then pull lhe са Ые assembIy forward and out of

з

Tran5mi55ion

(З - 5рееd)

- di5m8ntling

1 Place the complete unit оп а bench ог tabIe and ensure thal you have the following tools availabIe , in addition to the погтаl range of wrenches, etc.: (а) 2 pairs о' snap ring pliers - 1 expanding and 1 contracting (Ы Сорре, headed hammer, а! least 21Ь (с) Selection о' steel and brass drifts (d) Suitable containers (о hold sma/J parts (е) Enginee"s vise, securely mounted (f) Selection о' steel tubing 2 Dismantling of the transmission without the 10regoin9 еquiрmелt is not impossibIe , but will Ье very difficult. Read the whole of this Section before starting work. 3 Undo the capscrews securing the cover to the case, and remove the cover and gasket, 4 Remove the IOn9 spring and detent plug 1гот the top left-hand side of the case. (Early models have а retain ing screw : оп later models the cover retains the springJ. 5 Undo the capscrews attaching the extension housing to the case and remove the extension and gasket. 6 Undo the capscrews securing the front bearing retainer, and remove the retainer and gasket. 7 Remove the filler/ level plug from the right-hand side of the case

•

108

Fig. 6 .1

З-sрееd

transmission (Sec. 1)

LOW AND REVERSE SLIDING SLEEVE AND GEAR

FIRST·$PEED OUTPUT

5ECQND·$PEED

BEARJNG 5HДFТ

SECOND AND SYNCHRQNIZER

'нрит 5HAFT

INPUT

GEAR

SHAFТ SHAFТ

ЮLЕR

GEAR

GEA.

НОТI,

All FORWARD SPEED •

GEARS 'Н CONSTANT Mf;SH WIYН • COUNTER5HAfТ GEAR

Fig. 6.2 Internal c omponents and power 110w

(З-sрввdJ

(Sec . 1 )

,---------------------------------------------------------------------109

Fig. 6.3 4-speed transmission (Sec. 11

THIRD SPEED

FIRST

АНО

SECOND

SPEED SYNCHRONIZER

дно FQURTH SPEED SVNСНIЮNIZЕR

THIRD

SPEED GEAR SHAFТ

INPUT SHAFT

JDLER GEAR COUNTERSHAFT _ CLUSTER GEAR

......

REVERSE SllDlNG GEAR

НОТЕ:

All

HELICAL GEARS

IN CONSTANT MESH WITH соиНТЕИ$НАFТ GEAR

Fig. 6.4 Iпtегпаl components and power flow (4-speed) (Sec. 1)

•

Chapter 6 Transmission

110

, '1

GASKEТ

ниМВЕ.

PLA ТЕ

PLUGS

Fig. 6.5 Transmission C8se and 8ssociated parts (3-speedl (Sec. 3)

SEТ

SCREW

--",

SURFACE

SCREW .. ......-

ДНО 3RD SHIFT FORK РШG

INTERLQCK

e"LUG

1 ST

дНО SHIFТ

2ND SHIFТ

Fig. 6.7 Removing the countershaft roll pin (З-SР88d) (58С. З)

1sт AND REVERSE SHIFТ RAll

Fig. 6.6 Exploded view 01 shift rails апd forks (З-sрвud) (Sec. 3)

С/отр

Dummy Shoft

Fig. 6.8 Removing

thв

countershaft

{3-sрееdJ

(Sec. 3)

Fig. 6.9 Removing the output shaft bearing (З-SР88d) (58С. З)

and , working through the plug opening, drive out the гоll pin that secures the counte rshaft in the сазе, using а suitabIe sized drift (see

Fig . 6.7) . 8 Using а piece of tublng 01 slightly smaller diameter than the countershaft and about 1 t in shoгter, drive the countershaft out of the геаг of the casing , while supporting the countershaft gear cluster. Leave the tubing in the gear cluster to prevent the needle rollers from dropping out, and lower the countershaft gear cluster and thrust washers to the bottom of the case. 9 Оп some models, remove the snap-ring securing the speedometer

-

drivegear оп the output shaft. Slide the gear off the end of the shaft and remove the gear lock-bal l fгom the shaft. 10 Remove the snap-ring retaining the геаг bearing оп the output shaft and , using two screwdrivers placed between the outer snap-ring and сазе , carefully lever the bearing out of the case and slide it off the end of the output shaft. If the bearing cannot Ье removed in this таппег а special tool (No Т6ЗР - 7025 -д) (see Fig. 6.9) is availabIe from Ford dealers. 11 Place both shift 1evers in the neutral (center) position. Aemove the set-screw securing the 1stlreverse shift fork to the shift гаН then slid e

Chapter 6 Transmission те

rail OUt of the геаг of the case. 12 Slide the 1s tlr8verse synchronizer forward as far аз possibIe. then rotate т е shift fork upward and lift it out 01 the саsе. 13 Push the 2пd/Згd speed shift fork rearward 10 the 2nd speed position 10 ga in access to the retaining set-screw. Remove the set-screw пот

the fork then. using suitabIe pliers

ог

grips, rotate the shift rail

throu gh 900 as shown in Fig. 6.10. 14 Uft the interlock plug out of the case with а magnet and then {ар те геаг end of the 2пd/Згd shift га1l 10 remove the expansion plug

from the front of the case. Withdraw the shift rail. t 5 Remove the 2nd/3rd speed shift rail detent plug and spring from

111

bearings that тау have lallen out of the gear cluster. Note: There аге

25 needfe bearings in each end о{ the gear cluster. 21 Aemove the shift levers 1гот the side 01 the case Ьу undoing the securing nuts, withdrawing the levers and then sliding the shafts out 01 the case. Oiscard the O·ring seals. 22 00 not remove the TAS switch (;1 so equipped) Iгот the сазе, unless the switch is damaged. Aemoval 01 the switch will damage the plastic sealing tape. 23 The dismantling 01 the input and output shaft assembIies is described in the 10110wing Sections.

the case. 16 Pull the input shaft and bearing from the front of the case. 17 Rotate the 2пd/Згd speed shift fork upward and lift it from the case. 18 Carelully lift the output shaft assembIy out through the top 01 the case. 19 Drive the reverse idler gear shaft out 01 the case and lift the reverse idler gear and two thrust washers Irom the case. 20 Lift the countershaft gear cluster, thrust washers, and dummy shaft lгот the case. If а dummy shaft was not used collect апу needle

2ND

4

Iпрut

shaft (3-speed) -

dismапtliпg

1 The only time the input shaft requires dismantling is when the bearing ог shaft requires renewing. 2 With а pair 01 e)(panding snap-ring pliers, remove the small зпар­ ring which retains the bearing оп the input shaft. 3 With а soft-headed hammer gently tap the bearing 10гward and then remove it lrom the shaft.

SHAFТ АНО

дно

LEVER

I TOOL-T52T 6500-0JO

l

,

I

r Fig. 6.1 О Aotating the

2пd / Згd

SHIFТ

LEVER

speed shaft rail (3-speed) (See. 3) Fig. 6.11 Rеmоviпg the shift levers and shafts (З-sрвеd) (See. З)

6

INPUT

SHAFТ

ROLLER

AND

\ BEAII:ING II:ING

II:INGS

с',1:1

Fig. 6.1 3 Fig. 6.12 Lосаtiоп 01 TRS switeh some models. (See. З)

оп

Iпрut

shaft dismantled (See. 4)

....

-_ ._---

5

Тrапsmissiоп

Chapter 6

112

Output shaft

IЗ-sрввd)

4 Now гетоуе the next snap-ring and press the shaft out of the reverse gear and synchronizer sleeve assembIy, (see Fig. 6.15). 00 not attempt to гетоуе the 1st/reverse synchronizer hub from the shaft Ьу tгying ta hammer it ог Ьу prying it оН with levers as this will ргоЬаЫу cause damage to the synchronizer assembIy. 5 When dismantling the synchro hubs and sleeves, first refer to Fig. 6.16 and 6.17 , and etch аг lightly punch alignment marks оп each part. 6 Push the sleeves аН the hubs and separate the inserts and insert springs, making а nate which way round they аге installed. 00 not mix 1st/reverse synchro hub parts with thase fram the 2пd/Згd synchro hub assembIy.

- dismantling

1 For dismant1ing. mount the plain section of the shaft in а vise with 50ft jaw-grips. As each companent part is removed from the shaft make а note of its position and which way raund it is installed, then place it оп а clean sheet of рарег in the order of removal. 2 Aefer 10 Fig. 6.14. Remave the snap-ring from the front of the output shaft and slide the bIocking rings, the synchranizer hub and 2nd gear оН the shaft. 3 Аеmауе the next snap-ring and the tabbed thrust washer, then slide the 1 st gear and bIocking ring оН the shaft.

BLOCKING RING BLOCКlNG

~ING

SНAFT

SPEEDCМEТER

DRIVE GEAR

RINGS

./

LOCK BALL

I

OUTPUT •

)-1--

1ST GEAR

SNAP RINGS REAR REVERSE GEAR днр SLEEVE

THRUST WASHER

Fig. 6.14 Exploded view of output shaft assembIy IЗ-sрееdJ ISec. 5) Fig. 6.15 Removing 1 sl/reverse synchronizer IЗ-sрееdJ (Sec. 5) FRONT INSERT SPRING

ALIGNMENT MARKS

RING AND REVERSE GEAR

Fig. 6.16 Exploded view ot 1 stlreverse synchronizer

IЗ-sрееd)

(Sec. 5)

HUB AND SlEEVE

RtNG

•

~

tNSERT SPRtNG

Fig. 6.17 Exploded view ot 2пd/Згd synchronizer

IЗ-sрееdJ

(Sec. 51

•

Chapter 6 Transmission

8

Tran.miuion

IЭ-sрееd)

- examination

апd

113

renovation -'--PRESS

1 С1вап and then 8xsmine аll the dismantled рагtз far general wear, distor1ion and damage. 2 Examine the gears 10г excessive wear and chipping 01 the teeth.

RAМ

Renew аз necessary. 3 Examine the countershaft far signs 01 wear, where the countershaft gear cluster needie bearings гuл. 11 а smaH ridge сап Ье lel1 8t either end 01 the shaft it should Ье renewed. 4 The synchro btocking rings will ргоЬаЫу Ье badly WQГП and It is 1аlзв economy not to renew them . New rings will improve the smoothness and speed 01 shift considerabIy. 5 The needle roller bearings located between the позе 01 the output shaft and the annulus оп the геаг 01 the input shaft аге al50 liabIe (О wear and should Ье renewed. 6 Examine the condition of the two ba ll bearing assembIies, опв оп the input shaft and the опе оп the output shaft. Check them for noisy operation , 100senes5 between the inner and outer гасез and for general wear. Normally they 5hould Ье renewed оп а transmission that . . 15 Ьв1по rebuilt after а high тilеаов . 7 If the synchro hubs аге woгn 1! will Ье necessary to renew а сот plete assembIy аз the рагtз аге not supplied separately. 8 If the bush ing 1п the extension housing 1з woгn it 1з recommended that you take the housing to your 'осаl Ford repair statlon to have the bushing renewed. 9 Тhe 011 seals in the extension housing, the input shaft bearing retainer and the selector lever О-г1по зеа!з should Ье renewed аl each dlsmantling. Drive out the old seals with а drlft. When Installing new seals carefully tap the seals Into place, using а piece of wood to spread the load evenly, so that they enter their houslngs squarely. 10 The only paгt of the output shaft that 1з Iikely to Ье worn is the paгt where it enters the input shaft. However, examlne il thoroughly for апу signs of зсог1по ог picklng-up, and if damage 1з аррагеп! it should Ье renewed .

7

Input shaft IЭ-sрееdJ - ге88ветЫу

1 When installing the bearing оп the shaft ensure that the groove, cut 1п the outer periphery of the bearing , faces away from the оеаг. If the bearing Is installed the wrong way round It will not Ьв possibIe to fit the large snap-ring which retains the bearing in the housing. 2 Using the jaws of а vise as а suppoгt behind the bearing, tap the beari ng squarely into place Ьу striking the геаг of the input shaft with а soft-faced hammer. 3 Insta ll the snap-ring which retains the bearing in posilion оп the input shaft.

8

Output shaft (З-sрееdJ - Г8авветЫу

1 AssembIe the synchro hubs. Positlon the inseгt spring in the hub of the 1 st/reverse synchronizer. Make sure that the spring covers 811 the inseгt gfQOves. Start the hub оп the sleeve until the index marks, made at dismantling, properly allgn. Position the three inserts in the hub, ensuring that the small end Is оп the inside of the hub, then slide the sleeve and reverse gear onto the hub. 2 Fit опе i nseгt spring into а groove of the 2nd/3rd synchro hub, ensuring that аll three 1пзегt slot5 аге fully covered, then with the index mark5 оп the hub and 51eeve aligned staгt the hub into the sleeve. Place the three inseгts оп top of the retaining 5pring and push the a5sembIy together. Fit the remaining inseгt spring so that the 5рг1по ends cover the same 510t5 а5 the other spring. ОО not stagger the springs . 3 Before assembIlng the оеагз and synchro hub onto the output shaft lubricate the 5haft machined surfaces and splines with fresh transmission oil. 4 Carefully press the reverse оеаг and synchronizer assembIy onto the shaft, аз shown in Fig . 6. , 8, then Install the retaining snap-ri ng. 5 In5tall the bIocking г1по оп the tapered surface of the 1 st gear and slide the 1st gear onto the output 5haft with the bIocking ring facing toward the геаг of the 5haft. Rotate the gear аз песеззагу to engage wlth the three notches in the bIocking rlng with the synchronizer inseгts .

""'- ОUТРU l

SHAFT·

SYNCHRONIZER

Fig. 6.18 Fitting the 1st!reverse svnchronizer

(З-sрееdJ

(Sec. 8)

6 Secure the 1 st оеаг in position with the thrust washer and 5пар• rlng. 7 Install 1he bIocking ring onto the tapered surface of the 2nd gear. Slide the 2nd оеаг. wlth its bIocking ring , onto the shaft, en5uring that the tapered side of the оеаг face5 toward the front of the shaft. 8 Finally, slide the 2nd/3rd gear synchronizer onto the end of the shaft, and install the retaining snap-ring.

9

Tr8nsmission

(З-sрееdJ

-

геавветЫу

, Lubrlcate the O-ring seals and Install them оп the shift lever shafts. Install the shafts in the сазе and position а shift lever оп each shaft and secure them with а flat washer, lockwasher and nut. 2 Lubricate the reverse idler оеаг thrust surfaces in the сазе with а film of oil and install the two thrust washers in position. Hold the reverse idler gear in position and ins1all the reverse idler shaft. 3 Меазиге the rever5e idler gear endplay with а feeler gauge. If the endplay 1з not within the limits given in Specifications at the beginning of thls Chapter, remove the thru5t washers and in5tall washers of а sultabIe thickness to obtain the specified endplay. When the endplay 1з within limits, install the retaining roll pin . 4 Smear some grease Into each end of the co untershaft gear and inseгt the 25 roller bearlngs and а thrust washer оп each end of the оеаг. InstaJl the dummy shaft, used at dismantling. inside thf' countershaft gear to keep the bearings in рlасе . 5 Place the countershaft оеаг and dummy shaft assembIy in the case. Place the case in а veгtical positlon , align lhe gear Ьоге and the thrust washers with the bores in the case, and install the countershaft. 6 Position the case horizontal and , using а feeler gauge, check the endplay of the countershaft gear. If the endplay i5 not within the limits glven in Specifications at the beginning of this Chapter, replace thethrust washers with washer5 of the required thickness to obtain the specified endplay. 7 After ensuring that the endplay is within limits, install the dummy shaft in the countet5haft оеаг and leave the countershaft оеаг in the bottom of the сазе until the input and output shafts have Ьееп Instal'ed. в Install the output 5haft assembIy into the сазе through the top of the сазе. 9 Install а new snap-ring in the groove round the геаг bearing assembIy and drive the bearing along the shaft un1il it enters tM apeгtuгe in the геаг of the case. Ensure that the groove in the bearing is

IЮLL

I

ЮLЕR

GEAR

SHAFТ

Fig. 6.19 Fitting the геуегзе idler О88Г 8nd shaft (З-sрееdJ (Sec. 9)

8

114------------------------------------------------------------------------"' BEARINGS (25

ЕАен

~i O

\

BEARING REТAINER

8EARING REТAfNER

ROLL P1N

Fig. 6.20 Exploded view of countershaft gear (3-speed) (Sec. 9)

Fig. 6.21 Adjusting the gearshift linkage (3-speed) (Sec. 10)

"OD

V1EW 11'4 ORCLE W LOCK ROO АТТдСНМЕНТ

GAUGE PIN HOlE (LlSE

ALIGNМENT НО.

15 DRILl)

АНО REVERSE

SHIFT ROD

"00 ADJUSTMENT SLOI

Fig. 6.22 Gearshift linkage with lock-rod (later models) (Sec. 11 J

•

•

Chapter 6 Transmission toward

те геаг

of the case.

1О In51all а new retaining snap-ring оп the output shaft. 11 Сов' the Ьоге of the input shaft with а thin fllm of grease and 1П51а ll

12 In51all the input shaft, Згd gear and synchro rlng assembly through the front of the CBse, making sure that the end of the output shaft i5 correctly located in the гоНег bearing recess of the input shaft. 13 Install а new snap-ring in the front bearing gгoove and tap the bearing alon9 the input shaft until il enters its housing in the саsе. Carefully 1ар the bearing fully home. 14 Position the 2пd/Згd 9еаг shift fork оп the 2пd/Згd gear synchro hub. в

detent plug spring and

а

ptug in the case.

16 Push the 2пd/Згd 9еаг synchro hub as far as possibIe toward the геаг of the case (2nd speed position). 17 Align the hole in the shift fork with the case and push the 2nd/3rd gearshift rail in from the front of the case. It will Ье necessaгy to depress the detent plug to епаЫе the rail to enter the Ьоге. Push the rail inward until the detent ptug engages the forward notch (second speed position ). 18 Secure the fork with the set screw and then move the synchronizer to the neutral position. 19 Instalt the intertock ptug in the case. When the 2nd/3rd gearshift гаН in the neutral position, the top of the intertock plug wiJI Ье stightly lower than the surface of the 1stireverse shift rail Ьоге. 20 Push the 1 st/reverse synchronizer forward to the 1st speed position and instalt the 1 st/reverse shift fork in the synchronizer groove. Rotate the shift fark into the correct position and push the 1 st/reverse shift rail in from the геаг of the case. Push the гаН inward until the center notch (neutral) is in line with the detent Ьоге . 21 Secure the fork to the гаН with the set screw. 22 Install а new shift rail expansion plug in the front of the case , flush with ог to 0 .60 in (12 тт) below the face of the case to prevent interference with the clutch housing assembIy. 23 Place the transmisslon case in а vertical pasition and working through the filler hole. align the Ьоге of the countershaft gear and the thrust washers with the Ьоге of case using а screwdriver ог simllar tool . 24 Insert the cou ntershaft from the геаг of the case and push the dummy shaft out of the countergear with the countetshaft. 8efore the countershaft Is completety inserted, ensure that the roll pin hole in the shaft Is aligned with the hole in the case, then drive the countershaft Into place and install the гоН pin. 25 Check that the countershaft gear rotates smoothly. 26 tnstall а new front bearing retainer snap-ring onto the input shaft. 27 Install the input shaft bearing retainer and new gasket; ensure that the оil return slot Is at the bottom of the case. 28 Apply gasket sealer to the bearing retainer bolts and tighten them to the specified torque. 29 Install the speedometer drivegeaг lock-ball into the hole in the ou tput shaft, hold the ball in pasition and slide the drive gear оУег it. Secure with а snap-ring. 30 Coat а new extension housing gasket with sealer and position it оп the case . Coat the threads of the attaching screws with sealer. install the extension housing to the case and tighten the securing screws to the specified tarque. 31 Rotate the input shaft Ьу hand and check that all the gears сап Ье selected in turn and both shafts rotate smoothly. 32 Install the remaining detent plug and spring in the case. Оп early models Install the retaining screw; оп later models the spring is retained Ьу the соуег. 33 Coat а new соу ег gasket with sealer, install the top соуег and tighte n the capscrews to the specified torque. 34 Tighten the drain plug to the specified torque and Install the filler/ level plug temporarily.

1 О Gear shitt linkage learly З-sрввd models) - adjustment Loasen the three shift linkage adjusting nuts. Insert а 0.25 1п (6.3 тт) diameter rod through the control bracket and 'еуег alignment holes as shown in Fig. 6.21 . 2 Tighten the three linkage adjustment nuts and remove the alignment rod. 3 Start the engine and shift the selector 'еуег to each position to ensure that it aperates freely. 1

11 Gearshift linkage (18t8r З-sревd models) - adjustment

the 15 roller bearings.

15 Inslat!

115

Оп models 'гот 19708 tf8nsmission lock-rod connects the lower

steering column shift tube (о the т8пи81 tr8nsmission reverse lever. It locks th8 tf8nsm;ss;on ;п reverse g88f when the ;gn;t;on sw;tch is ;п the LOeK position. Adjustment С8П Ье cBrr;ed out only when the shift controJ BJignment ;s correct. 1 Place the hand shift 'еуег in neutral. Loosen the lock-rod-to-Iever nut. 2 Align the hole [п the steering column socket casting with the column alignment mark (see Fig. 6.22), and insert а 0.18 in (4.5 тт) dlameter pin . The column castlng must not rotate with the pin in positlon. 3 Tighten the tock-rod adjustment nut to а torque of 1О to 20 'Ы ft

11.3102.7 kgf ml. 4

Check for correct opetation .

12 Transmission lock-rod - removal 8nd install8tion 1 Disconnect the rod at the transmission 'еуег. 2 Аетоуе the retaining сliр and pull the rod out of the grommet located [п the 'еуег attached ta the steering cotumn shift tube and lift away the rod. 3 Installation is the геуегзе of the гетоуаl procedure . Adjust the lock-rod as described in Section 11 . 13 Tr8nsmission (4-speed) - dismantling 1 Refer to Section 3 and саггу out the operations [п paragraph 1 through 6. 2 Support the countershaft gear and, working from the frant af the case. push the countershaft aut of the геаг of the case using а dummy shaft (refer to Section 3, рага 8). Leave the dummy shaft [п the gear cluster, to prevent the needle rollers from dropping out, and lower the countershaft gear to the bottom of the case. 3 Place the 1st/2nd gear shift 'еуег and the reverse shift 'еуег in the neutral position. Position the Згd/4th gear shift 'еуег to engage with the Згd gear. 4 Аетоуе the Згd/4th speed shift fork securing screw, tap the inner end of the shift гаН to unseal the expansion plug from the front of the case; then withdraw the 3rd/4th shift rail from the front of the case. Collect the interlock pin fram the shift rail. 5 Remove the 1stl2nd speed shift fork securing screw and slide the 1st/2nd speed shift rail out of the геаг of the case. 6 Аетоуе the interlock plug and detent ptug from the top of the case. 7 Remave the snap-ring retaining the speedometet drivegear оп the output shaft, then slide the gear off the shaft and collect the speedometer gear drive ball . 8 Remove the output shaft bearing reta ining snap-ring and, using two screwdrivers, placed between the outer snap-ring and case, carefully 'еуег the bearing out of the case and slide it aff the end of the output shaft. If the bearing cannot Ье removed in this таппег а special tool (Na Т 64Р-7025-В) will Ье required. 9 Аетоуе the Input shaft and bearing assembIy, and the bIocking ring from the front of the case. 10 Моуе the output shaft to the right-hand side of the case, to provide clearance for the shift forks, then lift out the Згd/4th and 1st/reverse shift forks. 11 Hold the thrust washer and 1 st speed gear to prevent them from sliding off the shaft and гетоуе the output shaft through the tap of 1tte case as shawn [п Fig. 6.25. 12 Remove the reverse gear shift fark set-screw. rotate the геуегsе shift rail 90 0, and then slide the shift rail out of the геаг af the case. Lift out the reverse shift fork. 13 Аетоуе the reverse detent plug and spring. 14 Using а dummy shaft ( а suitabIe piece of tubing will do) remove the reverse idter gear shaft as shown in Fig. 6.27 . 15 Lift the reverse idler gear and thrust washers from the case. taking саге to keep the dummy shaft [п position to prevent the needle rollers dropping out. . 16 Lift the countershaft яеаг, thrust washers and dummy shaft assembIy from the case.

6

Chapter 6 Transmission

116

_-SРRlNG

fI •

DEТENT PLUG

06,,;:' С.2- :

. / FIRST AND SECONO

5РЕЕО

SHIFT RAIL

. ,::; - _ ; , '

~SCREW

AND FOURTH ~ - - SPHD SHIFT FORK

__ ....

FIRSТ

FIRST AN REYERSE 5РЕЕО

AND SECOND

SPEED

SHIFТ

SHIFТ

FORK

FORK

DETENT PLUG-+(j

_.

_INTERLOCK P'IN ~

SCREW~'"'~'\1 THIRD AND SPEED SHIFТ RAIL

rDEТENT PLUG

OUTPUT ТО

МОУЕD

RIGHT SIDE OF CASE

Fig. 6.24 Removing the shift forks

DEТENT

PLUG......-{)

SPRlNG _.

REVERSE

SHIFТ

REVERSE

RAll

158С.

FORK

-~, ~

(4-sрееdJ

131

THIRD AND FOURTH 5YNCHRONIZER

EXPAN SION

PlUG

ВОН

I

DRAIN PLUG

Fig. 6.25 Fig. 6 .23 Exploded view of shift rails and forks (4-speed) {Sec. 131

Lifting out the output shaft

assembIy (4-sрееdIISес. 1 З)

IDlER GEAR

SHAFТ

1001_ Т64Р·7140-А

Fig. 6.26 Rotating the reverse shift rail (4-speed) (Sec.

1ЗJ

Fig. 6.27 Removing the reverse idler gear shaft (4-speedl (Sec. 131

17 Undo the retaining nuts and remove the three shift levers. 18 Remove the three cams and shafts from inside the case . Discard the O-ring from each shaft. The dismantling of the input and output shafts is described in the following Sections.

14 Input shaft (4-speed) - dismantling This procedure is as described in Section 4.

•

Chapter 6 Transmission

I

15 Output shaft (4-speed) - dismапtliпg

17 Input shaft (4-speed) - reassembIy

1 Refer 10 Section 5 and proceed аз in paragraph 1. 2 Ае1ег 10 Fig. 6.28. Аетоуе the snap-rlng from the 1ront of the shaft and then slide the Згd/4th gear synchro hub, bIocking ring and Зrd gear off the shaft. 3 Aemove the ne)(t snap-ring and the 2nd gear thrust washer, then slide the 2nd gear апd the bIocking гlпg off the shaft. 4 Аетоув the ne)(t sпар- гiпg. 5 Аетоуе the thrust washer, 1 sl gear апd bIocking ring from the геаг 01 the shaft. Press the shaft out 01 the 1 stl2nd synchro hub. ОО not attempt to remove It Ьу trying to hammer ог ргу 11 off with levers as this will ргоЬаЫу damage the synchronizer assembIy. 6 When dlsmantНng the sупсhго hubs and sleeves, 11Г5! refer to Fig. 6.29 апd etch ог lightly punch аligпmепt marks оп each part. 7 Push the sleeves off the hubs апd separate the inserts and iпsегt springs, making а note which way round they аге Iпstаllеd. 00 поt mi)( the 1stl2nd 5ynchro hub parts with th05e from the Згd/4th synchro hub.

16

Тгапsmissiоп

117

{4-speedl- examination and renov8tion

This procedure is as described in Section 6.

This procedure is as described in Section 7.

18 Output shaft (4-speedl -

геаззвтЫу

1 Assembte the synchronizers. 1"5tall the hub in the sleeve. making sure that the index marks. made 8t disassembIy аге in аligпmепt. Posit;on the three inserts i"to place оп the hub then the insert springs, making $ure that the irregular surface (hump) is seated in опе of the

inserts. 00 not stagger the springs. 2 Before assembIing the gears and synchro hub O"to the output shaft, lubricate the splines and machined surfaces of the shaft with fresh transmission 011. 3 Install the 1stl2nd gear synchro hub onto the front of the output shaft with the shift fork groove toward the геаг 01 the shaft. The synchro hub is а press-1it оп the shaft and to avoid damaging the зуп­ chronizer аззетЫу, Install the synchro hub wlth the teeth end facing toward the геаг of the shaft. Fit the snap-ring. Place the bJocking rlng оп the 2nd gear. 4 5 Slide the 2nd gear onto the shaft, making sure that the inserts in the synchronizer engage the notches in the bIocking ring. 6 Install the 2nd gear thrust washer and snap-ring. $РЕЕDОМЕТЕК

ORIVE

SHAFТ

SEAL RING

RING

THRUST W'

FIRST

GEAR

SHAFТ

а....О

I

SPEEDOMEТER GEAR

•

DRIVE ВА LL

SNAP RING

6

THRUST WASHER THIRD SPEED GEAR

BLOCКlNG

RING

RING FIRST AND SECOND SPEED SYNCHRONIZER RING

SECOND SPEED GEAR SNAP RING

THIRD AND ЮURТН SPEED SYNCHRONIZER 5NAP RING

Fig. 6.28 Exploded view 01 output shaft assembIy (4-speed) (Sec. 15)

•

118------------------------------------------------------------------------' ЕТСН

INSERT_ INSERT SPRING

INSERT SPRING

1

FtRST AND SECOND SPEED SYNCHRONIZER

INSERT SPRINC _INSERT SPRING

HUMP

\ GROOVE ТО FACE TOWARD FRONT

THIRD AND FOURTH SPEED $YNCHRCNIZER

L---- OF

TRAN$MtSSION

Fig. 6.29 Dismantling the synchronizers (4-speed) (Sec. 15)

REVERSE GEAR

САМ

AND SHAFT AND SECDND SPEED

САМ

AND SHAFT

():2 . ·D·RING , D·R

~

THIRD AND FDURTH САМ

AND SHAFT

SPE~

FIRST AND SECOND SPEED

SHIFТ

LEVER

1

r

,

J

REVERSE

SHIFТ

LEVER

,

THIRD AND FOURTH SPEED

SHIFТ

LEVER

Fig. 6.30 Exploded view of сатз and shafts. and shift levers (4-speed) (Sec. 19)

•

Chapter 6 Transmission 7 S rк:le the Эrd gea r onto the shaft with the tapered sur1ace toward the front and tЛеп place а bIocking ring оп the Згd gear. 8 Slide the З rd/4th gear synchronizer onto the shaft and make sure mat те inser1s engage the notches in the bIocking ring. In5tall the

119

gear. Install the dummy shaft, used 8t dismantling, inside the

countershaft gear to keep the bearings in place. 3 Aefer to Section 9 , and С8ГГУ out the procedures described in

paragraph 5 through 7.

retaining snap-ring. 9 In51all the bIocking ring оп the 1st ge8t and then s1ide the gear onto tЛ е геаг of the output shaft. 10 I"st sll the thrust washer оп the гваг 01 the shaft.

19 Tr8nsmission l4-speed) - reassembIy 1 Lubricate the O-ring 5eals and install them оп the shift 'еуег shafts. Slide each сат and shaft i"to position in the transmission case, install the shift levers оп the shafts and secure them with а flat washer, lockw8sher and nut. 2 Smear зоте grease l"to each end 01 the countershaft gear and inseгt the 21 roller bearings and retai"ing washer in each e"d 01 the

4 Smear зоте gr8ase in the Ьоге at e8ch end 01 the reverse idler gear, hold the dummy shaft in the gear and install the 22 roller Ьеаг­ ings and the retainer washer in each end of the gear. 5 Install the reverse idler sliding gear оп the reverse idler gear with the shift fork groove toward the lront. 6 Apply а thin lilm 01 grease to the thrust surfaces in the case and locate the thrust washers in position, then install the reverse idler gear, sliding gear and dummy shaft in position and 1nstall the reverse id ler shaft. Make sure the shift 10rk groove is toward the lront of the case . 7 Check the reverse idler gear endplay with а leeler gauge. 11 the endplay is not within the limits given in Specifications 8! the beginning 01 this Chapter, repl8ce the thrust washers, as neces5ary to obtain the specilied endplay. 8 In5tal1 the reverse ge8r shift rail detent spring and plug , hold the

COUNТERSHAFТ

REТAINER

WASHER

WASHER

THRU$T

ROLLER 8EARINGS'

GEAR 8EARINGS REТAINER

WASHEIf

Fig. 6.З1 Exploded view of countershaft gear assembIy 14-speed) (Sec. 19) REVERSE GEAR

REТAINER

ROLLER

8

WASHER

WASHER

REТAINER

-

WASHER

IDLER GEAR

SLIDING аЕАР: • it>22З WASHER

Fig.

6.З2

Exploded view of

геуегзе

idler

оеаг

8ssembIy (4-speed) (Sec. 19)

Chapter 6 Transmission

120

•

teverse sh ift fork in place оп the reverse idler sliding gear and push the shift rail in from the геаг of the case. Install the shift fork securing

screw. 9 Install the output shaft assembIy through the tap of the сазе, аз shown in Fig. 6.25 , taking саге that the thrust washer does not s1ide оН .

1О InstaH the 1stJ2nd and 3rd/4th shift forks оп their respective gears. 11 Install а detent plug in the detent hole and position the reverse shift rail in neutral, then зтеаг the Згd/4th gear shift rail interlock pin w ith grease and in5tall 1! in the shift rail. 12 Push the Згd/4th gear shift гаН into place with the three detents towards the outside of the сазе . 1 3 Move the front synchronizвr into Згd gear and in5tall the Згd/4th gear shift fork 5ecuring 5crew, then move it to the neutral position and in5tall the 3rd/4th яеаг 5hift гаВ detent plug , 5pring and bolt in the lefthand 5ide of the са5е . In5tall the interlock pin (tapered end5) in the са5е .

14 Slide the 15t12nd яеаг 5hift fork into place and in5tall the 5hift fork • 5еСUГIПg 5crew . 15 Smear а thin fBm of grea5e ёп the Ьоге of the input 5haft and in5tall the 15 roller bearing5. 00 not apply too much grea5e а5 it coutd bIock the оё' hole5. 16 In5tall the front bIocking ring оп the 3rd/ 4th яеаг 5ynchronizer and in5tall the input 5haft яеаг in the са5е, making sure that the output shaft 5pigot enter5 the roller ЬеагёПЯ5 ёп the input 5haft and that попе of the bearing5 drop out. 17 Place а new ga5ket оп the input 5haft Ьеагёпя retainer, coat the securing bolt5 w ith 5eatant, then in5tall the retainer and tighten the bolt5 to the 5pecified torque . 18 In5tal l а new 5nap-ring in the ягооуе оп the геаг bearing and drive the bearing along the 5haft until it enter5 the case, then install а new retaining sn ap-ring оп the output 5haft. 19 P05 it ion the са5е vertically (see Fig. 6.33 ), align the counter5haft gear and thrust wa5her5 with the Ьоге in the case then insert the counter5haft gear and pU5h the dummy 5haft out of the countergear. Check that the countergear rotate5 freely. 20 In5tal l the 5peedometer drive gear 10ck-ЬаН into the hole ёп the output 5h aft and 51ide the drivegear оуег it. In5tall the retaining 5пар­ rin g. 21 P05it ion а new extension hou5ing gasket оп the case . Coat the

attaching screw5 with 5ealant, in5tall the exten5ion hou5ing and tighten the 5creW5 to the specified torque. 22 In5taJl the drain and filler plUg5. 23 Aotate the input 5haft and check that all the gear5 сап Ье 5elected in turn, and that both shaft5 rot8te 5moothly. 24 In5tall the гетаёпёпя detent plug and spring in the case. ОП early model5 install the retaining screw ; оп later model5 the 5pring i5 retained Ьу the соуег. 25 Coat the соуег securing 5creW5 with sealant and u5ing а new gasket in5tall the соуег оп the case . Tighten the securing cap5crew5 to the specified torque. 26 Соа! the 3rd/ 4th яеаг shift гаёl plug Ьоге with sealant and in5tall а new expansion plug.

20 Shift linkage (early 4-speed models) - adjustment 1 Loosen the three 5hift linkage adjustment nuts. Insert а рёесе of 0 .25 in (6 .3 тт) diameter rod through the 2 control bracket and levers а5 5hown ёп Fig. 6 .34 . 3 Tighten the three linkage adjustment nut5 and then гетоуе the alignment rod. Check the operation of the gearshift 'еувг. 4 21 Gearshift control installation

models) -

гетоуаl

REVEIlSE

SHrfТ

DUST

'00 FrRST AND SECOND SPEED I ROD

TOOL

Fig . 6.33 Installing the countershaft (Sec. 19)

and

1 Аетоуе the 5ё)( 5creW5 securing the 5hift 'еуег boot retainer, and slide the retainer and boot up the 'еуег . Аетоуе the plungers ' and 5prings from the 'еу ег ( 5ее Fig. 6.35). Undo the two 5h ift lever-to-trunnion 5ecuring bolt5 and гетоуе 2 the 5hift 'еуег. 3 From under the саг disconnect the three shift rods fTom the tran5mission Ьу removing the hairpin-type retaining clips. 4 Аетоуе the three bolt5 attaching the 5hift a5sembIy to the exten5ion hou5ing and withdraw the 5hift a5sembIy. 5 Аетоуе the back-up light 5witch from the 5hift аS5етЫу. 6 U5ing 5пар-гёпя plier5, гетоуе the snap-ring from the end of the selector shaft, then the flat washer and spring. Аетоуе the two se curing bolt5 and pul l the retainer, selector 7

GEAR

COUNТERSHAFT

(early 4-speed

LINKAGE ADJUSTMENT NUTS SHlfТ

THtRD АНО FOUIITH SPEED SHlfТ ROD

Fig. 6.34 Adjusting shift linkage (eatly 4-speed models) (Sec. 20)

•

Chapter 6

•

Тrапsmissiоп

121

I

I

RETAI

SHIFT LEVER ASSEMBL У ____.::

SPRING PLUNGER

SELECTOR

SUPPORT

1 • 2 SE LECTOR LEVER

STRAIGHT PIN пJ

/

NEUTRAL INDEX

· 4 SELECTOR LEVER

ВААСКЕТ

RETAINER FLAT WASHER/ SNAP

•

TRUNNION

STRAIGHT PIN ( LONG J

/

PIN REVERSE SELECTOR LEVER

~

..

сuтт Е:::R_ _

FLAT WASHER

SPRING

STUD

WAVE WASHER Fig. 6.35 Removing gsarshift control (early 4-speed models) (Sec. 21) 'еуегs

and bracket from the shatt. Using а pin punch drive the short selector

8

8 'еуег pin from the shaft, then drive the long trunnion pin from the shatt , and гетоуе the trun-

nion and shaft. 9 Clean and examine all the parts for wear and damage. Lubricate all friction surfa ces. 1 О Installation i5 the reverse 01 гвтоуаl procedure. Adjust the shift linkage as described in Section 20.

GAUGE PlN A ~I GNМ!NJ tЮLf (USE NO.

~O

. .";,;','oH. S HI FТ ''''

ROD

22 Shift linkage (Iater 4-speed models) - adjustment 1

Disconnect the battery ground lead from the negative terminal.

2 With the shift 'еувг in neutral, pull the lower boot up far enough to insert the alignment 'tool, (see Fig. 6.38) into the shift control assembIy . Make sure the tool is completely through and located in the notches оп both sides of the shift contro l housing. 3 If the al ignment tool enters free ly the adjustment 1s correct. For апу lever that is out of alignment, loosen the nuts attaching the shift control rods to the shaft levers and disconnect the reverse shift rod at the shift control assembIy. Rotate the reverse lever (the опе in the center) clockwise to shift into reverse gear. 4 Tighten the two forward-speed shift rods at the control assembIy. 5 Rota te the reverse lever cou nterclockwise until it stops, then attach the reverse shift rod to the control assembIy. 6 Remove the alignment tool. Connect the battery ground lead and

' ' ' ' ' " , 5HIFl CON1ROL ROD •

'0« REVER5E LOCK

5HIFТ

CON1ROL ROD

"DJUS1M EN ! NUT

аоо

Fig. 6.36 Shift linkage (later 4-speed models)

Chapter 6

122

Тrапsmissiоп

1~

1/ ." DIA .....--",....

THI N RUlE OR РIЕСЕ OF . 015" Т О . 020" THI(K SHIM STOCK. INSERT Т О Д О ЕРТ Н

ALIGNMENT TOQl - МАКЕ FROM 1/ 4 DIA. ROUNO STOCK

O F APPAOXIMATELY 1" AN D PUl L lE VE R ои т

SНIП

НANOLE

O F CONTROl A5SEM BLУ. SHtFT LEVER

о

•

7/ 16 FLAT WASHER

7! 16l0CK WASHER

CARRIAGE

SHIFT CONTROL

PIVOT

TRANSMISSION

ТО

EXТENStON

MOUNТlNG PLAТE

7/ 16-14)(3 НЕХ 80LT

,

·1 •

-

•

LI GHT

Fig. 6.37 Removing the shift lever 118t8r 4-speed modelsllSec. 24)

SWIТCH

LIGHT SWIТCH REТA\NER

.........

3,tв..16)( НЕХ

2. 75 U.B . S. НЕАО 80L Т

5HIFТ

ASSEМBLY

Fig. 6 .38 G88r shift controlassembIy (18t8r 4-SР88d models) (See8. 22 and 24)

install the boot. 7 Check that the shift shift positions.

mвchanism

operates smoothly through

аll

the

23 Lock-rod 118t8r 4-speed modelsl - adjustment Adjustment of the lock-rod is the for 3-speed tгапsтisзiопs.

зате аз

described in Section 1 1

24 Ge8rshjft control (Iater 4-speed models) inst8118tion

1

remov81 8nd

Disconnect the battery ground lead from the negative terminal.

2 Аетоуе the shift lever аз shown in Fig. 6.37. 3 Undo the four screws attaching the bezel and the upper and lower shift lever boots to the floor; гетоуе the bezel and upper boot. 4 Working under the саг, гетоуе the nuts зесuгiпg the shift rods to the shift control 'еуегз. 5 Disconnect the back-up light switch connector and гетоуе the switch Ьу pulling it from the retainer. 6 Taking саге not to damage the boot, puH the opening for the transmission shifter mounting plate down and ОУег the shift аззетЫу. 7 Аетоуе the bolts securing the shift control аззетЫу to the mounting plate оп the extension houslng and withdraw the control аззетЫу.

8 Insta11ation 1З the геуегзе of the removal procedure. Adjust the shift linkage аз described in Sections 23 and 24. Check that the shift mechanism operates smoothly through all shift positions.

25 Fault diagnosis - m8nual transmission Symptom

ReasonJs

Weak ог ineffective synchromesh

Synchronizing сопез worn, split Worn bIocking rings

Jumps out of gear

Detent springs broken Detent notches worn

ог

damaged

Excessive noise

Oillevel too low Incorrect grade of oil in transmission Bearings worn ог damaged Gear teeth worn ог damaged

Excessive difficulty in engaging gear

Clutch adjustment incorrect

,

•

Chapter 6 Transmission РААТ В

123

- Automatic transmission

26 Gen8ral description Тhe

three types of automatic transmission . С4 , С6 and FMX, used оп Mustang models аге З-sрееd units сараЫе of providing automatic upshifts and downshifts through the three forward gear rati05, and al50 тапиаl selection of 1ir51 and second g88(5. Тhe transmissions аге уегу similar consisting basically of а torque converter. planetary gear train, two multiple disc clutches and а hydraulic control system. Due 10 the complexity of the automatic transmission unit, if репаг­ тапее i$ not ир 10 standard, ог overhaul i5 necessaгy , it i5 imperative that this Ье 18ft 10 the 'осаl Ford repair 5t8tion who will have the special equipment required for fault diagnosis and rectification. It is Imponant that the fault Is diagnosed before the transmission unit Is removed fTom the саг, if at аН posslbIe. The content of the following Sections is therefore confined 10 supplying general information and апу seгvice information that сап Ье used Ьу the owner.

27 Special towing

ог гесоуегу

information •

1 Should it Ье necessary to have the саг towed to а repair station it must по1 Ье towed for more than 20 miles (32 km) and the speed must not e)(ceed зо mph (48 kph). Towing is permitted provided that the transmission is not damaged. that the oil level is correct and the selector lever is in the N position. 2 If there is а fault in the transmission ог the towing distance is more than 20 miles (32 km), the driveshaft should Ье removed. as described in Chapter 7, and the геаг of the transmission sealed to prevent the ingress of diгt . As ап alternative, the саг сап Ье suspended and towed with the геаг wheels off the ground. 3 Оп cars with automatic transmission it is по! possibIe to tow-staгt the саг.

28 Transmission fluid level- checking 1 When checking the fluid level. the fluid must Ье at its normal operating temperature - appro)(imately 150° F (65 0 С). This is best achieved Ьу driving the саг for about 5 miles (8 km) under noгmal running conditions. Park the саг оп 'еуеl ground, apply the parking brake and depress 2 the fo01 brake pedal. 3 Allow the engine to idle and shift the selector lever through аll the positions three times, then position the lever at Р. Do not switch off the engine during the fluid level check. 4 Pull the dlpstick out of the tube, wipe it clean and push 11 all the way back inlo the tube, then puH it out and check the fluid level. 5 The fluid level should Ье аЬоуе the ADD mark; if necessary, top-up with fluid , through the dipstick tube , to maintain the level between the ADD and FULL marks оп lhe dipstick. Use only the specified fluid in the transmission.

29 Transmissio" - remov81and 1"8181181io" 1 Jack-up the саг, and suppoгt it securely with jack stands, to obtain the ma)(imum possibIe working height under the саг. Disconnect the battery. Place а large drain рап beneath the transmission oil рап, then 2 working from the геаг, loosen the attaching bolts and allow the fluid to drain. Remove all the bolts e)(cept the two front ones, to drain as much fluid as possibIe , then temporarily refit two bolts at the геаг to hold it in place. Оп РЕА and PEF models of С4 transmission the fluid is drained Ьу removing the dipstick/filler tube. 3 Remove the torque сопуегtег dra1n plug access соуег from the lower fron1 side of the сопуегtег housing. 4 Rotate the engine , Ьу means of а wrench оп 1he crankshaft pulley attaching bolt, until the сопуегtег drain plug is accessibIe , then remove the plug and collect the fluid in the drain рап. After the fluid has Ьееп drained, install and tighten the drain plug. 5 Remove the four flywheel-to-conveгter attaching nuts, cranking

, Fig. 6.39

Сопуепег

drain plug loc81ion (Sec. 29)

the engine as necessary to gain access to the nuts. 6 Аетоуе the driveshaft, as described in Chapter 7 . and соуег the end of the transmission with а polythene bag to prevent the ingress of diгt . 7 Remove the staгter motor retaining bolts and position the staгter out of the way. 8 Remove the nuts that attach each muffler inlet pipe to the e)(haust manifolds. Separate the pipes from the manifolds and Bllow the exhaust system to hang оп the геаг a)(le. 9 Disconnect the speedometer саЫе from the e)(tension housing. 1О Disconnect the kickdown rod from the 1ransmission downshift 'еуег, ~nd the shift rod from the manual lever. Оп models with а column lock-rod, disconnect the rod at the transmission . 11 Disconnect the vacuum hose from the vacuum unit and remove it from the attaching clip оп the transmission. 12 Аетоуе the f1ller tube and dipstick. Оп some models the fШег tube is secured {о the cylinder head with а bolt. 1 3 Disconnect the staгter inhibitor (neutral staгt) switch leads from the retaining cl ips and connectors. 14 Position а trolley jack beneath the transmission and raise it so that 1t takes the weight of the transmission. 15 Remove the two nuts securing the engine геаг suppoгt to the crossmember. 16 Raise the transmission just enough 10 гетоуе the weight from the crossmember, гетоуе the crossmember-to-frame side support зесuг­ ing nuts and lift out the crossmember. 17 Remove the bolts attaching the engine геаг suppoгt 10 the e)(te"sion housing and remove the suppoгt. 18 Disconnect the fluid cooler lines at the transmission and plug them (о prevent the ingress of diгt. 19 Suppoгt the геаг of the e"gine with а jack ог other suitabIe

8

suppoгt .

20 Ensute that the transmission is securely mounted

оп

the trolley jack, then гетоуе the conveгter-to-engine bolts (С4 - five bolts; св and FMX - si)( bolts). 21 Carefully move the transmission rearward and downward, and remove it from under the саг. 22 Installation 01 the transmission is the геуегзе of the removal procedure, but the following po1nts should Ье noted: (а)

Rotate the converter to вliуn the drain plug with ;Is hole in the f/ywhee! (ь) Do not allow the trensmission 10 take в 'nose-down' ettitude as the converter will move forwBrd and disengage {гот the ритр уеаг

(с)

Adjust the kickdown rod end selector linkage as described in Sections ЗА, З 1 and З2 (d) After lowering the саг 10 Ihe ground. {ill the transmission with f/uid со bring the !evel ир 10 the FULL mark оп the dipstick; then check end top-up the f/u;d !evel as described in Section

28. 30 Manual shift linkage - adjus1ment 1 2

Place the transmission selector 'еуег in the D position. Jack-up and suppoгt the саг. Working underneath the

саг,

loosen

~

Chapter 6 Transmission

124

t..r,e manuall ever shift rod retaining nut (эее Fig. 6.40) and position the transmission manual lever 'п the О detent. 3 With the transmission selector lever and manual lеУег ,п the D positions, tighten the retaining nut 10 а torque of 1О to 20 'Ы ft {1 .3 10

2.7kgf

mJ.

4 Check the operation of the transmission in each selector lever position.

31 Transmission lock-rod - adjustment

models {гот 1970 а transmission lock-rod connects the lower steering column shift сuЬе to the mапиа! reverse /еуег. It locks the transmission ,"п reverse when the ign;tion switch 15 ,"П the LOCK posit'-on. 8efore attempt;ng tQ adjust the lock-rod ensure that the тапив! Iinkage is correctly adjusted as described ,"п Section ЗА. 1 Loosen the lock-rod retaining nut (see Fig. 6.40) оп the transmis-

ЗЗ

Neutral 5t8rt 5witch

(С4

8nd

С6

tf8n5mission5) - 8djustment

1 Loosen the two switch attaching bolts. 2 With the transmission selector lever 1п N (neutral) position, rotate the switch and install а No 43 drill Into the gauge pin holes. It must Ье inserted а fuH 0.48 in (12.30 тт) into the three holes of the switch (see Fig. 6.41). 3 Tighten the switch attaching bolts and гетоуе the drill. 4 Check the operation of the switch. The engine should start only when the transmission selector lever is in the N ог Р positions.

Оп

sion manuallever. 2 Place the selector lever in the О position. 3 Align the hole in the steering column socket casting with фе column alignment mark and Insert а 0.18 in (4. 5 тт) diameter pin. The column castlng must not rotate with the pin in position. 4 Tighte n the lock-rod retaining nut to а torque of 1О to 20 Ibf ft ( 1.3 to 2 .7 kgf т). 5 Aemove the alignment pin and check the operation of the linkage.

tгапsmissiоп апd С6

34 Neutral st8rt switch (FMX

transmission

wittl 429 CI О engine) - 8djustment 1 Shift the selector lever to N (neutral) positlon. 2 Undo the selector lever handle securing screws and remove the handle (see Fig. 6.401. 3 Aemove the dial housing securing screws and remove the housing. 4 Аетоуе the two pointer back-up shield securing screws and remove the shield. 5 Loosen the two screws securing the neutral start switch to the selector 'еуег housing. 6 Adjust the switch in accordance with the information оп the switch adjustment plate (see Fig . 6.42). •

32

Кickdown

rod - adjustment 35 Intermediate band (С4 and С61- adjustment

1 Disconnect the throttle and kickdown rod return springs. 2 Ho ld the carbureto r throttle lever in wide ореп position against the stop . 3 Hold the kickdown rod against the 'through detent' stop. 4 Тигп the adjustment screw оп the carburetor kickdown lever to obtain а clea rance of 0.04 to 0.08 in (1 to 2 тт) between the screw and the throttle lever. 5 Release the carburetor and transmlssion levers to the normal free position. 6 Install the throttle and kickdown rod return springs.

GRОММЕТ

~'

1 The intermediate band is used to hold the sun gear stationary to provide the second gear ratio. If it Is not correctly adju5ted there .will Ье поticеаЫе slip during fir5t to second gear change instead of the usual crisp action. 2 То adjust the intermediate band, undo and remove the adjustment screw locknut located оп th6 16ft-hand side of the transmission. 3 Tighten the adjusting screw, using а torqu6 wrench S6t to 1 О 1Ы ft 11.4 kgf т), and then back-off the adjustment screw turns оп С4 transmissions of 1 t turns оп С6 transmissions.

'!

_R ETAI NING CllP

I, 1 - ' - - - - COLUMN

().

$НIП

lEVER ТYPICAL

ЗЕТ SCREW

GAUGE PI N _ _ _ _ _ AllGNMENT HQlE (и $Е NO 150.ill)

WHEN MARKED •

r-ЮТ Е:

GROMMET ми$Т ВЕ REPlACED I F ROD 1$ REMOVED.

G

$ElECTQR LEVER POtNТER

L

ВАск·иР SН I ELD

• '00

$TART & BACK·UP LAMP CIRCUIT (FM X .ONLY )

I L EVER ENGAGE FLATS OF STUD 11'1 SLOT OF ROO BEFORE APPL YING TORQUE

,

lOC K ROD RETAINING " От

"ОТ

ЗЕАТ

SH IFT ROD

Fig. 6.40 Manual shift linkage - automatic transmission (Secs.

BEL Т

WARNING CIRCUIT (FMX TRANS. ONL У)

31 and 34)

•

Chapter 6 Transmission

125

NEUTRAL

SТART

ДНО

Fig . 6 .41 Neutral 5t811 switch adjustment (С4 and св tгапsmissiоп) (Sec. 33)

• NEUTRAL

All GNМENT МдRК

NEUTRA L

ACT UAT QR

РQSIТЮN

LEVE R

Fig . 6 .43 Adjusting intermediate band 150с.351

Fig. 6 .42 Neutral start switch adjustment (FMX transmission and св tгепsmissiоп with 429CI D enginel (Sec. 34)

Т59Р·77З70·8

Fig. 4

6.44

Adjusting

low 150С. 361

(reverse

band

'"sta ll а new locknut and tighten it to the specified torque, while

holding the adjusting screw to prevent it turn ing. 37 FMX transmission - band adjustment Э6

Low and r8verS8 band (С4 only) - adjustment

1 The low and reverse band is in operation when the selector lever is in the 1 о г R position. It holds the low and reverse pinion carrier stationary. If il i5 not correctly adjusted there will Ье а noticeabIe malfunction of the transmission, indicated Ьу there being по drive in the R position and also по engine braking when the selector 1ever is in the first gear position . 2 То adjust the low/ reverse band, undo and remove the adjusting screw locknuI. 3 Tighten the adjusting screw, using а torque wrench 5Bt to 1 О Ibf ft (1.4 kgf т ) and then back-off the adju5ting screw а full three turns. 4 1nstall а new locknut and lighten it 10 the specified torque, while holding Ihe adjusting screw 10 prevent it turning.

Adjustment of the front and геаг bands оп FMX transmissions necessitates the гвтоуа' of the transmission 0;1 рап and speciaJ adjusting wrenche5 5hould Ье u5ed. It i5, therefore, recommended that thi5 adjustment should Ье done Ьу the local repair station.

38 Fault diagnosis - automatic tгапsmissiоп As has Ьееп mentioned elsewhere in this Chapter, по service repair work should Ье considered Ьу апуопе without the specialist knowledge and equipment required 10 undertake Ihis work. This is al50 relevant 10 fault diagnosis. If а fault is evident саггу out the various adjustments previousty described and 1f the fault still exists consult the local repair station ог spec1alist.

Chapter 7 Driveshaft Contents Driveshaft - balance . . . . . . . . . . . . . . . . . . . . • . . . . . . • Driveshaft - removal and installation .............. . Fault diagnosis - driveshaft ..................... . Front universal joint - dismantling, overhaul and reassembIy

•

6

• •

General description . . . . . . . . . . . . . . . . . . . . . . . . . . . . Аеаг universal joint - dismantling, overhaul and reasseтbIy Universal joints - inspection and repair .............. .

2 7 4

• • • • • •

1 • • • •

5 3

Specific8tions

Туре

.................. . •

•

•

• • • • • • •

•• •

• •

•• •

•

• •

• •

•

One-piece tubular with single Cardan type universal joint at each end

• •

Torque wrench settings U-bolt nuts

1

.................. .

• • • • • • • •

•

IbI ft 8 to 15

• • • • • • • • • • • • •

General description

2

Drive i5 transmitted from the transmission to the геаг axle Ьу теапз of а finely balanced tubular driveshaft. Fitted at each end is а universal joint which allows for veгtical mavement of the геаг axle. Each universal joint camprises а four legged center spider, four needle тoller bearings and two yokes. Fore-and-aft movement of the геаг axle is absorbed Ьу а sliding spline in the front of the driveshaft which slides оуег а mating spline оп the геаг of the transmission mainshaft. АН models аге equipped with the sealed type of universal joint which requires по maintenance. The driveshaft is а relatively simple companent and is fairly еазу to overhaul and repair, provided that зраге рагtз аге readily to hand.

kgfm

2 10 2.07

Drive8haft - removaland in8tallation

1

Chock the front wheels, jack-up the геаг of the саг ог position the гваг of the саг оуег ог оп а гатр. 2 If the геаг of the саг is jacked-up, supplement the jack with support bIocks зо that danger is minimized should the jack fall. 3 If the геаг wheels аге off the ground, place the саг in gear and apply the parking brake to ensure that the driveshaft does not turn when ап attempt is made to loosen the four nuts securing the propeller shaft U-bolts to the геаг axle pinion flange. 4 Mark the pinion llange, U-bolts and driveshaft зо that they тау Ье re-installed in their original position. 5 Undo and гетоуе the four nuts secuгing the two U-bolts to the pinion flange, and гетоуе the U-bolts.

Fig. 7.1 ExpJoded view of driveshaft (Sec. 1 ) 1

2

3 4 5 б

7 8 9

Snsp-ring 8earing сир Thrust besring Sesl Spider Sliding spline

10

1

2

9

8

/

/- / ~~/

Nut

U-bolt Pinion flsnge

L:::: ...J-. ::::: ) 5ЗД -...\~Д7:9 AS

f= 54А ~(

0

11 D

14401

д55У .

~

{ 13A75fJ AS5Y.

. !ЗД 724

54

'--54-'"

I

: I

5'

LIGHТlNG SWIТCH

I

Г=

A5SY, н, FRONT DOOR COURТESY lЛМР

L.

S WIТCH

10

54-----' • +N OTE ; WIRE FUNCT t ON NOT APPllCABlE ТО THI5 CI RCU IT

I

Fig. WD8 Interior lighting wiring diagram - 1967

•

1 ~------------------------------------------------------~

14300 ASSY POWER SOURCE R. Н. ВООУ SIOE LAMP

·, 5

152--+,

~-38Д----+'

'---7--

' - - - - 654 - - \

д

'----38 WIRING

I

COLOR

С

О

О

Е

о

13076 R. Н. HEAOLAMP HI & LOW ВЕдМ

9В4д

о

>t+-11A -

ТО

2д

2

49

3А

3

50 5 8 9 10 11 34 13 14 15 25

14305

Д55У.

2 57F - R. Н. PARKING & TURN 5 1GNAL LAMP

11А

12А

•

t-----

12 13А

57 - - - '

14С

57Е

-./ . ; : - - 57F - . / ' - - - 57G-./

BROWN

984

THRU

WHITE-BLUE STRIPE GREEN-WHITE STRIPE ORANGE-BLUE STRIPE ORANGE-YELLOW STRIPE GREEN-ORANGE STRIPE GREEN-RED STRIPE BLACK-YELLOW STRIPE GREEN-BLACK 5TRIPE RED-BLACK STRI?E BLACK RED-YELLOW STRI?E BLACK-ORANGE STRIPE RED-BLUE STRIPE BLACK-YELLOW 5TRIPE BLACK

32

37 38д

38

57О

THRU

57 44 296 297 383

297д

ВШЕ

RED BLACK-GREEN 5TRIPE RED-WHITE 5TRIPE WhITE-RЕD STRIPE YELLOW BLACK-RED STRIPE GREEN BLUE-WHI ТЕ STRIPE BLUE-RED STRIPE GROUND SPLI CE

385

654 152 26 140А

~- 570 -~

:,...--

57С-,

- --.J 57 А ---.J

460

140 511

\ ' - - 5 7В

'---

40

г-

37 '-

~1--1-3A

FOR R.P.O. TURN SIGNALS

490

Е

О

• '"

Э

~~~1~984 - 11

3

---'11 Д -

L.H. PARKING & TURN SIGNAL LAMP С

11

==1

BROWN 57О-

14290

L. Н . ВООУ SIOE LAMP

D

11.-

Е

RED

--15--

•

HEADLAMP DIMMER 5WITCH

1112 13 12

12

L.H. HEADLAMP HI & LO ВЕАМ

814 - -

ДSГ.

12д

13

2 --------,

-12 - 13-

1

37 -

~3~7:-=~~~:j 477 1*

f"'._з

@

-+----+--2д

г-

STARTER MOTOR RELAY

-

~

5 ALTERNATOR REGULATOR 26~

IGNIТION SWIТCH

• Fig. WD9A Exterior lights and turn signals wiring diagram - 1968

,--------------------------------------------------------------------189 2 0 дмр. F US E

I

~ 137

~~~O

14 АМР. FUSE

~

;::;::;:~=,- 14 О . 140А

297д

"

49 0 У.

140

14С

5

32

FUSE PANEL

г-- 5 7С --....,.~

8

140

R. Н , АЕДА , 5 Т ОР &

iURN SIGNAl LAMP

о

•

38) 37 -.J

т

А, Н, BAck-ир

LAMP

30 3

9

2 - 385 482 - ...,-гт-460

Оп J) 148

,--37'

-1

хо:'.)

LICENSE PlдТE ILLUMINATION LAMP

- 4ЬО

-- 9 - 10 - 3

5 ТНА ING COLUMN WlRING

25 -

1...

" А -----~r::s'\ IGNITION SWI ТСН

MOOEl63 ONlV

'ii! ILLUMINAТlON

i

5ТО. PRОDUСТ10N

•

t

6, ~-+ ~

IN STRUMENT PANEL COU RTE $Y LAMPL .H. 5 ТО . PROD UCTION

?

аООА

57

MQDEL 76 & 63

JAMB 5WITCH

ООМЕ lAMA моон 6s ONlY

'ОА COURТESY LAMPS

L .H.

5ТО,

I

PRoa

1 138763 _ А55 У. ..о.

13А 719 ASSY.

С r-.

АI

SЗt;

(8LU.,

СОМРААТМЕНТ LAМ Р & SW\ ТСН

~

~;~=::::G) L.H,

53

I

LUGGAGE

5) - -

53

1 ЗА 769

53

А7

ASSY .

о

ооаА

COURTESV LAMP

53А

13А756

A5SY .

А . Р .О .

, I

'-----

14405 ASSY.

д

54. - ----=--~

L-_ _ _ _ ._ _ . '48 --,;;с-

L

~~

"-

5 3 - - -- - - --

54 - -- -_ __ _ __

DASH J PANEl "'-'

Fig. WD1 ЭВ Interior lights wiring diagram - 1969 Icontinuedl

I •

,~--------------------------------------------------------------------,

14300'_ _ A$SY.-

-

~'~4~,-=~,~,;-:f-,

POWER SOURCE

едТТЕАУ

38'

LEHGINE GROUNO

'" 14305 A$SY.

904

----@- '--- - - , STARTING мотаА

37

,,

'-- , ,

--

,,

\

,

-

ALTERNATOR

,,

I ~_14431 L.ASSY.

Р:Е

L.o.Y

I

262

9--~

,

,

4-14"240-" 14290 ASSY. SТДIПЕR МС

----35

DISTRIBUTOR

Г-@

,

904

AI,.TERNATOR REGULATOR

",

152

35

$PARK PLUGS

10

IGNI'fION COI L

37

262

ENGtNE 01L PRESSURE

$WIТCH О

I~

о

"1

(i-s1ВEN~'

р

.

з9

з9

л-

Зl

262 14401 A5SY.

ТЕМРЕААтиАЕ

SENOER

32'

10"730-

35 4

L __

152

t'?1 ТО RAOIO 152Д~ , CONDENSER

977"

904 ---=-==~

9

DUAL

ВААКЕ

-14

WARNING SW.

Fig. WD14A Ignition. starting and charging wiring diagram - 1970

•

•

,--------------------------------------------------------------1~

WIRINC COLOR 4

16

НОТЕ:

ALL СОННЕСТОА5 ААЕ 8LACK UNLESS OTHERWISE SPECIFIED

••

, i'---,

lЕТТЕR5

CIRCLEO

А$

SHOWN

IMOICATE CONMECTORS

-' -~

31 643 39

," /"""-DА5Н PANEL

904, )ОА 977

-

STARTER МОТОМ

АЕD-САЕЕН

STRIPE

STRIPE

PINK

YELlOW BLACK-RED STRIPE ОААНСЕ

8LACK

REO-BLUE STRIPE 8LACK-YELLOW STRIPE

REO-YELLOW STRIPE BLACK-GREEN STRIPE BLACK-УЕLlOW

STRIPE YELLOW-BLACK STRIPE RED-WНlТЕ STRIPE IJIOLEТ

(RESISTANCE WIAEI

IJIOLEТ

-14"'464_

--

, 000 '

WHlTE-ВLАСК

9"31 640 297,30

,

l.

'6

38 32 37

С Аоино

AlL

152,21

" ,.,

SPLICE

(')

16А

СООЕ

,.---$ТЦТ

'~-;:::: OFF 'ОН

,::=-;;16

ГI-

, I I

,

"

,"С'

'1

"'55У.

'97 904

•

977Д

L

ASSY. SWITCН

•

,UGS

0181

0 181

I.

"

.)...)2

32"

L SS4b

ОМ

15520

А55У.

---'1

--+

>-"

~З7А

_31

FOR MANUAL TRANS.

r297A

FOR

5ТААТ ~ НЕит.

FOR

Аито

+--±==":;~

SW.

TRANS.

=F===;:I~:

==

r-- 640----' 904

т ДСНОМЕТЕА

_О,

о

о .

•••

/-.,

:. 11=========+======:]

31

1

977

I' D

977А

-144 89 ·

,

I

57

'9

_./

I !.-:!\-I -

' •• 1

.• •0•••• 0

I

-о.:: LAMP

100 DI t

ALLOrNER MODS.

WARNING

D

о

Ь3С

PRESSURE

ID

DASH РАНЕ

SТО.

II

PRINTEO CIRCU IT

с .

A.LT •

·14489·

WRNG. САМР

OUA.L BRAICE

-

ТО

FUEL

( GAGE

WRNG. САМР

29 ..., SENOER VIA 1440S ASSY

640!! --1

ТО

FUSE

PNL.

, EL

, I t

Fig. WD14B Ignition. starting and charging wiring diagram 1970 (continued)

•

~----------------------------------------------------------~

IHOO ASSY,

{

-

984"(18)

2Al181

ЗВАНЫ

.

STARТlNC IIIОТОА:

II.H. SIDE

RELAY

"'ARICER ,",МР

ВАТТЕRV ,НООD

TURN

I

•

5ТО,

- - - - - - - - - - ...... - 1

13234

I

ASSY,

iI

I

I I

I ___________ II L

•••

11" -

2(181 - - - l ~L 57АО81 -

-

984С 2П81

О

WHT ,-BLUE (181

о·

~t-

--;--=== --,

-

-

-

57"-

1

13А357 ASSY •. - (

2АI181

I

г

I

• •

• ••

HEADLAMP

__ " __ _ -@[()j __ , _ J I I Г - - 2в - -@~ - 2 - J 57С -;;-==~

57(1 81 12081

II .H. SPOA:T LAMP МОО. ь)с DNLY

I 1I I I 1 I 1 I

r 3

------------"

..,

....."

0::0> ,) s О " ' АЕD

-----~ ....---4@

~

10

"------~г_--------"-----------------

()

ASSY .

_ _ _ _.....J. '__ _ _ _ _ _ _ , . _________________________

Fig. WD1681nterior lights wiring diagr8m - 1970 Icontinu8dl

•

•

1~300' __- ,

ASSY,-

-

DOS8-14448-A ТЕЯМ, BLOCK

"

о

еДТТЕИУ

LENGJNE GROUND

-

-

[\

•

\

,,

з7C ct\r32А----@1 i'" ~/ --1 ' оъ- - о

'" -

"

-(}

37'

. (88

МОТОЯ

СИЕЕН

-

14431 ASSY.

16.

РЕи.у

36

- - -Ig)

/

STARTING

8LUE

Ь:)4

088 -

•

--

1гН

,..

-

З7В~655

-"'000'---

31с-

6" AL Т[ЯН"ТОII 51'ДIПЕR

-

" ...J

I

DIS TRI8UTOR

~

,

ALTERNATOR REGULATOR

5

-

-

I

--

5PARK PLUG5

~

8

3

16

3

I

?

6

32

•

2

-

7 IGNПIОN

" '"

COIL 1. .

ENGINE OIL

0-887

PRESSURE

SWITCH О

1~

-о

~

"1

о

0-83

./ - 39 -

-

31- CI 14289

ASSY .

ав,О

.,

0-8'\

~

39 31 16 ,

l

7

6

-

-

-

=:

1" 14290 A5SY.

ENGINE -0-88

5

r

I

ТЕМРЕидтиЯЕ

-:-

32

16

$ЕНОЕИ

6

32'

, , С7АВ-14А:Ю 9 - А

"36

655 I I

t

90'

L-_36'_©

ТО RАОЮ

•I

L

:3

)7"

-Cf::=

,' 904 .C6AB-14A309-A

CONOENSER

I

-

39 91,7.1.

~~

OUAL

Fig. W017A Ignition. charging and

8R~

staгting

WARHING SW

,

'6

~

977

LC8AB-14A309-A

wiring diagtam -1971

i~ DА$Н PANEl

•

,-----------------------------------------------------------~5

СООЕ

WIAING COLOR

Эl

RED-lТ. GREEN STRIPE WНITE-REO STRIPE

"

YELLOW.oWHIТE ООТ

16

НОТЕ:

ALL CQNNECТORS дЯЕ BI..ACK UNLESS OTHERWISE 5PECIFIED

32 35

)0"',36 •

з7

SPL IC E GROUND

~

А

38

"

ALL lEHERS CIRCLEO AS 5 HQWN INDICATE CONNECTOAS дно ARE

•,

:!-,- DА5Н РАНН

STAltTER

МОТОА

РАНН

-•

RЕD-WИIТЕ

STRIPE STRIPE

9"

LT. GREEN-RED STRIPE

YELLOW-l Т. GREEN STRIPE RED~RANGE

STRIPE

PURPLE-WHIТE

STRfPE

YElLOW-WИIТЕ

STRIPE

START

'r - - - ."'

г-- -

-

"297

I~

,

'-' 16А

BLACK~RANGE

"'97" '" '" 9" '"

DIAB- 14489 -LA F"USE

YELlQW BLACK BLACK-L Т. CREEH ООТ BLACK-L Т • САЕЕН НА5Н RED-YELLOW HASH

29

ТО

RED-LT. BLUE STRIPE LT. GREEN-6LACK STRIPE ORANGE-l Т. BLUE 5TRIPE

DFF lOCK АССУ .

37д

IS ACTUATED ВУ rGNlТlDH КЕУ

' LUG5

,

0-121

~=-~=16 ТО FUSE 168 POl.

01-32-, "--31А

'54-"'"

"

51ART· HEUT. SW. FOR AU ТО TRANS.

Эl

7к

~

•

, ,

19J

14401 "55'\'.

ТО ·

FUSE PHL .

16

ТАСНОМЕТЕ!!: 5ТО. 63R ALL ОТНЕ!!: МОО5. II:.P.O.

10В923

А55У.

PRINTED crRCUIT

,

977"

• ----977--'

00000 080 0 0 9"

--+I--.J LI-

DUAL BRAKE ТО

FUEL I GAGE 29 ~ SENDER VrA 14405 ASSY.

ТО

FUSE PNL.

10 COHSТAНT

VOLTAGE UNIT

Fig. WD17B Ignition. charging and starting wiring diagram - 1971 (continuedl

•

,

~ ----------------------------------------------------------~

,-14300 "55У.

--

-1"18-, 57С

37' ,

START'~

MOTDR REL.AY

R,H.SIt)E МАНКЕН ,-,М.

8AHERV '_С ' - - ~301

г C8ZB-13A210-A

1----------1-: I

А55)'. ~

0::::= = - - 1 4

ELK.-YEL. \181 WHT .-BLUE !JB) .

G

BLACK

U

=-'

-,

- - 2 - - +---,

'---:-::: =': Н,Н. FRONT РАНК & тинн

"55)'

13234

I,

I I I I

-

srCNAL

l

5"

САм.

,,-

, ,

C8"'8-14489-Y

57' _-'~_

'

,

"

_ 511> ШJ)

-

( в

" • .- -+-1-+--+ - -:

•

"-~

~~ -,,

OIA8-14489-LA ТО IGNITIQN SWITCH

г С 92 8- 144 89-"

. :.> ........_ ..... -т-

2

,--',, --'

29EoC - - - ,

С_ "

57С

TURN 51GHAL FL.ASHER

57О -,

г

57,

]

j~'' -

'---385( 16

АМР CIRCUl T ВАЕАКЕА

IS

i ••

I

I

,

-11 )u

I '""

'

,

d 1'-'

( ....... "1 ';I

Q

I--H-i, -

1

v

ЕМЕАGЕНСУ

WARNINC F~S,Ii~R

000 8- 14489-" - /' Т О PRINТE D СКТ .

----:.--t-т,,;;:---+- ==Г'

I

57r

-

~~UJ

( С >

8О ДА D

-

STO'L.AMP

•

SWITCH

."

< и> о

l S(8) 14

о о

C9A8-14489 - K

---~ " ~I~-tI ---++--"C ---''1----

2

--:!'::==-~ "=-;-12>======t---

ТО HEADLAMP SWIТ CH

,

(,>

,

I

'.7А

" ',' •

I

CSAB-llА648 -А ~

"с

+-

I

!

I 5

-14'

< ','

f

10 FUSE pANEL

)

:.. \...... C4f}8-144~9_A,

HEADLAMP ' - _ _. _- , OIMMER SWIT CH

Fig. W01 88 Exterior lights and turn signals wiring diagram - 1971 (continued)

rтEM о - 4 - --' RED ТО l •• 05

,

•

208 GLOVE

14300 ASSY,

'" ~ 19,. ~ --4!l! \ _ - ~

--

LAMP

O"SH PANEL

?

ВОХ

([1i

11,

,,

GLOVE вох SWITCH

546

;Г::Г -

0) &

~

г

STARTINC

'3B71~~.

rem

ВАТТЕАУ

,"')1 ASSV.

(R.P.O.J

1'1 ~ i

•

.ос

-

,

7 1/2 АМР

376

BLK ' (18)

,, ,, I

МАР

57

lAMP & SWITCH ASSY.

5,7

г---------------,

1

,,

53

ffiП''1Е'J

30

15650-

A.ssy.

54

I L _ _______ _ __

'-

19·

15702

37'

AS SY, (R , P .O,)

~

j!

0-4'

~

,с

ENCINE.

он

СОМРТ. САМР т , Р. О)

•

ГО"

, 114.

,

CO NSOLE ClOCK

•

,

-

40

::УI , -@ ~ -а: tIf~~1iL ' , icj...

& МОО

•

Ь3А

CLOCK

',

,

r

5 Т О. МОО. b5F'

r

~~

C1C~A LIGHTER

1) 1

~

57.

\

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57'

~

C"'RLТR Ф -570~ IlLUM

,

,

19F

W!SWIPER.~

+'

SW.I LLUM.

но. LP.

~75

:'76

14Е

Q

т

ILLUM.

О5SY. ISAsoe PIINDL

•

I

•

SW. ®=.5,:~

ТО

~M.

Т1I AНS.OI,P, O,)

DASH

г

Г ,, ,< "Е

•

, I

0- 7

PANEL~I

, •

i.'1

ff····

fIICIфе • • •

.'10 .to , "7/

54.

.: o~

•••••• фее&ее

6--'

о

1 00

О

go

ОООО О Ф

0 00000

r О о'

1-,. ';6

о о

.J

,

" OOO~o9; 0000

15056 ASSY.

,

R.P ,O.

1* 37'

5:4

157'

НТА.

• •

LA мр ILLUM ОА ALL AUTO

й~576

[Q(

О

20 О

F'US E PANEL.

'J.

Fig. WD19A Interior lights wiring diagram - 1971

о

о

о

о

.: : О

qО

О

О

'I ,I ' , , 1,О ,' ,, ,, , 01О ') О

О

I О

О I

t (]

О I

,о

О

т

О

, , ;~ О "~-

~

,о ,о

-•

,--------------------------------------------------------------------209 т,Р.О.)

-----54А -

=-,54

=

г

%~/

53

C8AB-14489-L

, \

OOD8-1~489-D

I

J

"

,

"6- ~ 1

'. :~.

~

9

~,

WIRING COLOR

L . _ __

SWITCH FOR COURTESY L.AMPS L.H. А,Р,О. CONV, СНЕСК.

,

14 .1.9 37 40 53

'4 55 57 159 ] 73

-------I~-~I--Q А.Н.

CQURTESY LAMP

':Ji:I (АТ INSTR. PANEU -

5>С:-'

СООЕ

DООА JA.МE!

C81.8-14489-T -

BROWN LT. 8LUE1tED 5TRIPE YELLOW LT.BLUE-wнrТЕS1ll:IРЕ

BLACK-LT. BLUE SntlPE

LТ. GREEN-УЕlLОW STRIPE

BLACK-PINK STRIPE BLACK RED·PIHK STRIPE PINK-wl-iIТЕ SТRI~E

ОООА J"MB SWITCH

FOR COUATESY LAMPS А,Н. 5ТО. РАОD.

-

•

GRDUND

SPLICE

ОК

BLANK

НОТЕ

UNLESS ОТНЕRWlSЕ SPECIFIED ALL CONNECTORS ARI! BL.AQК

SWITCH

t';\

5>

-

5

ЗА

l8ii---

\fJI

L,H. COU.RTESY LAMP (АТ INSTR. PANELJ

C3T8-141.309-06 ....1

14401 ASSY. ТО КЕУ

WARNING

BUZZER OOOB-14489-o \

!

i

-, 173 ,.,,J,

138712 ASSY.

" 5ЗВ~ г 54С -

. . . 1 +, ,

" ' '

'-C3TB-14A309-A

.-

,

,,

ОООН

JAMB SWITCH FOR COURTESY LAMPS L,H.

LUGGAGE СОМРТ, LAMP & SWITCH ASSY, - (R ,Р ,О ,) 14401

S4~~ 5>" 5>'

-PRINTEO СIRСUП аО АНО CLUSTER ILLUM, SHOWN

--

54

~o

.., "1 oг.i~ .. о

-137

НЕО

---@

"~7~' , , ,О'55У ,

5> ----1@':;;>:>-_"LU' 'Ш~, Ю,.

ASSY.

,, ООМЕ lдMP ~S:SY,

10

1- _ _ _ _ _ _

- -______ -.J Fig. WD19B Interior lights wiring diagram - 1971 (continuedl

•

,

•

I•• I --

--

_.

• •

•~

-

.' r:

--

,,

'" .:. '"-•3 (

-

+с

о

•

•

1___1

1

,

, ••,

••

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-

о

о

-• -

-•

,

,•, •• •

•, ," •

6

-

•

•

•

--

, •, I

.. .-

•••

:"

•

••

• - - .'• Г'• 1,

••

-о

,-

• -.••••_. (~I'

о

• •••

-о

~T-

•

•

•

•

••-

,• ••• •• • • , • ••• • -• I •

•• ..

>

>

. ,i-----о 1 ••

•

~ ..... 'iЗО .,:1:11.--

-о

-'I!"

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О

е

• ~ ." .-

...,-- •< ••J,- -•

... > ::;

,

••• _о -

L

,

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.-

IZ •

•?

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--• •" , •• •- • • •• •• ,

о

-

>

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:..... 'i'

•

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g>

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,

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. о>

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Fig. 11.1 Front suspension

\

, (8ве

1)

• •

, Chapter 11 Suspension and steering

235

I

---- --

,

REAR SHACKLE

/

••

FRONT HANGER - - -__

Fig. 11.2 Аваг suspension (Sec 11

IN PU1" SHAFT

SECTQR SHAFT ADJUHMEN T SCREW

I

i

I

I

ID ЕNТ I F IСАТЮN

SECTf)R SHAFT

SECТOR

TAG

SHAFT CQVER

Fig. 11.3 Steering gear - manual and non-integral power steering (Sec 1) аЬоуе

the gear and агоНег bearing in the housing below the gear. The worm bearing preload is controlled Ьу the large adjusting nut w hich is threaded int o the housing, and the sector shaft mesh is controlled Ьу эп adjusting sc rew located in the housing соуег. The steering linkage consist s of а Pitman агт, steering 8rm -t o-idler агт rod , idler агт and connecting rods. 4 Two types of power steering аге аvаi l а Ы е as ап option . ОП model s 10 1970 а non-integral power steer1ng system 1s used. It 1s а hydraulical ly controlled linkage type wh1 ch includes ап 1nte9ra l pum p and fluid r ese гvo 1r . а control valve . а power cyHnder and flu1d 11nes. The pump 1s belt-driven from the engine crank-shaft. Оп 1971 / 7 3 models а Sag1naw integral power steering gear is 5 used. It operates Ьу displac1ng fluid to provide pressure ass1stance only when tu rn 1ng. As the gear assembIy 1s always fu ll of fluid. all internal componen ts of the gear аге immersed in flu id making per1od1c lubrication unnecessary. The fluid also acts as а cushi on to absorb road shocks th at may Ь е transmitted to the driver. AII fluid passages аге internal except the pressure and return hoses between the gear and the pump I Fig. 11 .4 ).

6 The steering column 1s of the collapsibIe type. It will coJlapse Ьу approximately s1x inches upon а hard impact. Опсе the steering colu mn has Ьееп collapsed. а complete new steering column must Ье installed , together with new brackets, which also shear away during impact. ,

2

Front hub and bearing (drum brakes) - removal and install8-

tion 1 Apply the parking brake, chock the гваг wheels. jack-up the fгont of the саг and support it оп jack stands. Remove the roadwheel . 2 Carefully ргу off the grease сар. Aemove the cotter pin. nut lock, adjusting nut and washer (photos). 3 Aemove the outer beating сопе and гоНег assembIy. then pull the hub assembIy off the wheel spindle . I 4 Aemove and discard the gtease retainer. Remove the inner bearing с опе and roller assembIy fгom the hub. 5 Clean the outer and inner bearing cups in the hub with solvent and

11

~ ------------------------------------------------------~

ADJUSTER

VALVE

TORSIDN ВАА

INLET

STUB

о ,

,

ТEFLDN

N

RING

RING

'

BEARINGS

ААУ

VALVE TEFLON SEALS

ААСК

NUT SECTOR SHAFT

Fig. 11 .4 Cutaway view of int89r81 power steering 988Г ISec 1)

нив "'но BRAKE

DRUM

GREASE

INNER BEARIHG

A5SEМBLY

REТAINER

QUTER

ADJUSTING NUT

BEARrNG QUTER BEARING

2.2А Remove the cotter pin, nut lock. adjusting

nut ...

СОНЕ АНО

INNER СОНЕАНО

ROLLER

СОПЕR

PIN_

NUT lOCK

NUT~

A5SEМBLY

нив BOLТ

Fig . 11 .5 E)(plodвd view offront wheel and bearings - drum brakes (Sec 2)

2.28 ... and washer

I

I

I

r

f

Chapter 11 Suspension and steering inspect far scoring. pitting and excessive wear. If the cups

аге

worn

237

О!

damaged. гетovе them from the hub with а suitabIe drift. 6 Clean the cone and roller assembIies, and examine them far wear аnd damage. If апу part of the bearing assembIy i5 defective the Ьеаrinя must ьв renewed as а complete unit. Сlезп the hub and

spindle 10 гетоуе

а1l

old grease.

7 Install the outer and inner bearing cups in the hub, using а suitabIe diameter tubular drift 10 drive them fully home. 8 Pack the inside of the hub with the specified wheel bearing grease until t he grease i5 flush with the inside diameter of both bearing cups. lubricate the bearing сапе and roller assembIies Ьу working аз mu ch grea se 85 possibIe between the rollers and cages (photo! . 9 Ins eгt the inner bearing сопе and roller assembIy in the hub then install а new grease retainer using а tubular drift. Take саге not 10 disto гt the retainer, and ensure that it i5 properly 5eated. 10 Дdjust the brake shoe5, as described in Chapter 9, then install the hub and drum assembIy оп the wheel spindle. Кеер the hub centered оп the 5pindle to avoid damaging the grease retaineT. 11 In5ta ll the outer bearing сопе and roller assembIy, the flat washer and adjusting nut. 12 In5tall the roadwheel . 13 Whi!e rotating the hub, torque tighten the adjusting nut to 17 to 25 !Ы ft (2. 4 to 3.4 kgf т! to seat the bearings. Ba ck-off the adjusting nut опе half turn , Ihen retighten il to 1 О to 15 Ibfft (1.4 10 2 .0 kg1 т! . 14 Inslal! the nut lock so that the c8stellations аге aligned with the cotter pin hole оп the spindle. Install а new cotter pin and bend the ends round the castellated 11ange of the nut lock. In5tall the grease сар .

15

Дdjust

the brakes as described in Chapter 9. Install the hub wheel соу ег, and lower the 1ront 01 the саг .

сар ог

з

Front hub Bnd b8aring (dilc brBkes) - гетоувl Bnd in8t8118tion

1

Сапу

out the operations in Section 2, paragraph 1. 2 Remove the brake caliper from the rotor, as described in Chapter 9. and tie il up to prevent damage to the brake hose. 3 Carry out the operations in Section 2, paragraph 2 through 9. 4 Inslsll the hub and rotor assembIy оп the spindle, taking саге not 10 damage the grease retainer. 5 In5tall the outer bearing сопе and roller assembIy, the flat washer ancl adjusting nut. 6 Дdjust the wheel bearings аз described in Seclion 2, paragraph5 1Запd1 4 .

7 In slat! the brake саНрег (see Chapter 9) 8 Inslall the roadwheel and hub сар , ог wheel соуег, and lower the front of the с аг . 9 8efore driving the саг, pump the brake pedal several lime5 10 obtain normal psd 11ning-Io-rotor clearance.

tUS

АНО

ROTOR

2 .8 Hub packed with grease

4

St8bilizer Ьаг - гетоуаl and inlt8118tio"

Raise the 1ront of the саг and support 11 оп jack 5tand5. Remove the link bolts and in5ulators attaching the stabitizer Ьаг to the lower suspension arms. 3 Disconnect both attaching brackets and remove the stabilizer Ьаг. 4 Installation is the геуегзе of the removal procedure. Always U5e new insulators. When Installlng the link bolts make sure that the bolt head Is а! the top to prevent It foullng the brake hose.

1 2

5

Lower suspension

вгт

гетОУ81

8nd inlt811ation

1 Position а support between the upper arm and frame side гаН . as shown in Fig. 11.7 , then raise the front of the с аг and support It оп jack stands. Remove the roadwheel. 2 Remove the cotter pin , caste llated nut and adjusting nut from the fronl of the strut. 3 Using two pry bars, опе at each side and at the rear of the front washer, separate the inner sleeve from the outer sleeve and remove the front insulator.

INNER aEARING CUP

.uSEМ8LY

strut -

GREASE I

OUTER lEARING

ADJUSТING

NUT ouтeo

lEARING СОНЕАНО

GREASE САР

ROLLER

11

.... -

COII&

HUТ

'оек

ASSEМILY

HU.IOLT

• Flg. 11.6 Exploded view of front hub Bnd bearings - disc brakes (Sec З)

Chapter 11 Suspension and steering

ZЗ8

SECUII:ELY

Fig. 11.7

иррег агт

support in position (Secs 5 and 7)

ЗА" CQLD

.OlLED

.-...;

RADtUS ВОТТОМ ЕDСЕ--'

4

Remove the strut-to-tower arm attaching bolts and 11ft out the

strut. 5 In5tall а new геаг washer, aute r sleeve and insulator bushing оп the 1ront end 01 the strut. 6 Locate the strut in the crossmember and install the strut-to-arm attaching bolts. Install а new 1ront insulator, washer, inner sleeve and adjustment nut.

7

Install the roadwheel and lower the саг. Аетоуе the upper агт

support.

8

Adjust the

сатЬег

and caster (see Section 42) then install the

castellated nut and cotter pin.

в

Coil spring - removal and i"5t8118tio"

1 Raise the hood. Undo the attaching nuts and гетоуе the shock absorber and upper mounting bracket as ап assembIy. TURN

ТО

N U T - - -....

Тоо! Т

63

Р.SЗ10-А

• sрппg.

7 Position the spring upper insu lator оп the spring and secure it in place with tape. В Position the spring in the spring tower and compress the spting with the spring compressor. 9 Swing the upper агт inward and insert the bolts through the holes in the side of the spring tower. Install the nuts and tighten them to а torque of 75 to 100 Ibfft (10.4to 13 . В kgf m). 1О Release the spring pressure and guide the spting into the upper arm spring seat. The end of the spring must not Ье more than 0.5 in ( 12.7 mm) from the tab оп the spring seat. Remove the spring соm­ pressor. 11 Install the hub assembly as described in Section 2 ог 3. 12 Lower the front о' the саг and install the shock absorber and upper bracket assembly, making sure the shock absorber lower studs аге in the pivot plate holes.

7 1 - - - - - - 1 1 " '.. Adopt~r P/ot~

SHAFТ SCREW----=

T~'

Low~r Adopt~r

Raise the front of the саг and support it оп jack stands. 3 Remove the hub assembIy as described in Section 2 ог 3. 4 Install а spring compressor tool (see Fig. 11.В) and compress the spring to remove all tension from the control arms. 5 Remove the two upper arm-to-spring tower attaching nuts and swing the upper arm outward from the spring towet. 6 Release the spring compressor and remove it, then lift out the 2

Plote

HALF BALL RETAINER

Fig. 11.8 Installing the spring compressor tool (Sec 6)

Lower suspension

агт

- removal and installation

1 Position а support between the иррег arm апр side rail as shown in Fig. 11.7. Raise the front of the саг and suppor1 it оп jack stands. Remove the roadwheel. 2 Disconnect the stabilizer Ьаг and the strut from the lower arm (see Sections 4 and 5). 3 Remove the cotter pin from the nut оп the lower balljoint stud , loosen the nut опе ог two turns but do not remove it а! this stage. 4 Straighten the cotter pin оп the upper balljoint stud nut. Positi on а balljoint remover tool between the иррег and lower balljoint studs (see Fig. 11.9). Make sure the (ооl is seated оп the ends of the Stud5 ~nd not оп the nuts. 5 Turn the tool with а wrench until the studs аге under cOn5iderabIe pressure, and then strike the spindle, пеаг the lower stud, а sharp bIow with а hammer to break the stud 1005е from the spindle. 00 not free the stud with tool pressuгe only. 6 Remove the nut from the lower balljoint stud and lower the агm. 7 Remove the lower arm-to-underbody pivot bolt and Hh out the lower arm. 8 Examine the агт for damage and the balljoint for wear. Renew the arm , if necessary, аз а complete unit. 00 not install new balljoints оп а used suspension arm. 9 Installation is the reverse of the removal procedure. Tighten the

I

Chapter 11 Suspension and steering

[,

paragraph 3 through 5) then гетоуе the nut from the upper balljoint

Tool- T62F-3006-A

UPPER 8All

239

stud and litt the stud out of the spindle. 7 Аетоуе the upper агт inner shaft attaching nuts, from inside the

~PPO'-'-

engine compartment, and lift out the upper агт.

8 Examine the агт for damage and the balljoint for wear. 00 not wash the balljoint in grease solvent. Aenew the агт, if necessary, 85 а coтplete unit. Оо not install new balljoints оп а used агт. 9 In5tallation is the f8verse of the removal procedure. Tighten the

I

upper balljoint stud nut and the upper агт inner shaft nuts to the specified torque. If the upper агт is being renewed as а result of accident damage, check the cBster, сатЬе г and toe-in (see Section

421. .

иррег

9

Toel_ Т57Р·ЗОО6-А LOWER BALL JQINT

Fig. 11.9 Loosening the balljoint studs (Sec 7) lower balljoint stud nut and the lower arm-to-underbody pivot bolt nut to the specified torque. Check caster, camber and toe-in (see Section

421.

8

иррег

sU5pension

агт

-

гвтоуаl

8"d i"5t8118tio"

1 Raise the front of the саг and support it оп jack stands positioned und er th e frame. Remove the roadwheel. 2 Remove the shock аЬэогЬег lower attaching nuts. 3 Undo the attaching nuts and remove the shock absorber and upper mounting bracket аэ ап aS5embIy. Instal! а spring compressor tool and compress the spring, (see 4 Section 6). 5 Position а jack stand ог other suitabIe support under the lower агт.

6

Loosen the upper balljoint stud

ёп

the spindle, (see Section 7 ,

suspension

агт

shaft and/or bushing - renewel

1 Aemove the upper arm as described in Section 8. 2 Un5crew the bushings from the shaft and arm, then remove the shaft from the arm. 3 P05ition the shaft in the arm, grease the new bushings and 0rin9s, then install the bushings 1005е оп the shaft. 4 Center the shaft in the suspension arm. Aefer to Fig. 11.11 and screw in the bushings until the dimensions Д and В аге equal. 5 Make а spacer from а piece of 0.75 in (19 mm) diameter steel tube. The spacer should Ье 6li ёп (176 mm) long for рге 1971 models, and 8-1 in (206 mm) long for models from 1971 оп. 6 Force the spacer between the flanges of the upper агт, as shown ёп Fig. 11.12, then torque-tighten the bushings to 25 to 35 Ibf ft (3.5 to 4.8 kgf m). 7 Aemove the spacer and check that the shaft is free to turn without binding. 8 Install the upper arm (see Section 8).

1 О Front wheel 5pindle -

гетоуа'

and in5t8118tio"

1 Aemove the hub assembIy as described in Section 2 ог З. 2 Оп models with drum brakes remove the brake backing plate (see Chapter 9), and suppoгt it to avoid damage to the brake hose. ОП

BUSHING

I

.

'

------.-.-.-'ВUsнING

.....

) ,НОС, ДВ")"

1 ,,'

::----

---- ~'-

СдМ

REAR HUT

"дТ

----.1

SEAT-I-_..

I

BUSHING

SLEEve

i--~

INNER SLEEVE

FR~T

ADJUSTMENT

BRACKEТ

...,

WASНER

HUT

Fig. 11.1 О Exploded view offront suspension (Sec 8)

LOWER BALL JOINT

•

Chapter "

240

Suspension and steering

•

Fig. 11.11 Centering the upper arm shaft (Sae 9)

models with disc brakes remove the three caliper shield attaching bolts and lift off the shield . 3 Using а balljoint separator, disconnect the connecting rod end from the spindle arm . 4 Loosen the upper and lower suspension агт balljoints in the spindle аз described in Section 7. 5 Position а jack ог similar support under the lower suspension вгт. Аетоуе

the upper and lower balljoint stud nuts. then lower the jack

and remove the spindle. 6 Installation i5 the reverse of the removal procedure.

11 Front shock 1

аЬаогЬег

Raise the hood and

shock

гетоуе

аЬзогЬег

Fig. 11.12 Torque-tighten the upper

втт

bushings (Sec 9)

access соуег, Fig. 11.1 З. Оп convertibIe models the геаг seat and seat back must Ье removed. 3 Remove the shock аЬзогЬег upper attaching nut. 4 The shock аЬзогЬег сап now Ье compressed and rernoved lгот the саг. Remove the bushings lгот the studs. 5 Inspect and check the shock absorber as described in Section 11. 6 In stallation is the reverse 01 the removal procedure.

the shock

аЬзогЬег иррег

1Э

-

гетоуаl

and installation

1 Disconnect the shock absorber lrom the spring clip plate (see Fig. 11.15 and photo). 2 Working in the luggage compartment, гетоуе the shock аЬзогЬег

11.1 Front shock absorber upper mounting

Аваг

spring - removal and installation

mounting

2 Aaise the front of the vehicle and position jack stands under the lower агтз. 3 Remove the two shock absorber lower attaching nuts and the insulators (photo). 4 Lift the shock аЬзогЬег and upper bracket from the spring tower. and гетоуе the bracket lrom the shock аЬзогЬег. 5 Clean the exterior and inspect the shaft 10г signs of corTosion ОГ distortion, and the body for damage ог 10г slgns 01 hydraulic fluid leaks. 6 Check the action Ьу expanding and contracting to ascertain if equal resistance is lelt оп both strokes. If the resistance is уегу uneven the unit must Ье renewed. Always renew them in pairs, either both lront опез ог both геаг ones. 7 Installation is the reverse 01 the removal procedure . When positioning the shock absorber and upper mounting bracket in the spring tower ensure that the shock absorber lower studs аге in the pivot plate holes.

Аваг

SUPPORT STAND

- removal and in5t8118tion

bracket attaching nuts (photo).

12

SPACER

1 Aaise the геаг of the саг and support it with jack stands under the body and under the геаг axle. 2 Disconnect the lower end of the shock absorber lrom the spting clip plate and push the shock absorber out 01 the way. Аетоуе the supports lгот under the axle. 3 Автоуе the spring cl ip plate retaining nuts lгот the U-bolts and remove the plate. Jack-up the геаг axle just enough to take the weight off the spting. 4 Aemove the two attaching nuts, the геаг shackle Ьаг and the two shackle inner bushings. Aemove the гваг shackle assembIy and the two outer bushings. 5 Aemove the 1ront hanger bolt from the еуе at the lront end of the spring and then lift out the spring. 6 If апу 01 the shackles ог bushings аге worn they must Ье renewed. 11 the lront еуе bushing is being renewed , it сап Ье removed and а new опе installed Ьу using а long threaded bolt , а distance piece 01 similar diametet as the bushing and large llat washers. Tightening the nut will draw the old bushing out 01 the spring еуе ог draw а new опе into positlon. Fig. 11.14 shows the Ford tool being used to install а new bushing. 7 If а spring leal is broken ог the spring has weakened, then it should Ье renewed: in this event the othet геаг spring should Ье renewed at the same time. 8 Installation is the reverse 01 the removal procedure. Тighten the

11.3 Front shock absorber lower mounting

12.1

Аеаг

shock absorber lower mounting

Chapter 1 1 Suspension and steering

SНOCK

241

ABSQRBER ACCESS СОУЕ!!:

т001- T64N.S781.

,

AJ"

А4

( дdopfer)

I ,

. ВЗ

·81 ( 801t)

,

Tool-

• Fig. 11.14 Removing the

гваг

spring front bushing (Sec 13)

LUGGAGE COMPДRTMENT

FlOOR PANEL

Fig . 11 . 1 3 Removing the

гваг

ассезз соувг (Sвc

shock 12)

аЬзогЬег

,,

VIEW

SНACKLE

PS

SPRI NG

У

VlEW Z

SНACKlE

REAR

BU5HING

5НACKLE

-. SF'RI NG

SHOCK ABSORBER

MOUNTING BQL Т QIREC TION QF SHACKLE QPTIONAL

VlEW W

FRONT

ЕУЕ

SPRING

PLATE V1EW

У

Fig. 11 .1 5 Exploded view 01 гваг suspension (Secs 12 and 13)

front hanger bolt and the shack!e locknuts 10 the specified torque after the саг has Ьееп lowered 10 the ground.

14 Steering

g88t (тапиаl)

- removal end instelletion

1 Raise the front of the саг and support it оп jack stands. 2 Aemove the bolts connecting the flexibIe coupling to the steering shaft. 3 Ае тоуе the nut that secures the Pitman агт to the sector shaft and. using а putter. гетоуе the агт from the sector shaft. Do not hammer оп the end of the puller as this сап damage the steering gear. 4 Оп some models with manual transmission it тау Ье necessary {о

disconnect the clutch linkage. and оп some models the exhaust system must Ье lowered. {о provide enough clearance for removal of the агт. 5 Аетоуе the three bolts securing the steering gear {о the side rai! and lift out the steering gear. 6 Installation is the reverse of the гетоуаl procedure.

15 Steering reassembIy

gear

(manual)

-

dismantling.

overhaul

and

•

1 Clean the exterior of the steering gear. гетоуе the filler ptug and drain the oil. 2 Rotate the steering shaft to the center position.

11

Chapter 11 Suspension and steering

242

~\ АНО

SHIM

8USHING

SECTOR SHAFT ADJUSTING SCREW ' S E AL

Fig. 11.17 Sector shaft and housing - manual steering _

ШР

lOCK NUT STEERING

BEARING - агт

~

GШОЕ \

(See 14)

(See 15)

HQIJSING 8EARING

Fig. 11.16 Removing the pitman

яеаг

•

8EARINGS

~,-CCA"P

8EAR1NG CUP

SEAL

. BEARI

НС

NUT

Fig. 1, .18 Steering shaft and associated parts - manual steering gear (Sae 15)

3

Аетоуе

the sector shaft adjusting screw locknut and the housing соуег securing bOlts, then гетоуе the sector shaft with the соуег. Separate the CQver from the shaft Ьу turning the adjusting screw clockwise. Кеер the shim with the screw. 4 Loosen the worm bearing adjuster nut, then гетоуе the adjuster assembIy and the steering shaft upper bearing. 5 Carefully риН the steer;ng shaft and ballnut from the housing. Кеер the ballnut from running down to either end of the worm as it тау damage the ball return guides. 6 Аетоуе the ball return guide clamp and the ball геlигп guides from the Ьаllпиl. Кеер the ballnul 'clamp side up' until ready to гетоуе the balls. 7 Науе а suitabIe clean container ready, then turn the ballnut оуег and rotale the worm shaft from side to side until all the bafls have Ьееп collected. The ballnut will now slide off the worm. 8 Аетоуе the иррег bearing сир from the bearing adjuster and the lower сир from the housing. If necessary. tap the housing ог adjusler оп а bIock of wood to get the bearing cups out. 9 If the sector shaft bearing is worn ог damaged press 11 and the оН seal out of the housing. 10 Clean all lhe dismantled parts. Inspect the sector shaft and steering shaft for pitting, burrs. cracks ог wear. Examine the bearlngs for wear ог damage. Aenew all the oil seals. 11 During assembIy apply steering gear lubricant to the bearing5 and 5eals. 12 If the sector shaft bearing wa5 removed, press а new bearing into the housing and install а new oil seal . 13 In5tall а bearing cup in the lower end of the housing and in the adju5ter. In5tall а new seal in the bearing adjuster. 14 In5ert the ball guide5 into the hole5 in the ballnut. tap them lightly. if necessary. to seat them. Use the wooden handle of а 5crewdriver ог similar. 15 tnsert half of the 'balls into the hole in the to p of each ball guide. It та у Ье necessary to rotale the shaft slightly опе way, then the other to distribute the ba115. 16 In5tall the ball guide clamp and tighten the securing screW5 to the specified torque. Check that the worm 5haft rotates freely. 17 Соа! the th read5 of the 5teering shaft bea ring adjuster, the housing соуег bolts and the sector adjusting screw with ап oilresistant sealing compound. Take саге not to 9е1 апу sealer оп the steering shaft bearings. 18 Lubricate the worm bearings. sector shaft bearings and gear teeth with steering gear oil. 19 Clamp the housing in а vise with the sector shaft horizontal and

install the steering shaft lower bearing in its cup, then insert the steering shaft and ballnut assembIy in the housing. 20 Position lhe steering shaft иррег bearing оп the top of the worm and install the steering shaft bearing adju5ter and then the adjuster nut. Leave the nut loose. 21 Using а Ibf in torque wrench. preload the worm bearing to the specified value (see Specifications at the beginning of lhis Chapter). 22 Inslall the sector shaft adjusting screw and shim, and check the end clearance between the screw head and the end of the sector shaft. The end clearance must not exceed 0·002 in (0·050 mm); add shims, if necessary. to reduce the endplay. 23 Start the adjusling screw into the housing соуег. InSlal1 а new gaskel оп the housing соуег. 24 Aotate the steering shaft until lhe ballnut teeth аге in position 10 mesh with the sector gear. tilling the housing so that the ballnut will tip toward the housing соуег opening. 25 With the соуе г screwed onto the adjusting screw. inslall the sector shaft and соуег to the housing. 26 Тиrn the соуег out of the way and fill lhe housing wilh lhe specified steering gear oil. Push the housing соуег and sector shaft аээетЫу into place and install the two соуег securing bolts. While

NUT

LOCK NUT \.-'."

• Fig. 11.19 Checking lhe shaft bearing pteload (Sec 15)

I

! Chapter 11 Suspension and steering

243

I

I

,

Fig. 11.22 Power steering

ритр

dipstick (Sec 18)

Fig. 11.21 Checking steering gear preload (Sec 17)

Fig. 11.20 Adjusting the sector shaft mesh load (Sec 17) tightening the

соуег

and the Full mark (see Fig. 11.221. If necessary top-up with automatic transmission fluid. Take саге not {о overfill the reservoir.

bolts make sure there is clearance between the

ballnut and sector яеаг teeth. 27 In5tafl the sector shaft adjusting screw locknut loosely

оп

the adjusting screw, adjust the sector shaft mesh load to the specified value (see Specifications at the beginning of this Chapter) then tighten the locknut.

,6

Мвпиаl

steering gear - oillevel check

1

Аетоуе

the fi ller pl ug and

2

Slowly

tuгп

иррег соуег

bolt.

the steering wheel to the right

and check that the oil rises to the

соуег

'о

the end of its travel

bolt hole, then slowly turn the

5teering wheel to the left to the end of it5 travel and check that the oil rise5 to the filler plug hole. 3 If the оН does по! ri5e in both the cover bolt hole and the filler plug hole. tap-up with the specified steering gear оН. 4 In5tatl the cover bolt and filler plug.

AirbIeeding 4 If there 1з air (п the system. 1ndicated Ьу bubbIes (п the f luid, then the system mU5t Ье bIed. 5 Ensure that the reservoir (5 f illed to the correct level and that the fluid 1s а! normal operating temperature (1 65 ° 10 175°F). Тигп the steering wheel from lock-to-Iock until the bubbIes аге removed. Оо поl hold the wheels against their stops. Recheck the fluid level . Рumр drivebelt 6 If the pump belt i5 broken , glazed ог worn it must 7 The pump drivebelt tension cannot Ье checked

renewed. accuгately using the thumb pressure and belt deflection method. Д belt tension gauge must Ье used. Check and adjust the belt tension as follows : (8) When installin9 а new beft the tension shoufd Ье within 120

(ь)

17 Manual steering gear - adjustment (in-situ) 1 Disco nnect the Pitman arm from the 5teering Pitman arm-to-idler arm rod (see Section 14) . 2 loo5en the sector shaft adjusting screw locknut and turn the adjusting screw counterclockwise. 3 Usin g а torque wrench оп the steering wheel nut (see Fig. 11.21) and with the steering whee l off-center, check that the pull required to rotate the input shaft about lt turn5, either side of center, is within the limits specified (see Specifications at the beginning of thi5 Chapter). 4 Adjustment i5 Ьу loosening the steering shaft bearing adjuster locknut, and tightening ог backing-off the bearing adjuster to obtain the со ггес! preload. Тighten the bearing adjuster locknut and recheck the preload. 5 Turn the 5teering wheel slowly to either stop, (turn gently against the 5tops to avoid damaging the ball return guides) then center the ballnut. 6 Тшп the sector adjust1ng screw clockwi5e until the specified torque required to rotate the worm past its center (high spot) 1s reached . Hold the sector adjusting screw from turn1ng and tighten the locknut, then recheck. the backlash. 7 Connect the Pitman arm to the steering arm-to-idler arm rod. 18 Power steering - checks and adjustments

Fluid 'еуеl check 1 Аип the engine until the fluid 1s at normal operating temperature, then turn the steering wheel slowly from lock-to-Iock several times (do по! hold against the stops). 2 Switch off the engine. 3 Check the fluid level in the power 5teering reservo1r. The level must show оп the cross-hatching between the bottom of the dipstick

Ье

to 150 (Ь (54 (о 68 *9) and a(ter it has Ьееп гuп (ог 15 minutes it shoufd Ье within 90 (о 120 IЬ (40 to 54 *9) Adjust the tension Ьу 100senin9 the adjusting and mounting bolts оп the (гоп! (асе о( the рumр cover plate (hub sidel (see Fig. 11.231. Place а tension уаuие in the drivebeft, insert а ргу Ьаг as shown in Fi9. 11.24 and adjust the tension. CAUTI О N : 00 not fever against the f/uid reservoir as it сап easi!y Ье damaged. Тighten the adjusting агm bolt (irst and then the mоuпапи bolts. Rechec* the tension.

Power steering hoses В

Examine the input and output hoses for signs of leakage, cracks deterioration. Aenew defective hoses.

ог

19 Power steering gear (non-integra!) - removal, overhaul and installat10n Refer to Sections 14 and 15.

20 Power steering pump drivebelt - renewal 1 If equipped with ап air conditioner, loosen the idler риllеу , attaching bolts and remove the compressor drivebelt. 2 loosen the three bolt5 and опе nut attach1ng the pump to the pump bracket, and remove the belt. 3 Install the new belt оп the pulleY5 and adju5t the tension (5ее Section 18). 4 Install the compressor drivebelt (if so equipped) and adjust the tension as described in Chapter 2. 21 Pawer steering pump - removal and installation 1 Disconnect the fluid into а container.

гeturn

hose

а!

I

the reservoir and drain the fluid

11

Chapter 11 Suspension and steering

21.3 Aemoving the power steering pump Fig. 11.23 Power steering pump adjusting and mounting bolts (Sec 18)

Fig. 11.24

power steering pump drive

belt tension (Sec 18) 2

Disconnect the pressure hose from the

ритр.

3 Аетоуе the three bolts and опе nut attaching the pump to the mounting bracket , and Hft out the ритр and drivebelt (photo). 4 Installation is the re verse of the removal procedure . Adjust the drivebelt tensi on (see Section 18). Fill the pump reservoir with power steering fluid and cycle the system to гетоуе air from the system as

described in Sectio" 18.

22 Power steering pump - overhaul

1 Overhaul of the unit must Ье carried out in а clean агеа as cleanliness is of the utmost imроrtэпсе. Before dismantling the pump, clean the exterior with а 50lvent and drain as much of the fluid а5 p05sibIe. Wa5h all the parts (except 5ealsJ in а cleaning 50lvent. 2 It i5 recommended that the pump is attached to ап adaptor ptate, for mounting it in а vise, to prevent damage to the unit when It Is being dlsmantled and reassembIed. А suitabIe adaptor сап Ье made from steet ptate. The Ford adaptor i5 5hown in the associated iIIustratlons. 3 Remove the outtet fltting nut and the identi1ication tag.

4 Position the pump with the pulley upwards and, using а bIock of wood and а ptastic hammer, remove the риmр reservoir and зеаl Ьу tapping around the flange 01 the reservoir and оп the underside 01 the flller neck. 5 Invert the pump assembIy, undo the pump housing attaching bolts and remove the pump housing. 6 Remove the O-rlng seal, the oil зсгееп (if instalted) and the рге­ ssure springs 1rom the риmр housing. 7 Remove and discard the pump соуег gasket. 8 Remove the retainer end ptatB and иррвг pressure ptate (in some pumps, the end plate and иррег pressure plate аге integral). 9 Remove the loose-fitting dowet pin. Take саге not to bend the fixed dowel pin which remains in the housing plate assembIy. 1О Remove the rotor assembIy taking саге to prevent the springs and slippers from falling out and getting lost. 11 Using а suitabIe puller remove the риmр pulley. Install а t - 16 in cap5crew in the end of the риmр shaft to prevent damaging the end of the shaft (see Fig. 11.27). Note: То prevent damage (о the inteгna!

thrust areas the pulley must pressure оп the рumр shaft. 12 Clean

апу

rust, dirt and

Ье

removed without app!ying in-and-out

Ьиггз

from the end 01 the rotor shaft and

О'

DRIVE PULLEY

SL IPPER AND SPRI NG .....~ FILLER TUBE

_

M EТERI NG

""

FLOW. CONTROL VALVE

ORIFICE PLUG

Fig. 11.25 Sectional view 01 power steering

риmр

(Sec. 22)

,

Chapter 11 Suspension and steering

245 LOWER PRESSURE

UPPER PRESSURE PLATE

• RETAINER

ROTOR SHAFT

ЕНD

PUMP VAlVE

P'N

ASS EMBl у

r

СДМ

AND ROTO,ll: ASSEMBLY

I

PUМP H()JS ING

Q·RING ' -

ASSEMBL

'ОЕНТ

PULLEY

PRESSURE SPRING

,

, PLA ТЕ AND BUSHING ASSEMB Lу

I

F1ТПNG

GASKE T

SCR EW дно WASHER ASSE MBL у

RESERVQIR НЕХ

O·RI NG

HGUSING GASKET

Fig . 11.26 Exploded view of power steering pump (Sec 22)

NUT

I

t I RELIEF VALVE PLUNGER

Fig. 11.28 Cleaning the pawer steering pump relief valve (Sec 221 сат

Fig. 11.27 Removing the power steering purnp pulley (Sec 22) •

гетоуе

it from the housing ptate.

13 Aemove the lower pressure plate. 14 Wash all the parts in air. Clean the relief valve

with

а

а

naptha 50lvent, and dry with compressed Ьу depressing the tip of the relief уа1уе pin,

pin punch, several times to remove the oi l, then submerge the

valve in а container of clean solvent and гврезt the procedure. The valve must тоуе freely ; jf the pin is bent ог damaged the valve mЦБt Ье renewed. 15 Renew all gaskets and seals ехсер! the rotor shaft seal which does по! have (о Ье renewed un less it is defective. Examine all the сот­ ponent parts for wear and damage. Do not dismantle the rotor and

assembIy: if the slippers аге wоrп renew the assembIy. Examine the rotor shaft front and геаг thrust faces for scorlng and wear, and the seal for damage. When removing the rotor shaft seal wrap а piece of 0·005 shim stock round the shaft and push it into the inside diameter of the seal until it Is against the bushing, (о prevent scoring of the shaft. Use а sharp tool to pierce the metal part 01 the seal and prise it out, see Fig. 11 .29. Install а new seal , using а suitabIe piece 01 stee~ tubing to tap the seal ,п flush with the end of the seal Ьоге . 16 Mount the pump with the pulley end facing down, and insert the lower pressure plate оп the anchor pin with the wide chamfered slots а! the cen ter hole facing upward (see Fig. 11 .ЗО). ,7 Dip the rotor shaft , п power steering fluid , then insert the shaft through the lower pressure plate and housing. 18 Install the rotor and сат assembIy onto the ритр housing plate with the fixed dowel passing through the first hole to the left 01 the сат notch when the arrow оп the са т outside diameter is pointing toward the 10wer pressure plate (see Fig. 11 . З 1 ). If the сат and rotor assembIy will not seat, turn the rotor shaft slightly until the spline teeth mesh. allowing the сат and rotor to drop down into position.

11 ...;...;..--

Chapter 11 Suspension and steering

246 •

,9

In5eгt

the 1005e-flttlng do wel through the

с ат

insert and lower

plate . into the hole in the housing plate assembIy. The height of both dowels should Ье equal. lubri cate the rotor, springs, slippers and inseгt with pawer steering fluid.

20 In5tall the

иррег

сат

pressure plate with the face having the tapered

notch down against the сат inseгt . The fixed dowel should pass through the round dowel hole and the 10058 dowel through the elo ngated hole. The 510t between the ears о п the pressure plate

outside diameter should match the notch diameter ( зее Fig. 1 1.32) .

оп

the

са т

insert outside

21 In stall the retainer end plate 50 that the 51о! о п the end plate outside diameter matches the notches 01 the upper pressure plate and

c_m I Fig. 11 .331. 22 Install the ритр valve assembIy O- ring seal onto the pump valve,

.005

SНI M

taking care not to twist the seal. 23 Place the pump valve assembIy оп top of the retainer end plate with the large exhaust slot оп the pump valve in line with the outside diameter notches of the previously assembIed parts. Ensure that the stack o f parts аге 1ully seated ; ;f correctly assembIed the relief valve stem w il l Ье in I;ne with the fl uid return hole ;п the pump housing plate . 24 Smear а I;ttle petroleum jelly оп the pump housing plate and ;nstall the gasket. 25 Insert the pressure plate springs in the pockets in the pump valve assembIy. Use а little petroleum jelly to hold them in position. 26 Using а clamp. bIапk-оff the intake hole in the housing , as shown in Fig. 11.35. 27 Lubricate the inside 01 the housing and the housing cover seal with power steering fluid. Using two studs (t- 1 6 х '·55 ;п) as positioning guides, instal l опе in the housing plate bolt hole closest to the drain hole and the other in the bolt hole d;ametri cally opposite.

STOCK

, Fig. 11.29 Removing the rotor shaft seal (Sec 22)

FIXED

ROUND NQT CH QN THI S SIDE

STE P WIDE CHAMFERED

Fig. 11.30

Fig. 11.31

IпstаШпg

the lower pressure plate (Sec 22)

IпstаШпg

аS5етЫу

the сат and rotor (Sec 22)

Fig. 11.32 In5talling the upper pressure plate (Sec 22)

Too l

FIXED

169Р· З В586.А

ЕХ НД ЩТ

SLOT

Fig. 11.33 Align the 510t оп the endplat8 with the notches of the upper pre5sure plate (Sec 22)

Fig . 11.34 Install;ng the valve and springs

IS.c 221

Fig. 11.35 Using а clamp to bIапk-оff the intake hole (Sec 22)

,

Chapter 11 Suspension and steering

247

23 Power steering pump - st8rt-up procedure 8fter overh8ul

,

Ироп iпШаl

, Fig. 11.36 Checking the ритр rotating torque IS.c 22)

5tart-up after а power 5teering риmр ог steering gear overhaul there is frequently excessive noise and aeration. This is due (о air trapped "п the overhauled unit which mixes with the surging fluid and causes aeration. The ргоЫеm сап Ье minimized if the following procedure is used: 1 Disconnect the соН wire to prevent the engine staгting. 2 Fill the reseгvoir with power steering fluid. 3 While continuing to add fluid , have ап assistant crank the engine and at the same time turn the steering wheel approximately 30 degrees each side of center. 4 Recheck the fluid level and fill as required. 5 Aeconnect the coil wire, then 5tart the engine and allow it to run for several minutes. 8 Rotate the steeting wheel from 5top- to- stop to remove the air from the sY5tem. 7 Shut ОН the engine and check the fluid level.

24 Non-integral power 5teering system control valve centering spring - adjustment 1 Raise the front of the саг and support it оп stand5. 2 Aemove the two spring сар attaching screws and the 5pring сар !photo). 3 Tighten the adjusting nut, then loosen il t tutn . ОО not tighten the adjusling nut too tight (72 to 100 Ibf in ). 4 Install the spring сар 10 the valve housing and 5ecure it with the two screws and lockwashers. 5 lower the саг . Staгt the engine and check the turning effort with а spring scale attached to the rim of the steering wheel. The etfort required to turn the steering wheel in both directions should not exceed 8·51Ь (2·9 kg).

I Too/·T6SP· 3А733 - А

25 Non-integral power 5188ring control valve - removal and installation

Fig. 11.37 Installin9 the

,

ритр

pulley ISec 22)

28 Align the small oil hole in the housing rim with the 011 hole in the housing plate. 29 Install the housing, applying ап even downward pressure . Take саге not 10 move the pressure ptate springs out of position. Aemove the guide studs. 30 In5ta11 the housing retaining bolts f inger- tight and remove the

clamp. 3 1 Tighten the retaining bolts eventy to

1 Disconnect the four flu1d line fitting5 at the controt valve and drain the fluid into а suitаЫе container. Тшп the frOnl wheets 10 the left and right several times to force all the fluid from the system (photo) . loosen the clamping nut and bolt at the right end of the sleeve. 2 Аетоуе the roll pin from the steering arm-to-idler агт rod through the hole in the sleeve. 3 Аетоуе the control valve ball stud nut and IJsing а suitabIe baltjoint separator disconnect the Ьа" 5tud from the Pitman arm . 4 Turn the front wheels fully to the left and remove the control valve Ьу un5crewing it from the center link steering arm-to-idler агт rod. 5 То in5talt the valve, 5crew il onto the center link until about four

а

torque of 28 10 32 'Ы tt (3·8 to 4·4 kgf m). Install а t х 16 hex head screw, finger-tight , into the end 01 the rotor shaft, then using а torque wrench check the input torque of the shaft (эее Fig. 11 .36). The torque should not exceed 15 'Ы in (17·2 kgf ст). If it does, loosen the retaining bolts, rotate the rotor shaft, then re-torque the bolts evenly and again check the shaft torque. (lf the input 5haft torque 5till exceeds the limit specified it cannot Ье u5ed and must Ье dismantled and re-examined). 32 Install the reservoir O-ring оп the housing plate. Apply petroleum jelly to the seal and to the in5ide diameter of the reservoir flange. 33 Install the reservoir with the notch in the reseгvoir flange aligned with the notch in the outside diameter of the pump housing plate and bushing аssеmЫу. Тар at the геаг оп the outer согпеГ5 of the reservoir. Use а pla5tic hammer to avoid damaging the reseгvoir. Make 5ure the reservoir 1s seated оп the housing plate. 34 In5tall the service tag and the outlet valve fltting , then the outlet valve fitting nut and tighten it to а torque of 43 (о 47 Ibf ft (5·9 to 8·4 kgfm). . 35 Using а 5uitаЫе tool install the pulley оп the shaft. Fig. 11 .37 shows the special Ford t.ool being u5ed. It Is most Important that the pulley i5 installed without applying in- and-out pressure оп the shaft, to prevent damage to internal thrust areas.

11

24.2 Non-integral power steering control valve with spring

сар

removed

Chapter 11 Suspension and steering

248 •

PUMP

ERVO IR

25.1 Disconnect the fluid lines from the control valve CONTROL V AL УЕ

СОNNЕСТ1NG

ROD STUD

!:!J VALvE

PQWER CYLINDER

Fig. 1, .38 Non-integral power steering system ISec 25) Fig. 11.39 Insta11in9 the control valve (поп­ inte9f81 power steering) (Sec. 25)

threads аге still visibIe ОП the link. 6 Position the ball stud in the Pitman агт. 7 Measure the distance between the center of the grease plug in the sleeve and the center of the stud а! the inner end of the left spindle connecting rod (зее Fig. 11.39). The distance should Ье 4·8751п (124 тт). If necessary, turn the valve оп the center link to in crease ОГ decrease the distance. 8 Align the hole in the steering arm-to-idler агт rod with the slot пваг the end of the valve sleeve. 1"5tall the roll pin in the rod hole to lock the valve оп the rod. 9 Tighten the valve sleeve clamp bolt and the ball stud nut. 1"5tall а new cotter pin. 10 Fill the reservoir with steering яеаг fluid. Run the engine for а few minutes then turn the steering wheel from lock-to-Iock several times and check the system for leaks. 11 Check the fluid level and top-up if necessary. 12 Check the effoгt to turn the steering wheel in both directions (see Section 24).

7 Remove the spacer, bushing and seal from the sleeve end of the housing. 8 Drive the stop pin out of the regulator stop with а punch (see Fig.11 .401. 9 Turn the travel regulator stop counterclockwise in the slee"e and withdraw it from the slee"e. 1О Remo"e the valve spool bolt, spacer and rubber washer. 11 Remove the rubber boot and clamp fTom the "al"e sleeve. 12 Slide the bumper, spring and ball stud seat out and гето"е the ball socket from the sleeve. 1 3 Remo"e the return poгt hose seat and then the return poгt reHef val"e.

.-

VALVE

26 Non-integral power steering control velve - overhaul 1 Clean all fluid and diгt from the exterior of the contro! valve. 2 Remove the two attaching screws and the centering spring сар from the valve housing, (see Fig. 11.41 ). 3 Mount the valve in а soft-jawed vise. hold it Ьу the sleeve flange to prevent damage to the housing spool ог sleeve. 4 Undo the nut" оп the end of the valve spoo! bolt and remove the washers, spacer, centering spring , adaptor and bushing. 5 Undo the two attaching bolts and separate the housing from 'the sleeve, then remove the plug from the sleeve. 6 Push the valve spool out of the centering spring end of the valve housing and remove the seal from the spool.

;...-STOP PlN ВДН

STUD

SOCKEТ

TRAVEL REGULATOR STOP

Fig. 11,40 Driving out the stop pin (Sec 26)

Chapter 11 Suspension and steering

249

SPRING RЕАаЮN

ADAPТER

•

NUT

510Р

PIN

SPRING PLUG AND

SPACER

WASHER

CUSHION

SPACER

VALYE SPOOl SEALS

•

VALVE SEAl BUSHINGS

I

LUBRICATION

:.~

1RAVEl REGUlATOR

,

BUMPER SPRING BAll

SEATS

ВАН

SOCKET

VAlVE

SlEEVE

Fig. 11.41 Exploded view 01 control valve Inon-integral power steering) (Sec 26) TIGHТEN

NUT 5NUG

PUSH FORWARD ТО СНЕСК

(90·1001101· LBS) ТНЕН LOOSEN % TURN О" THREADS OF BOL Т

I

VALVE SPOOl MOVEMENT

ADJUSTING ---..... NUT

,

CENTERING SPRING

Fig. 11.42 Removing the reaction valve 15.с

I

261

АОАРТЕА

Fig. 11.43 Adjusting the control valve centering spring (Sec 26)

14 Аетоуе the plug , spring , O-r1ng and reaction valve (see Fig . 11.421. 15 Clean all the parts and inspect for wear, scoring ог other damage. Install new seals and O- rings. Before reassembIing the contгol valve , coat аН metal parts with steering gear fluid . Smear the seals with а silicone grease. 16 AeassembIy is the reverse of the dismantling procedure. Adjust the control valve centering spring as described in Section 24. 17 Mount the valve in а vise , as shown in Fig. 11.44. and check the spool for freedom of movement Ьу pushing foгward оп the сар end and then turning it Tound and pushing оп the sleeve end.

27 Non-i"tegral power steering cylinder tio"

геmоуаl

8nd i"st8118-

1 Disconnect the two fluid hoses fгom the power cylinder and allow them to drain into а container (photo). 2 Aemove the nuts, washer and insulator from the end of the power cylinder rod . 3 Withdraw the cotter pin and гетоуе the power cylinder stud-toce"ter link securing nut, then disconnect the cylinder from the center link, using а balljoint separator.

Fig. 11 .44 Checking the control valve spool for friction of movement (Sec 26)

4 Aemove the insulator sleeve and washer from the end of the power cylinder rod. 5 Installation is the reverse of the removal procedure. Fill the reservoir and bIeed the air from the system as described in Section 18.

28 Power steeri"g cyli"der

зеа)

- removal and i"stallation

1 Mount the power cylinder in а vise, taking саге not to damage it. and remove the snap-ring from the end of the cylinder. 2 Pull the piston rod out all the way to гетоуе the scraper. bushing.. and seals. If the seals do not соте out with the piston rod use а sharp tool to pick them out taking саге not to damage the shaft ог seal seat. 3 Use аН the parts in the repair kit. Coat the seals and the piston rod with silicone grease and then install all the parts оп the piston rod in the order shown in Fig. 11 .45. 4 Push the rod all the way into the cylinder then tap the assembIed parts fully in. as shown in Fig. 11.46, and install the snap-ring.

11

29 l"tegr81 power steering gear - removal and i"8t8118t10" 1

Disconnect the pressure and return lines from the steering gear.

•

Chapter 11 Suspension and steering

250 •

'ЕАС

RUBBER WIPER

, 27.1 Disconnect the fluid hoses from the power cylinder

Fig. 1, .45 Removing the power cylinder seaJs (Sec 281

RETURN PQRT

PORT SECТOR SНДFТ

TORSION BAR

ЮWER

ADJUSnIENT SCREW

CYUNDER

STUB

SНAFT

ADJUSTER PLUG

Fig. 11.46 In5t811ing the power cylinder seal5 (58С 28)

RETAINING RING

HQUSING

SEC TOR SHAFT

END PLUG Fig, 1, .47 Removing the retaining ring (Sec 29)

Fig. 11 .48 Integral power 5teering gear - Saginaw (Sec ЗО)

Plug the lines and ports to prevent the ingress of dirt. 2 Remove the tWQ bolts securing the flex соирliпя to the steering яеаг and to the column. 3 Raise the front of the саг and support it оп stands. Undo the Pitman агт securing nut and using а suitabIe puller гетоуе the Pitman агrn . 00 not hammer оп the end of the puHer as the steering 9еаг may Ье damaged. 4 Оп cars with manual transmission remove the clutch 'еувг retracting spring. 5 Support the 5teering яеаг and remove the three anaching bolt5. Work the 5teering яеаг 1гее 01 the 11ех cou pling and lift it out. 6 When in5talling the 5teering gear, 5et the 5teering wheel 50 that the 5poke5 аге horizontal and the roadwheel5 аге in the 5traight-ahead p05ition. Center the 5teering gear input 5haft and then in5tall the 5teering gear u5ing the геуеГ5е 01 the removal procedure. Tighten the Pitman arm 5ecuring nut and the 5teering gear attaching bolt5 to the 5pecified torque. 7 Саггу out the 5tart-up procedure described in Section 23.

ЗО

Integral power steering gear - dismantling

Note: Specia/

(00/ по.

Т65Р-ЗD517--А

о, аn

equ;valen(

wШ Ье

needed du,;ng th;s ope,ation. 1 Аеlег to Section 22 paragraph 1. 2 Mount the steering gear in а vise. 3 Remove the retaining ring (see Fig. 11.47). 4 Rotate the input shaft counterc1ockwi5e to foree the plug out of the housing. Do not rotate the shaft more than neeessary ог the balls will lall out. Remove the O-ring. 5 Aotate the input shaft clockwise to draw the piston inward then гетоуе the end plug lгот the piston. 6 Aemove the seetor shaft adjusting serew and the lour cover attaching screws then rotate the adjusting serew with ап Allen wreneh until the соуег is lгее 01 the housing. Remove the еоуег and O-ring. 7 Aemove the seetor shaft. 11 neee5sary, tap the shaft with а plastic hammer.

Chapter 11 Suspension and steering

•

•

8

251

Aemove the adjuster plug locknut and the adjuster plug (Fig.

11.501.

31 l"t89r81 power steering оваг houaing - dismantling. геПОУ8-

9 Insert the tool shown in Fig. 1 1.51 Into the end of the rack piston until it contacts the wormshaft. Rotate the stub shaft counterclockwise until the worm is free 01 the rack piston. Withdraw the piston and keep the tool in position to prevent the balls dropping out. 10 Pull the stub shaft and valve assembIy from the housing and li" out the worm, lower thrust bearing and the races.

tio" and reassembIy 1 Refer to Fig. 11 .52 and гетоуе the snap-ring, lower зрасег washer, lower зеаl (doubIe lip), зрасег washer апd upper зеаl. 2 Examine the housing bearing far wear; гетоуе it, if worn ог damaged using а suitabIe drift. Д stop ring is 10cated in the piston Ьоге.

TEFLON RINGS O-RING SEAL

---+

....

~~

VAlVE SPOOL

ADJUSTER--+

• SECТOR

(З)

SHAFT

,._

PORT SEAT ЕСК VALVE т

--

VAlVE

ClAMP-- - - + ВALL REТURN

_

GUIDE ТНRUSТ

BALLS - - - -..

RING

··6EARING RACK

SEAL SEAL AOJUSTER PLUG SEAl

BEARING

ЕНО

PLUG RIHG

ЕНО

PLUG

RING

Fig _11.49 Exploded view 01 power steering ооаг - Saginaw (Sec за)

UPPER SЕдl (SINGLE

SECTOR 5НАFТ BEARING тооl

LIP )

LOWER SEAl

SPACER WASHER

,"АР

RING

•

Fig. 11.50 Removing the adjuster plug (Sec ЗО)

О,

11

INlET PORT SEAT Л RПURN

PORT

SEAT Тооl

_

т

6SP_3Dsf7_A

Fig. 11.51 Removing the rack piston (Sec

Fig . 11.52 Exploded viow 01 steering gear housing sssombIy (Sec за)

З1)

Chapter 11 Suspension and steering

252 •

Do по1 attempt to гетоуе it; if it is damaged the housing assembIy must Ье renewed. То гетоуе а damaged paгt seat, cut а thread in the seat and, using а bolt, nut and flst washer, withdraw the seat (see Fig. 11.53). Аетоуе the check valve and spring from the inlet part. 3 Insert the spring, check valve and new seat in the inlet part and using а drift with а СОПС8уе end to fit оп the valve seat, drive the seat

into place. In5tall the ouHet part seat. 4 Press а new sector shaft bearing into the housing until the иррег end is 0·030 in (О· 76 тт) below the housing Ьоге. 5 Lubricate the new seals with power steering fluid. Install the single lip seal and spacer washer, and using а suitabIe drift, drive them in far enough to ptovide clearance for the other эеаl. The эеаl muэt not bottom оп the end of the counterbore. Fit the doubI e liр seal and эрасег washer, and drive them in only far enough 10 allow for the installation of the retaining snap-ring.

32 Adjuster plug (int8gr81 power steeringJ re8ssembIy

dismentling snd

Remove the thrust bearing retainer, as эhоwп in Fig. 11.54, taking саге not 10 зсоге the needle bearing Ьоге . then lift the зрасег, thrust bearing, гасез and O-ring from the plug. 2 Remove the dust seal retaining ring , and using а drift iпэеrtеd from the зрас ег end, remove the roller bearing, oil seal and dust зеаl ( зее 1

Fig. 11.55). 3 Install the new bearing with the manufacluгer's marking facing outwards and drive it into the plug until it i5 flush with the bottom suriace of the stub shaft 5еаl Ьоге. 4 Install the new оН seal, dust эеаl and snap-ring. Fit the duэt seal with it5 smooth rubber suriace facing outwards. 5 Install а new O-ring seal, then аэsеmЫе 1he thrust bearing outer гасе, the thrust bearing, inner гасе and spacer оп the adjuster plug , then install the bearing retainer.

;::--., 5/ 16·18.2" Т

33 Stub Sh8ft a"d rotary valve аззвтЫу (i"t8gral pOW8r st88ri"g) - dismantling a"d Г8аВВ8тЫу Invert the valve and tap оп а bIock of wood until the torsion Ьаг сар 5eparates from the valve body. Discard the cap-to-body O-ring. 2 PU5h the stub shaft through the valve body until the drive pin hole is visibIe. 3 TBt the stub shaft, зо that the drive pin witl disengage from the 5pool, and геmоуе it from the valve body and зрооl assembIy (Fig. 1

11.56). Slide the 5рооl out of the top of the valve body. 5 Clean а" the parts, examine 10г wear ог damage. and renew defective parts. In5tall new 0 -ring5 and Teflon 5eals оп the valve body. lubri cate the part5 with power steering fluid. 6 In5tall the dampener O-ring оп the 5pool and 51ide the 5pool into the body with а turning motion. Take саге по! to damage the O-ring. locate the drive pin hole opposite the deep notch in the valve body. 7 In51sl1 lhe stub 5haft in the spool with the drive pin hole aligned with the hole in the spool. 8 In5ert lhe drive pin inl0 the зрооl hole and риН the assembIy into lhe va lve body keeping the сар 510t and pin aligned. When the сар 5eats correctly in the valve body, the top surface of the сар 5hould Ье at least 0·094 in (2·38 mm) below the notch . 9 In5tall а new cap-to-body O-ring. 4

Fig. 11.53 Removing а port seat (Sec 31 J

BEARING RETAINER

SPACER

34 Rsck pi5ton (i"t8gral pOW8r 8t88ring) reass8mbly Not8 : Specia/ tool

по.

Т65Р-3D517-А

ог аn

dismantling and

equivalent will

Ье

needed during this operation.

Fig. 11.54 Removing the thrust bearing r8tain8r (Sec 32)

BEARING I

1 Cut the Teflon ring and O-ring from lhe piston. 2 Place the assembIy оп а clean lint-free cloth; remove the 5creW5 attaching the ball return guide cla mp (о the rack piston , and remove the clamp (Fi9. 11.57). 3 lift off the Ьа" return guides from the rack piston . 4 Remove the tool. left in the piston when dismantling the steering 9еаг, and remove the remaining balls. PlUG

THRUSТ

OOST SEAl

Q.RING

r

SPACER

I

., INNER RACE

I

QUTER RACE

Fig . 11 .55 Exploded view of adjuster plug (Sec 321

ROllER BEARING

RETAINING RING

Chapter 11 Suspension and steering

•

5 Clean the parts, examining for damage tive parts.

ог

wear; renew

апу

defec-

Fig. 11 .59 for sizes of service replacement Ьаllз availabIe . 13 Note the ball 5ize 5tamped оп the rack piston. In5tatl the next size targer to increase preload. If the rack piston is devoid of а size-stamp, the original batl code size was No. 7. 14 Each ball size larger increase5 preload approximately 1 'Ы in (, ·1 5 kgf cm). Final preload оп replacement balls should Ье 2 to 3 'Ы in (2·3

6 Lubricate а new O-ri"g and Teflo" ri"g, then i"5t811 the O-r1"g оп the piston taking саге по1 to twist 1t. Slide the Теllо" r1"g 1"to place. Do not stretch it unnecessarily. 7 Slide the worm (Fig. 11.58) fuHy i"to the rack piston. Load 16 balls into the guide hole "earest the Т8110" ring , slowly rot8ti"g the worm counterclockwise. thus feeding the balls through circuit. Alter"8te the dark colored and polished balls through the circuit as they аге loaded. в Apply petroleum jelly to опе of the ba ll return guides and i"5tall the remaining balls in the guide. The constant f8tio gear reQuires 22 balls, and the v8fiabIe ratio gear 24 balls. Position the other half of the guide, and insert the balls into the holes in the rack piston. Ensure that dark and pollshed balls аге alternated in the rack piston. In5tall the ball return guide ctamp, and retain with the 5CreWS and lockwa5her5. 9 When the rack piston passes оувг the high point in the center of the worm ягооув there 5hould Ьв а preload of 1 to 41Ы in (1·,5 to 4 ·6 kgf ст). Clamp the rack piston in а soft-jawed vise, wormshaft pointing up. Avoid overtightening which might cause distortion. 1О Place the valvв assembIy оп thв worm , and engage the worm drive pins. Rotate the worm untll It extends 1t in (32 mm) from the rack piston to thв thrust bвaring face to obtain the center position. 11 Place а torque wrench (t in deep wall, 12-point socket) оп the stub shaft, rotating the wrench through а 600 агс in both directions several times. Take а torque reading. The optimum reading with the worm rot8ting should Ье between 1 and 4 'Ы in (1 · 15 and 4·6 kgf cm). 12 In8tall а new set of balls if this reading is too high ог too low. See

•

10 3 -45 kgf ст).

15 Remove the valve aS8embIy from the worm and retease the rack piston from the vise. 16 Iпзвrt tool Т65Р-3D517 -А into the plug end of the rack and piston so that it contacts the wormshaft (Fig. 11.60). Apply pressure оп the tool and rotate the wormshaft out of the piston and rack. Leave the tool in p05ition untit the piston is instatled in the housing.

35 Int8gr81 pOW8r 5t88ring gear - re855embIy Mount the steering gear ho w 'ing in а vise. 2 During assembIy lubricate the parts with power steering fluid. Lubricate Teflon rings and 0 -ring5 with petroleum jetly. 3 See Fig. 11.49. In5tall the thrust bearing and гасез оп the worm. Align the valve body drive pin оп the worm with the narrow 510t in the valve body. 4 Instalt the valve and wormshaft a55embIy Ьу pushing оп the outer diameter of the valve body. The assembIy 15 correctly seated when the fluid return hole in the gear hou5ing is fully visibIe . 5 Install а new O-ring in the аdjuзtег plug groove and in5eгt the adjuster plug оувг the end of the stub 5haft and tighten it just enough to зваt the рагtз. Instatl the locknut loosely оп the adju5ter plug. 1

TEFLON SEAL$

о"'

HOLE

VALVE SPOOL

Q·AING

ВООУ

DAIVE PIN

DAMPENEA Q.RING

TOASION

едА

O·RINGS

Fig. 11.56 Stub shaft and rotary valve assembIy (Sвc 33)

I

RJNG

+ - - RACК

•

253

РI

STOO

DARK COlO RED BAlLS

END

Fig. 11.58 Installing the worm and balls (Sec 34)

Code Diameter Size Меап

Size Range о! (lnch)

ВаН

6

0.28117

0.28112-0.28122

7

0.28125

0.28120-0.28130

8

0.28133

0.28128-0.28138

9

0.28141

0.28136-0.28146

10

0.28149

0.28 144-0.28154

11

0.28157

0.28152-0.28162

-

Fig. 11 .59 Worm Ьа" sizes (Sec 34)

11

BAll RETURN GU1DE

CLAМP

Fig. 11.57 Exploded viвw of rack pi5ton assembIy (Sec 34)

Т65Р.3О517 · Д

Fig. 11 .60 Installing the Ьа" retaining tool in the rack pi5ton (Sec 35)

Chapter 11 Suspension and steering

254 •

AII.., Wrend!

SECTOR SHAFT дDJUSТМЕNТ

То"",,,

.оом

Wre,,,:h

NARROW PIN 5LOT

Fig. 11.61 Installing the valve and wormshaft assembIy ISec 351

Fig. 11.63 Adjusting the sector shaft mesh load (S8C Too l.

351

Т6SР·ЗDSJ7.Д

· 3805 ,.1

Fig. 11.62 Installing the rack piston ISec 351 Fig. 11.64 Steering wheel alignment matks (S8C 3бl

6 Tighten the adjuster plug white turning the input shaft. Аз 500П аз additional torque is noted back-off the adjuster plug t turn. Measure the input shaft turning torque with а torque wrench. 7 Tighten the adjuster plug to obtain а 1 to 3 'Ы in (,·15 to 3·45 kgf cm) preload in ехсвss of the figure noted in paragraph 6, then tighten the adjuster plug locknut. Recheck the preload; it тust not exceed 8

Ibf In (9·20 kgl cml. In5tall the rack piston in the housing. Ве sure the ball retaining tool is contacting the wormshaft and push the piston inward. Turn the stub shaft clockwise until the middle rack groove in the piston is aligned with the center of the sector shaft roller bearing, then remove the tool from the housing (Flg. 11.62). 9 Install а new O-ring in the sector shaft cover. Screw the cover onto the adjusting screw until it bottoms then back it оН 1t turns. 10 Install the sector shaft зо that the center gear tooth meshes with the centet groove in the rack piston; push the cover down оп the housing and install the securing screws. Install the locknut loosely оп the adjustet screw. 11 Install the end plug in the rack piston and tighten it to 50 to 100 Ibf ft (7 10 13 kgl ml . 12 Install а new епс! plug O-ring in the housing. Iпзегt the end plug in the housing and tap it lightly with а plastic hammer to зеа! it against the O-ring. then install the retainer ring. 1З Center the worm and fit а torque wrench оп the input shaft (зее 8

36 Steering wheel - removal and installation 1 Disconnect the ground саЫе from the negative terminal оп the battery. 2 Remove the crash pad attaching screws and lift оН the pad. Remove the horn ring (if so equipped) Ьу turning it clockwise to release the locking tabs. Disconnect the horn wires. 3 Remove the steering wheel securing nut. Make alignment marks оп the column shaft and wheel hub (unless already marked - Fig.

11.641. 4 Install

а

steering wheel puller and remove the wheel. 00 not изе а kпосk-оН риНег ог strike the end of the steering shaft with а hammer аз this will саиsе damage to the column bearing ог the collapsibIe column. 5 Installing is the reverse of the removal procedure. Make зиге the matching marks аге atigned. Tighten the steering wheel securing пи! to а torque of ЗА to 40 1Ы ft (4.14 to 5.52 kgf т).

31 Steering column upper 5haft beating - removal a"d i"5t81Iatio"

FIg. 11 . 631 .

Fixed columns

14 With the gear оп center and the sector shaft adjuster backed-off, measure the turning torque. Adjust the sector shaft thrust screw зо that the preload is 4 to 8 'Ы in (4·60 to 9·20 kgf cm) in ехсезз of the figure previously obtained. Readings should Ье made through ап аге not exceeding 20 degrees, with the gear оп center. 15 Tighten the sector shaft adjuster screw locknut to а torque of ЗА

1 Disconnect the horn and tur" indicator wires at the connectOT. 2 Remove the steering wheel (see Section З6). 3 Remove the turn indicator lever. 4 Undo the turn indicator switch attaching screws and lift the switch over the end of the steering shaft and place it to опе side. 5 Remove the snap-ring from the top of the steering shaft. 6 Loosen the two flange-to-steering column tube retaining nuts to

1035 Ibf 11 (4·14 10 4·83 kgl ml.

•

Chaptar 11 Suspension and steering

•

disengage them from the tube . then (alse the

I1аП9е

255

upward while

tapping the steering shaft lightly w ith а plastic hammer 10 free the bearing and flange from the shaft. 7 Аетоуе the bearing and insulator from the 11апяе . 8 Instaltation is the геуегsе 01 the removal procedure. When installing the new bearing, uзе а piece 01 tublng and the steering wheel nut 88 shown in Fig. 11.65 10 ргеss the bearing into position .

Tilt columns 9

Aemove the tilt column mechanism as described in Section 39.

1О Position the I1аП9е casting w ith the smaller bearing facing downward. Drive lightly оп the Quter гаее at each 5101 with а small diameter pin punch . Invert the 118П9е and remove the larger upper bearing in the звте way. 11 Install the bearings, using а socket wrench 01 the S8me diameter as the bearing outer races, and tap the bearlngs Into place. ,2 Install the tilt column mechanism as described in Section 39 .

•

эв

5t88ri"g column - гетОУ81 8nd in5t8118tio"

Disconnect the battery negati ... e саЫе. Disconnect the transmission lock rod О1 installed ) and the two nuts retaining the flex coupling to the steering shaft (fixed columns) . Оп tilt columns, remove the опе bolt attaching the flex coupling to the shaft.

1 2

Fig. 11 .65 Installing the

иррег

bearing - fixed steering column

(58С

37)

STEERING WHEEL

SUPPORT

!

BRAKE PEDA L SUPPORT

SIGNAL LEVER

r

СОШМN

UPPER

BRA CKEТ

I 0--'-:---------- COLUМN TU6E 1 LCМ'ER

6R ACK ET

,

'- ' ....-:;

11

TIL Т VACUUM MOTOR

ТОЕ PlдТE

-------- FlЕХ COJPLING

Fig . 11.66 Steering column assembIy 1969 model (Sec

З8)

Chapter 11 Suspension and steering

256

•

VIEW

TRIM

У

TRIM

_ - - - - CLIP, VIEW Z

BRACKET

~ _ _ _ _ _.:::::~~: BRACHT

Д

WIR E _----: CONN EC TOR 8R ACKEТ

Fig. 11.67 Steering column assembIy 1973 modellSec (Оп early models disconnect the vacuum motor control саЫе! ,

3 RemOV8 the four screws in the toe-ptate. 4 Disconnect the electrical connectors. 5 Аетоуе the four nuts securing the cotumn to the brake support bracket, then drop the column from the instrument panel and гетауе it from the саг. 6 '"stallation i5 the reverse of the гетоуаl procedure. Make sure the flex coupling i5 not distorted when tightening the attaching nuts.

39 Tilt steering column mechanism - temoval and i"st8118tio" 1 2 3 4

Disconnect the batteгy ground саЫе. Disconnect the steering shaft at the flex coupling. Aemove the steering wheel (see Section 36). Aemove the turn indicator lever and switch as described in Section

37 .

5

Insert а wire pin Ёп the hole located оп the outside of the flange casting adjacent to the turn indicator warning flasher button . 6 Turn the Ignition key 10 the ON position, depress the wire рЁп and 11ft out the lock cylinder. Aemove the lock cylinder spring clips from the lock cylinder housing. 7 Using а flat bIaded screwdriver, insert the bIade into the recess in the drivegear at the bottom of the housing. TUTn the drivegear three notches in а counterclockwise direction. Aemove the snap· ring , washer and drlvegear ( эее Fig. 11 .70) . Note the posltion of the drivegear to the upper actuator teeth. 8 Undo the cover attaching screws and lift the cover over the shaft. Unhook the upper actuator from the lower actuator. 9 Aemove the column {гЁт shrouds, the steering column instrument рапеl trim cover, and the bolts attaching the column brackets {о the brake support bracket. Allow the column to drop down, exposing the Ignition switch . 10 Aemove the three Allen screws attaching the lower flange casting {о the outer tube. 11 Loosen the Ignition switch nut and remove the rod from the switch end. 12 Aemove the two spring clips holding the wire Ьаlе which acts as а release lever for the 10cking lever and remove the wire bale (see Fig.

11.71). 13 Using а small drift, drive out the Aemove the locking lever and spring.

рЁп

securing the locking lever.

эв)

14 Aemove the steering shaft snap· ring. 15 Separate the upper and 10wer flange castings Ьу removing the two pivot рЁпэ as shown 1п Fig. 11 .72. 16 Aemove the 10wer actuator and ignltion switch rod . 17 То remove the socket casting . rotate the Ёппег tube and socket casting to expose the retaining bolt, then remove the Ьоlt and lift оН the casting. 18 Ins1a1lation is the reverse of the removal procedure. Use а C· clamp {о press the pivot pins in10 place. 00 not use the old рЁПЭ if loose in the holes (Fig . l ' .73 J.

40 Steering linakge connecting rod e"ds - remov81 8"d I"St8118· tion 1 The connect ing rod ends. which аге screwed into the adjusting sleeves. cannot Ье greased ог serviced. When the ball·studs Ьесоте worn and loose the ends must Ье renewed (photoJ. 2 Aemove the cotter рЁП and nut from the ball·stud . 3 Disconnect the end from the spindle агт ог сеп1ег link using а balljoint separator. 4 Loosen the connecting rod sleeve clamp bolts and count the number of turns required to remove the rod end . 5 Screw the new rod end Into the sleeve the same number of turns as was required 10 remove the old rod end and tighten the clamp boJts. 6 Connect the rod end to the spindle агт ог center link, then tigh1en the retaining nut to the specified torque and install the соНег рЁп. 7 It will Ье necessary to have the fTont wheel alignment checked, refer to Section 42.

41 Steering linkaQe idler tio"

агт

and bracket - removal and l"staI18-

1 When lhe idler arm bushings аге worn the complete idler arm assembIy must Ье renewed. 2 Aemove the cotter pin and nut attachlng the steering center 11nk to the idler агт . 3 Aemove 1he two bolts attaching the Idler агт and bracket assembIy to the frame and lift away the assembIy {photoJ. 4 Instatlation is the reverse of the removal procedure .

-

•

,

•

,

•

TERMINAL АНО

•

WIRE

,

иРРЕА

8EARtNG

SHAOUD

SLEEVE

TURN SIGNAL

LOCK CVLINDER

SHAFT

ASSEMBLY

WASHER IGNIТЮN SWIТCH

SHIFT

SNAP RIN.G

,'8 ,

_______----..CJ"', 2

- LOCK

тиВЕ

INSERT-ЗЕ71б

ORIVE

Р

~

,

LOCK

ASSEM8LY

,1'

L ___ --

АстиАТОА

\:rz.

•

SHAOUD AETAINER

СОУЕR

LtGHT

SWITCH - ' 5520 STEERING COLUMN тиве ASSEMBL у

е 6щsn EL' L L 'O!:I

( А 1NO

(6Е :>85) sщd :Jofl!d 8Ч~ БЩflОШ81;t

1113I:1JS)

..,. 6(lOC' dS'9!

,ОО!

'ZL·1. L 'Вы

•

,

~

,---------------------------------------------------------------------261

•

r

ADJUSTING 5L EEVE VtEW A RМ

Х

AND

ASSEMBL У

,,

,

~

/

vlEW Z

А'М

CONNE CTING ROQ

END A5SEMBl У (lNNER)

VIEW Z

Fig. 11.74 Steering linkage - manual or integral power steering (Sec 41 )

,• •

•

/ ASSEMBL У

•

(,

STEER ING CENTER LINK

•

\

.00 END ASSEMBLY 11

VIEW

Х

(OUTER )

VIEW CONNE CTING RO:O/ END ASS EMB L (INNER )

•

I

•

~:_4

1.•

/

VEHICLE PITМAN

.

ARM

- -.а

-

11 VIEW Z

Fig 1, .75 Steering linkage - non-integral power steering (Sec 41) I

FRONT OF _

VIEW U

Chapter 11 Suspension and steering

262

4 Indications of incorrect wheel alignment аге uneven tire wear and erratic steering, particularly when turning. То check, wheel alignment requires special mea5uring equipment so this is а job for а service stat10n with the necessaгy equipment. Ensure that а complete inspection of the fгопt susрепsiоп and steer1ng 1s made before the аligпmепt i5 check,ed.

•

43 Wheels and tires

41.3 Steering linkage idler

агт гетоуаl

42 Front wheel alignment - checking and

аdjustmвпt

1 Unless the front suspension ог steering linkage has Ьееп damaged , the castor angl8 , сат Ьег angle. turning angle and the 10e-in wilt ПО1 alt8r, provided the suspension balljoints ог suspension агт pivot bushings and 5t8erin9 linkages аге по1 worn.

2

Оп

modets before 1967 castot and

сатЬег

angles

аге

adjusted

Ьу

shims between the fгэте bracket and the upper suspension агт pivot shaft. Оп models from 1967 castor is adjusted Ьу al18rin9 the length of the struts, and сатЬег i5 adjusted Ьу the eccentric сат located at the lower агт attachment 10 the fгэте . Turning angle i5 по1 adjustabIe; it i5 а result of ca5tor, camber зпd toe-in adju5tment and i5 check,ed after the5e adju5tments аге made. 3 Toe-in is adjusted Ьу loosening the clamp5 оп the connecting rod sleeves and turning the sleeves as required.

1 То provide equal, and obtain maximum wear 1rom all the tires they shou ld Ье rotated оп the саг at inteгvals of 6000 miles (1 О 000 k,m) to the 10110wiпg pattern: Spare to offside rear Offside rear Со nearside front Nearside front (о nearside rear Nearside rear Со offside front Offside front to spare Wheels should Ье rebalanced when this is done. However, some owners baulk, at the prospect of having 10 Ьиу 1ive new tires al l а! опсе and tend to let two гип оп and replace а ра1г only. The new pair should always Ье оп the 1ront wheels, as these аге the most important 1rom the safety aspect 01 steering and braking. 2 Never mix tires of а radial and crosspJy construction оп the same саг, as the basic design differences сап cause unusual and, in certa in conditions, уегу dangerous hand ling and braking ch aracteristics. 11 ап emergency should 10гсе the use 01 two different types, make sure the radials аге оп the геаг wheels and drive particu larly care1ully. 11 three 01 the 1ive wheels have radial tires then make sure that по more than two гadia l s аге in use оп the саг (and those at the геаг) . Aationalize the tires at the earliest possibIe opportunity. 3 Wheels аге normally not subject {о seгvicing probIems, but when tires аге renewed ог changed the wheels should Ье balanced to reduce vibration and wear. 11 а wheel is suspected 01 damage - caused Ьу hitting а сигЬ ог pothole which could distort it out 01 true, change it and have it checked 10г balance and true-running at the earlie5t opportunity. 4 When install1n9 wheels do not overtighten the nuts. The maximum possibIe manual torque applied Ьу the manufacturers wheel wrench is adequate. It also prevents difficulty when the same wheel wrench has to Ье used in ап emergency to remove the wheels.

•

Chapter 11 Suspension and steering

263

•

I

•

44 Fault diagnosis - Suspension and steering Before diagnosing faults !гот the following chart, check that 1 Binding brakes 2 'псоггес! 'mix' of radial and cross-ply tires 3 Incorrect 1ire pressures 4 Misalignment of the body fгэmе ог геаг axle

апу iггеgu/агШеs аге поС

Symptom

Steering wheel апу

caused Ьу:

R88S0n/s

сап Ье

moved considerabIy before

sign of movement of the wheets i5

Vehicle difficult 10 steer in

а

Wear in the steering linkage, gear and column coupling

аррагепt

consistent straight lin8 (wandering)

As аЬоуе Wheel aHgnment incorrect (indicated Ьу excessive ог uneven 1ire wear) Front wheel hub bearings 1005e ОГ worn Wогп balljoints оп connecting rods ог suspension arms

Steering stiff and heavy

Incorrect wheel alignment findicated Ьу excessive ог uneven tire wear) Excessive wear ог seizure in опе ог more of the ЬаЩоiпts in the steering linkage ог suspension arms Excessive wear in the steering gear unit

Wheel wobbIe and vibration

Road wheels out of balance Road wheels buckled Wheel alignment incorrect Wear in the steering linkage , suspension arm balljoints suspension arm pivot bushings Broken front spring

Excessive pitching and rolling

оп

corners and during braking

ог

Defective shock absorbers and/ or broken spring

Faults which сап usually Ье attributed to the power steering system exclusively Саг

wanders

Low fluid level Air in system

Steering stiff

Steering stiff оп

Low fluid level Air in system Pump control valves seized Reservoir fНter bIocked Damaged seals in steering gear опе

lock only

Lack of pressure

оп опе

side of piston due to wear

Front wheels wobbIe

Air in system

Steering heavy if steering wheel is being turned

Slack pump driv:ebelt Pump control valve bIocked Air in system

11

-

•

•

•

Chapter 12 Bodywork and fittings Contents Air conditioning system - general . . . . . . • . . . . . . . . . . . . . . Ооог alignment .. ... ....... . ................•.. Ооог latch actuating rod - adjustment . . . . . . . . • . . . . . • • . Ооот latch - emergency opening procedure ..........•. ОООТ latch - геП'10vаl and installation .. .... . . ... ..... . Ооог latch striker - adjustment . . . . . . . . . . . . . , ... .... . 'Ооог ареп' warning switch - adjustment . ... .... ... .• . . Doors - гетоуаl and instal18tion . . . . . . . . . . • . . . . . . . • . .

37

Ооог

10

trim panel- гетоуаl and installation ...... . . . ..•. . Ооот window - гетоуа' and installation ..... .... .... • .. Ооог Ооот

windows learly models) - adjustment . . . . • . • . . . . . . . . .

windows (later modelsJ - adjustment . ...•........... Floor console - removal and installation .... .....• .•. . . ... Front bumper - removal and installation .... .....• . ....... General description ................. . ............. . Heater bIower motor - removal and installation ..... . . ..... . Heater саге - removal and installation .... . ....... , .... . Heater - general .. ...... ....... ...... .... • • . . ..... Heater - removal and installation ........... ... • . •...... Hood - alignment ..... .. ........... .... .•. · . . . . . . Hood latch - adjustment ................... •. • • • • • • • Hydraulic system (ConvertibIe top) - bIeeding .... . . · . . . . . .

1

12 16 25 14 13 15 11 18 20 21 28 31 1

40 41 38 39 6 7 35

General description

, The two-door body is of а unitized, all-welded construction which makes it а уегу strong and torsionally rigid shell which сап withstand а considerabIe amount of stress. 2 Three types of body аге used оп the different models: Hardtop, Fastback (Sportroof) and ConvertibIe.

2

МаiпtепаПС8

- body 8xterior

, The general condition of а car's bodywork is the опе thing that sig nificantly affects its value . Maintenance is easy but needs to Ье regular. Neglect. particularly after minor damage. сап lead quickly to further deterioration and costly repair bills. It is important also to keep watch оп those parts of the саг not immediately visibIe. for instance the underside. inside all the wheel aprons and the lower part of the engine compartment. 2 The basic maintenance routine for the bodywork 1s washing - рге­ ferably with а lot of water, from а hose. This will remove all the loose solids which тау have stuck to the саг. It (з important to flush these off (п such а way аз tp prevent grit from scratching the finish. 3 The wheel аргопз and underbody need wa5hing (п the same way 10 remove апу accumulated mud which will retain moisture and tend to encourage rust. Paradoxically enough, the best time to clean the underbody and wheel aprons is in wet weather when the mud (5 thoroughly wet and soft. In Уегу wet weather the underbody 15 usually cl eaned of large accumulations automatically and this is а good time for inspection. 4 Periodically, it is а good idea to have the whole о' the undet5ide of the саг steam cleaned. engine compartment included. 50 that а thorough inspection сап Ье carried out to see what minor repairs and renovations аге neces5ary. Steam clea ning is ауаilаЫе at тапу garages and i5 песв55агу 'ог removal of accumulation of оНу grime

Instrument panel pad - гетоуаl and installatlon ........ ... Lift cylinder (ConvertibIe top) - removal and ln5tallation ... . . . Maintenance - body exterior ........... .. ......... . .. Maintenance - body interior , ...... " .... , ... ,.... . .. . Major body damage - гераlг ....... " .... ,.. . ......... Minor body damage - repair .................... ,.... . Motor and ритр (ConvertlbIe top) - overhaul ., ...... " . , . . Motor and pump (ConvertibIe top) - гетоуа' and installation ... Out5ide door handle - гет оуа' and ln5tallation .. ,..... ..... Quarter window gla5s (Hardtop and ConvertibIe) - гетоуа' and installation ........... , ....... ,.... . .......... ... Ouarter window (Hardtop and СопуепlЫе) - adju5tment ...... Quarter window regulator (Hardtop and ConvertibIe) - removal and installation ......................... ,.,....... Radiator grille - гетоуа' and lnstallation . , ..... , . , . . . . .. Аваг Ьиmрег - removal and installatlon ........ , .'. ' . ,... Trunk lid - alignment ................... ... ..• , . . .. Trunk lid hinge torsion Ьаг - adjustment .............•... Window regulator mechani5m - Iubrication ... ,...... .... Window regulator - гетоуа' and installation .... , , . . . . . . . . W indshield and back window - general ., ..... ,......... .

29

36 2 3 5 4 34 зз

26 22 24 23

30 32 9

8 17 19 27

which 50metimes (з allowed to cake thick (п certain areas пеаг the engine, transmission and back axle. If steam cleaning facilities аге not availabIe, there аге опе ог two excellent grease solvents availabIe which сап Ье brU5h applied. The dirt сап then Ье simply hosed off, 5 After washing paintwork, wipe off with а chamois leather to 9ive ап un5potted clear fini5h. А coat of clear protective wax polish will give added protection against chemical pollutants in the air. If the paintwork sheen has dulled ог oxidised . и5е а cleaner/polishe r сот­ bination to restore the brilliance of the shine. Always check that the door and ventilator opening drain holes and pipes аге completely clear so that water сап drain out. 6 Bright work 5hould Ье treated (п the same way as paintwoгk. Windshields сап Ье kept clear of the smeary film. which often appears, if detergent is added to the water (п the windshield washer reservoir. Use а mild опе. such as washing-up liquid. Never и5е апу type of wax ог chromium polish оп glas5.

3

Меiпtепепсе

- body

iпtегiог

1 Mats and carpets 5hould Ье brushed ог vacuum cleaned regularly to keep them free from grlt. If they аге badly stained remove them from the саг for scrubbing ог sponging and make quite sure they аге dry before installation. Seats and interior trim panels сап Ье kept clean Ьу 8 wipe оуег with а damp cloth, If they do become stained (which с ап Ье more apparent оп light coloured upholstery) use а little liquid detergent and а soft паН brush to scour the grime out of the grain of the material, ОО not forget to keep the headlining clean in the same way as the upholstery. When using liquid cleaners inside the саг do not over-wet the surfaces being cleaned. Exce5sive damp could get into the seams and padded interior cau51ng 5tains, offensive odors ог еуеп rot. " the inside of the саг gets wet accidentally it is worthwhHe taking the troubIe to dry it out properly. particularly where carpets аге involved. Do поt 'еауе oil ог electric heaters inside the саг for thi5 риГР05е.

Chapter 12 Bodywork and fittings уои

•

,

I

I

I

265

4

Minor body damage - repair

See photo sequences оп pages 270 апd 27'

Repair о' minor scratches in the bodywork If the scratch is уегу superficial , and does not penetrate to the metal of the bodywork, repair is уегу simple. Lightly rub the агев of the scratch with а paintwork renovator ог а уегу fine cutting paste, to гетоуе loose paint from the scratch and to с1еаг the surrounding bodywork of wax polish . Rinse the агев with clean water. Apply touch-up paint to the scratch using а thin paint brush; соп ­ tinue to apply thin layers of paint until the surface of the paint in the scratch is level with the surrounding paintwork. Allow the new paint at teast two weeks to harden , then , bIend it into the surrounding paintwork Ьу rubbing the paintwork in the scratch агеа with а paintwork renovator ог а very fine cutting paste. Finally apply wax polish. Ап alternative to painting over the scratch is to use pa;nt patches. Use the same preparation for the affected агеа ; then simply pick а patch of а suitabIe size to cover the scratch completely. Hold the patch against the scratch and burnish its backing рарвг; the patch will adhere to the paintwork, freeing itself fгom the backing рарег at the same time. Polish the affected агеа to bIend the patch into the surгounding paintwork. Where а scratch has penetrated right through to the metal of the bodywork, causing the metal to rust, а diffetent repait technique is required, Remove апу loose rust from the bottom 01 the scratch with а penknife, then apply rust inhibiting paint to prevent the formation of rust in the future. Using а гиЬЬег ог nyton appHcator fill the scratch with bodystopper paste. If required , this paint сап Ье mixed with cellulose thinners 10 provide а very thin paste which is ideal 10г lilling narrow scratches, Before 1he stopper paste in the scratch hardens, wrap а piece of smooth соНоп rag around the tip of the finger, Dip the finger in cellulose thinners and then quickly sweep it across the surface of the stopper paste, this wШ ensure that it is stightly hollowed. The scratch сап now Ье painted over as described еагliег in th is 5ection,

Repair о' dents in the bodywork When deep denting of the bodywork has taken place, the first task is 10 риН the dent out, until the aHected bodywork almost attains its original shape, There is I1ttle роiпt iп trying to restore the огigiпаl shape comptetely, as the metal in the damaged агеа will have s1retched ОП impact and cannot Ье reshaped fully 10 its original contour, 11 is better to bring the level of the dent ир to а point which is about t inch (3тт) below the level of the surrounding bodywork, 'П cases where the dent Is veгy shallow anyway, it is not worth trying to pull i1 out at аll, If the underside of the dent is accessibIe, It сап Ье hammered out gentty from behind, using а mallet with а wooden ог plastic head. W hilst doing this, hold а suitabIe bIock 01 wood lirmly against the outside of the dent. This bIock will аЬзогЬ the impact lгот the hammer bIows and thus prevent а large аге а of bodywork from being 'beHedоиС

5hould the dent Ье in а section of the bodywork which has doubIe skin ог some other factor making it inaccessibIe from behind , а different technique is catled fot. Drill several зта" holes through the m etal inside the dent агеа - particularty in the deeper sections. Then screw long self-tapping screws into the holes just sufficiently for them 10 gain good purchase in the me1al. Now the dent сап Ье pulled out Ьу pulling оп the protruding heads of the screws with а pair of pliers. The next stage of the repair is the removal 01 the paint from the damaged агеа , and from ап inch ог so of the surrounding 'sound' bodywork. This is accomplished most easily Ьу using а wire brush ог abrasive pad оп а 'power driН, although i1 сап Ье done just as effectively Ьу hand, using shee1s of abrasive рарег. То complete the preparations for litting, score the surface of the Ьаге metal with а screwdriver ог the tang of а lile, ог alternatively, drill small holes in the affected агеа. This will pгovide а really good 'key' for the filler paste. То complete the гера]г see the 5ection оп filting and respraying.

-

Repair о' rust holes

ог

gashes in the bodywork

Remove all paint from the affected агеа and from ап inch ог so of the surrounding 'sound' bodywork, using ап abrasive pad ог а wire brush оп а power drill. 11 these аге not availabte а few sheets of аЬга­ sive рарег will do the job just as effectively. With the раiпt removed

will Ье аЫе to gauge the severity of the corrosion and therefore decide whether to renew the whole panel , (;f this is possibte), ог to repair the affected агеа. Replacement body panels аге not as ехреп ­ sive as most people think and it is often quicker and тоге satisfactory to lit а new рапеl than to attempt to repair large агеаз of corrosion. Remove all 1he littings from the affected агеа except those which will act as а guide to the or1g1nal shape of the damaged bodywork (eg headlamp shells etc). Then, using tin snips ог а hacksaw bIade , remove а" lоозе metal and апу other metal badly affected Ьу corrosion. Наттег the edges of the holes inwards in order to create а slight depression for the fШег paste. Wire-brush the affected агеа to remove the powdery rust from the surface of the remaining metal. Paint the affected агеа with rust inhibiting paint; 11 the back of the rus1ed агеа is accessibte , treat 1his also. Before filling сап take place it will Ье necessaгy to btock the hole in some way. This сап Ье achieved Ьу the use of опе 01 the following materials: Zinc gauze, Aluminum 1аре ог Polyuгethane foam. Zlnc gauze is ргоЬаЫу the best ma1erial to use 10г а large hole. CU1 а piece 10 the approximate size and shape 01 the hole to Ье filled, then position it in the hole so that its edges аге below the level of the зиг­ rounding bodywork. It сап Ье retained in position Ьу several btobs of filler paste around its peripheгy. Aluminum {аре should Ье used for small ог very narrow holes. Pull а piece оН the roll and trim i1 to the appгoximate size and shape required, then pull off the backing рарег (;f used) and stick the tape over the hole; it сап Ье overlapped if the thickness of опе piece is insufficient. Burnish down the edges 01 the tape with 1he handle of а screwdriver ог similar, 10 ensure that the tape is securely attached to the metal underneath. Polyurethane foam is best used where the hole is situated in а section of the bodywork 01 complex shape, backed Ьу а small Ьох section (eg where the sitl рапеl meets the геаг wheel аргоп оп mOS1 сагз). The изиаl mixing procedure for this foam is as follows: Put equal amounts of fluid from each of the two cans provided in the kits, in10 опе container. 5tir until the mixture begins 10 thicken , then quickly рош this mixture into the hole, and hold а piece 01 cardboard over the larger apertures. Almost immediately the polyurethane witl begin to expand and Ье forced out 01 апу small holes left unbtocked. When the foam hardens It сап Ье cut back to just below the level of the surrounding bodywork with а hacksaw btade. The affected агеа must now Ье filled and sprayed - see 5ection оп l111ing and respraying. в odywork

repairs - filling and respraying

Before using this 5ection, see the 5eC1ions оп dent, deep scratch, rust hole and gash repairs. Мапу types of bodyfitler аге availabte, but generatty speaking those proprietaгy kits which contain а tin of filler paste and а tube of resin hardener аге best for this type of repair. А wide, flexibIe plastic ог nylon applicator will Ье found invaluabIe for imparting а smooth and welt contoured finish to the surface 01 the filler. Mix ир а li111e fШег оп а clean piece of card ог board - use the hardener sparingly (foltow the maker's instructions оп the pack), otherwise the filler will set very rapidly. Using the appticator, apply the filler paste 10 1he prepared агеа; draw the applicator асгозз the зигfасе 01 the filter 10 achieve the coгrect contour and to level the ljlter suгface. As 50ОП as а contour that approximates the correct опе is achieved, stop working the paste - 11 уои саггу оп too 10ng the paste will Ьесоте sticky and begin 10 'pickир ' оп the applicator. Continue to add thin lауегз of filler paste at twenty-minute intervals until the level of the fШег is just 'proud ' of the surгounding bodywork. ~ Опсе the filler has hardened, excess сап Ье removed using а coarse-cut file. From then оп , progressively finer grades of abrasive рарег should Ье used, starting with а 40 grade ' wet - and - dгy' рарег. Always wrap the abraslve рарег around а flat rubber, cork ог wooden btock - otherwise the surface of the filter will not Ье completely flat. During the smoothing of the filler surface the 'wet-and-dгy' рарег should Ье periodically rinsed in water - this will ensure tha1 а veгy smooth finish is imparted to the filler at the final stage. At this stage the 'dent' should Ье surrounded Ьу а ring of Ьаге metal, which in turn should Ье encircled Ьу the finely 'feathered' edge of the good paintwork. Rinse the repair агеа with clean water, until alt of the dust produced Ьу the rubbing-down operation is gone.

12

Chapter 12 Bodywork and fittings

266 Spray the whole repair

•

will show up

агев

апу imреrfесtiопs

with

in the

а

light coat of grey primer - this

suгface

01 the filler. Aepair these

imperfections with fresh filler paste ог bodystopper and опев тоге smooth the surface with abrasive рарег. If bodystopper is used, it сап Ье

mixed with cellulose thinners to form

а

really thin paste which is

ideaJ for filling small holes. Repeat this spray and repair procedure until you аге satisfied that the surface of the filler, and the feathered edge of the paintwork аге perfect. Clean the repair агев with clean water and allow to dry fully. The repair агев is now ready for spraying. Paint spraying must Ье carried Qut in а warm, dry, windless and dust free atmosphere. This condition сап Ье created artificially if уои have access to а large indoor working агеа , but if you аге forced to work in the ореп , уои will have to pick уош day carefully. If уои аге working indoors, dousing the floor in the work агеа with water will 'Iay' the dust which would otherwise Ье in the эtmоsрhеге. If the герэiг агеэ is confined to опе body panel,

mэsk off the surrounding panets; this witl hetp to minimise the effects of а stight mis-match in paint cotours. Bodywork fittings (eg chrome

strips, door handles etc) will aJso need to Ье masked off. Use genuine masking tape and several thicknesses of newspaper for the masking operation. Before commencing to spray, agitate the aerosol сап thoroughly, then spray а test агаа (ап old tin, ог similar) until the technique is mastered. Соуег the repair агеа with а thick coat of primer; the thickness should Ье built up usif1g several thln layers of paint rather than опе thick опе. Using 400 grade 'wet-and-dry' рарег, rub down the surface of the primer until it is realty smooth. While doing this, the work агеа should Ье thoroughly doused with water, and the wet-anddry рарег periodically rinsed in water. Allow to dry before spraying оп тоге paint. Spray оп the top coat, again buitding ир the thickness Ьу using several thin layers of paint. Start spraying in the centre of the repair

Fig. 12.1 Hood alignment - adjustment points (Sec 6) Fig. 12.3 Typical hood bumper - adjustment (Sec 7)

,

~\ Fig. 12.2 Hood latch - adjustment (Sвc 7)

Fig. 12.4 Trunk lid torsion

Ьаг

- adjustment (Sec 8)

,

Chapter 12 Bodywork and fittings

• •

агев

and then using а circutar motion, work outwards until the whote repair агев and about 2 inches of the surrounding original paintwork is covered. Аетоуе all masking material 1О 10 , 5 minutes апег spraying оп the fiпаl coat of paint . AHow the new paint at least 2 weeks 10 harden fully, then, using а paintwork renovator ог а уегу fine cutting paste bIend the edges of the new раiпt into the existing paintwork . Finally apply wax polish.

5

, •

,

,

J.NU T

Major body damage - repair

Where serious damage has occuгred ог large areas need renewal due 10 neglect, it means that new sections will need welding in and this is best left 10 the professionals. 11 the damage is due 10 impact it will also Ье песезsагу 10 completely check the alignment of the body shell structure. Оие to the principle of construction the strength and shape of the whole сап Ье affected Ьу damage to а paгt . 'П such саэеэ the services of а Ford repair station with specialist checking jigs аге essential.

6 I

267

HINCiE ASSEM6L У

Hood - alignment

1 Loosen the hinge-to-hood securing bolts and move the hood from side to side аэ песеээагу. 2 Loosen the hinge-to-fender аргоп securing bolts and adjust the vertical . and fore-and-aft position of the hood (Fig. 12. 1). з The hood Ьитрегэ located оп 'ор of the radiator эиррогt сап Ье adjusted ир and down to provide а level surface alignment of the hood with the front fenders. 4 Tighten the securing bolts.

7

Fig. 12.5 Trunk lid hinge - 1965/70 (Sec 9)

Hood latch - adjustment $CRE'II'

The hood 18(ch сап Ье moved !гот s;de-(o-side (о align "с with the hood latch hook 8nd up-and-down (о obtain 8 flush Пс with the !ront fenders. The hood mU5t Ье properJy 8ligned before adjusting the hood /a(ch. 1 Loosen the hood lalch securing bolts until they аге just 'ооэе enough 10 move Ihe lalch. 2 Position the latch in aHgnment with Ihe hood latch hook. 3 Loosen the locknuts оп the two hood bumpers and lower the bumpers. 4 Adjust the hood latch ир ог down. as necessary. to obtain а flush fit between the 10P of the hood and the fenders when ап upward рге ­ ssure is applied 10 the front of the hood. then tighten the hood latch securlng bolts. 5 Raise the two hood bumpers 10 elimlnate апу looseness when the hood Is closed. Tighten the hood Ьитрег locknuts.

8

Trunk lid hinge torsion

Ьаг

ШССАС Е

CO MPARTMEHT DOOR

--

,, , , /

•

----

~~ ,-'----

- adjustment

•

-

-

Fig. 12.6 Trunk lid hinge - Hardtop and ConvertibIe (1971/73) (Sec 9) 1 Check the рор-ир distance of the trunk lid when il is ореп. 1I should Ье approximalely 3 inches. If the Irunk lid pops ореп тоге than 3 inches the torsion Ьаг 2 tension should Ье decreased and if it does not рор- ир when the catch is released the tension should Ье increased. Caution: Take саге when adjusting the tor5ion Ьаг 85 it ;5 under ten5ion and could 5pring ои! о! control '" not handled carefully. 3 То adjust the torsion Ьаг tension . place а piece of suitabIe 5teel Ьаг over the end of the t'orsion Ьаг . а5 shown in Fig. 12.4. then rotate the Ьаг rearward at point С and reposition point В in another notch 10 increase ог decrease the torsion Ьаг tension. as nece5sary. 4 After adju5tment . the difference of the position of the torsion Ьаг end5 between the right and left side must not Ье more Ihan опе notch.

9

Trunk lid - alignment

1 The trunk lid is adju5ted from side-to-5ide Ьу 100sen1ng the hingeto-lid attachment 5creW5 and moving the lid as песе55агу. 2 То adjust the veгtical aJignment оп рге-1971 models 1005еп the

hinge-to-hinge support attachment 5crews and move the lid up ог down а5 necessary. 3 Оп models from 1971 the vertical adjustment is made Ьу 1005еп­ ing the hinge-to-door attachment screws and the lid а5 reQuired. ог оп some models Ьу removing ог adding shims between the hinge and lid. 4 After correct alignment ha5 Ьееп achieved . tighten all the attachment screws. • 1 О Ooor trim panel - removal and installation

1965-1968 models 1 Оп early models remove the window regulator handle. using а handle-removing tool (availabIe at m05t auto supply shops! to di5engage the retaining spring сliр . ОП later models remove the handle retaining screw and withdraw the handle (photo). 2 Aemove the door-pull 5ecuring screws and the armrest (photos). 3 Undo the retaining 5crew and remove the door latch handle (photol.

12

Chapter 12 Bodywork and fittings

268

4 Аетоуе all the trim рапе' retaining screws and thеп pry the рапеl retaining clips out of the inner рапе' and гетоуе the panel. Аетоуе the watershield (photo). 5 Installation i5 the reverse 01 the гетоуаl procedure. Apply water-

•

resistant sealer at each

рапе'

retaining

сliр

and around the window

regulator shaft.

1969 - 73 models 6

Fig. 12.7 Trunk lid hinge-

Fastback 11971/731

158С

91

Аетоуе

the door lock push button control knob. 7 Аетоуе the window regulator retaining screw CDver and retaining screw and pull the handle off the shaft (photos). Аетоуе the three retaining screws from the armrest assembIy and 8 withdraw the armrest. , 9 Pry the two door-pull handle соуег assembIies from the handle , undo the two handle retaining screws and remove the pull handle. 1О Aem ove the two retaining nuts and remove the door remote control handle from the door.

10.1 Aemoving the window regulator handle retaining screw

1 0.2А Ooor-pull secu ring screws

, О. 28 Aemoving the door-pull and armrest

, 0.3 The door latch handle 1s secured with а screw

10.4 Ооог with trim panel removed and watershield pulied back

10.7 А Aemoving the window regulator handle retaining screw соуег ...

10.78 ... and the retaining screw

10.12 Fitting the trim panel

оп

the door

•

Chapter 12 Bodywork and fittings 11 Using а wide-bIаdеd knife, ог similar tool, ргу the trim рапе' retaining ctips out of the inner рапе' of the door and гетоуе the panel.

the watershield. 12 In5talli"9 the trim panel is the

Аетоуе

Apply water-resistant sealer

оуег

геуегэе

of the

гетоуа'

procedure.

each retaining clip hole and around

the window regulator shaft hole (photo).

,

I

11 Doors -

гетоуаl

and instelling

1 Ореп the door and place а support under the door to take its weight. The help 01 ап assistant should al50 Ье enlisted to hold the door. 2 Аетоуе the door trim рапе' as described in Section 10. 3 Scribe aHgnment marks оп the hinges and doOt to assist when installing. 4 Аетоуе the hinge-to-door attachment bolts and lift away the door. 5 InstaНing the door 1s the reverse of the removal procedure. Check the door aHgnment and, 1f песеззагу, adjust аз de5cribed in Section 12.

12

Ооог

alignment

1 The door hinges have enlarged holes to provide adjustment of the door position. Always ensure that hinge5 аге correctly positioned before making а latch 5triker adjustment. 2 Refer to Fig. 12.8 to determine which hinge bolts must Ье loosened to move the door in the required direction. 3 Remove the door trim рапеl and hinge access covers. Loosen the hinge bolt5 just enough to allow movement of the door with а padded ргу Ьаг. Take саге not to damage the paint finish when u5ing the ргу Ьаг.

4 Моуе the door as necessary, then tighten the hinge bolt5 and check the door fit. 5 Repeat the operation until the correct alignment is obtained, and check the striker plate a1ignment for correct clos1ng. 6 Install the door trim рапе! and h1nge ассе5З covers.

13

Ооог

269

latch striker - adjustment

1 The striker pin сап Ье adjusted tateratty and veгticaHy as well as fore-and-aft. 00 not adjust the /atch striker to overcome door S8g. 2 Adjust the latch striker position with 5hims (о obtain the clearance shown in Fig. 12.9. Check the clearance Ьу applying а thin film of grease to the striker, and then , as the door Is closed and opened а mеаsuгаЫе pattern witl result.

14

Ооог

latch -

геmоуа'

and Install8tion

1 Remove the door trim рапеl and watershield а5 described in Section 1О. 2 Disconnect the four rods from the latch аssеmЫу. 3 Undo the three latch attachment screW5 and remove the latch. 4 Remove the rod retaining clips and the 'doo r-open' warning switch from the latch. 5 Refitting i5 the rever5e of the removal procedure. Adjust the warning switch and the latch actuating rod as described in Sections 15 and 16 respectively.

15 'Door

ореп' waгning

switch - adjustment

1 Remove the door latch а5 de5cribed in Section 14. 2 Loosen the 5witch attachment screw and 5et the door latch in the cl05ed position. 3 Position the switch contact пеаг the latch cam, (з ее Fig. 12.10), but по! touching it, then t1ghten the switch attachment screw. 4 5е! the door latch foг the safety and ореп positions. The switch contact must make electrical contact with the cam when the latch i5 in the safety and ореп positions. 5 In5tall the door latch (See Section 14).

, LA ТСН SТRI КЕ R

I

,

•

I

3/32" MINIMUM

~,M"X IMUM lATCH

\

...

"'-

ASSEM6L у'

Fig. 12.9 Door latch striker - adjustment (Sec 13) ОРЕН

DOOR

WA.RNING

2 LATCH

Fig. 12.8 Ооог alignment - adjustment points (Sec 12!

SWITCH

Fig. 12.1 О 'Door

ореп' waгning

switch (Sec 15)

These photos illustrate а method of repairing simple dents. They are intended to supplement Body repair daтage in this Chapter and should по! Ье used as the sole instructions for body repair оп these vehicles .

•

11 уои can't access the backside 01 the body рапеl to hammer ои! the dent, pull it Qut with а slide-hammer-type dent puller. 1" the deepest por1ion 01 the dent ог alo"9 the crease line, drill ог punch hole(s) at least опе inch арап . ..

1

тinor

... then screw the slide-hammer into the hole and operate it. Тар with а hammer near the edge 01 the dent to help 'рор' the metal back to its original shape. When you're finished, the dent area should Ье close to its original contour and about 1/8-inch below the sur1ace 01 the surrounding metal

2

Using coarse-grit sandpaper, remove the paint down to the Ьаге metal. Hand sanding works fine, but the disc sander shown here makes the job faster. Use finer (about 320-grit) sandpaper to feather-edge the paint а! least опе inch around the dent агеа

4 When the paint is removed, touch will probabIy Ье more help1ul than sight 10r telling if the metal is 5traight. Hammer down the high spots or rai5e the low spots as nece55ary. Clean the repair area with waxlsilicone remover

5 Following 'аЬеl instructions, mix ир а batch 01 plastic filler and hardener. The ratio 01 filler to hardener is critical, and, if уои mix it incorrectly, it will either not сиге properly ог сиге too quickly (уои won't have time to file and sand it into shape)

6 Working quickly 50 the filler doesn't harden, u5e а pla5tic applicator to press the body filler firmly into the metal, assuring it bonds completely. Work the filler until it matches the original contour and is slightly аЬоуе the surrounding metal

з

•

•

,

7 Let the filler harden until уои сап just dent it with your fingernail. Use а body 1ile or Surform tool (shown here) to roughshape the filler

8 Use coarse-grit sandpaper and а sanding board or bIock to work the filler down until it's smooth and еуеп. Work down to finer grits 01 sandpaper - always using а board or bIock - ending up with 360 or 400 grit

I

I

,

10

9 Уои shouldn't Ье аЫе to 1ее' апу ridge at the tгапsitiоп from the fjller to the bare metal or from the bare теtзl to the old paint. As 500П as the repair is flat and uniform, remove the dust and mask off the adjacent panels or trim pieces

Appty severallayers 01 primer to the area. Don't spray the primer оп too heavy, so it sags or runs, and make sure each coat is dry be10re you spray оп the next опе. А pr01essional-type spray gun is being used here, but aerosol spray primer is availabIe inexpensively 1rom auto parts stores

11 The primer will help reveal imper1ections or scratches. Fill these with glazing compound. Follow the lаЬеl instructions and sand it with З6О ОТ 4oo-9rit sandpaper until it's smooth. Repeat the glazing, sanding and rеsрrауiпg until the primer reveals а perfectly smooth surface

12 Finish sand the primer with very fine sandpaper (400 or 600grit) to remove the primer overspray. Clean the area with wаtэr and allow it to dry. Use а tack rag to remove апу dust, then apply the 1inish coat. Don't attempt to rub out or wax the repair area until the paint has dried completely (at least мо weeks)

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I

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Chapter 12 Bodvwork and fittings

272

• 16 Door letch 8ctuating rod - adjustment

(XJТSIDE

QJTSIDE PUSH ВUТТCN PIN

HANDLE

BELLCRANK

1 Remove the door trim panel and watershield as described in Section 1 О. 2 Disconnect the latch actuating rod from the latch actuating rod lever. 3 Adjust the length of the rod to obtain the dimension 0.0 15 0.078 in (0.38 - 1.98 тт) at А in Fig. 12.11. 4 Install the latch actuating rod in the latch actuating rod lever and flt the retaining clip. 5 Check the operatlon of the door handle pushbutton and the latch assembIy. 6 Instatl the door watershield and trim panel, (See Section 1О).

17 Window regulator mechanism -lubric8tion

_l.ATCH

ACTUдTIНG

"00

1 The door window mechanlsm should Ье lubri cated whenever the glass channel ог window regulator is removed ог if excessive effort is . required (о operate the windows. 2 Apply ап even coating of polyethylene grease (о the window regulatot гоНегз. shafts and roller guides, where indicated Ьу shaded areas (Fig. 12 .12).

ADJUSТ RCD ТО 08TAIN DIМENSION "Д ..

18 Door window - removaland installation

Early models

l.ATCH ACTUATING R(Ю

LEVER LATCH LOCKING LEVER

Fig. 12.11 Door latch 8ctuating rod - adjustment (Sec 16)

,.