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Group 3 Suspension, Steering, Wheels & Tires

Group 3 Suspension, Steering, Wheels & Tires

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3 -1
P A R T
3 -1
S U S P E N S IO N ,
S T E E R IN G , W H E E L S
A N D
T IR E S G E N E R A L S E R V IC E .
P A R T
3 -2
S U S P E N S IO N
" " " " " " " "
P A R T
3 -3
M A N U A L
S T E E R IN G.
. . . . . . . . . .
P A G E
P A R T3 -4
P A R T
3 -5
W H E E L SA N D
T IR E S. . . .
P A R T
3 -6
S P E C IF IC A T IO N S.. . . . . .
P A G E
.
.
.
.
.3 -3 4
3 -1
. . .3-44
. .3 -1 1
3 -4 9
S U S P E N S IO N , S T E E R IN G , W H E E L S
A N D
T IR E S G E N E R A L S E R V IC E
S e c tio n
P a g e
1 D ia g n o s is a n d T e s tin g
3 -1
M a n u a l S te e rin g
3 -1
P o w e r S te e rin g
3 -1
F r o n t W h e e l A lig n m e n t
C hecks.
. . . . . . . . . . . . .3 -4
E q u ip m e n t In s ta lla tio n.
. . . . . . . . . . . . . . . . . .3 -4
C a s te r
3 -6
C am ber
3 -6
T o e -In
3 -6
F ro n t
W h e e l T u rn in g
A n g le.
. . . . . . . . . . . . .3 -6
2
C om m on
A d ju s tm e n ts
a n d
R e p a irs
.3 -6
C a s te r a n d C a m b e r A d ju s tm e n ts
3 -6
M u s ta n g
3 -6
C o m e t, F a lc o n ,
a n d F a ir la n e
3 -7
T o e -In a n d S te e rin g W h e e l A lig n m e n t
A d ju s tm e n ts
3 -7
S e c tio n
P a g e
S t e e r i n g G e a r L u b r i c a n t C h e c k i n g
P ro c e d u re
3 -8
M u s ta n g
3 -8
C o m e t, F a lc o n , a n d F a ir la n e
3 -8
3 C le a n in g a n d In s p e c tio n
3 -9
S te e rin g G e a r C le a n in ga n d In s p e c tio n. ....... 3 -9
F lu s h in g th e P o w e r S te e rin g S y s te m
3 -9
F ro n t E n d G e n e ra lIn s p e c tio n. . . . . . . . . . . . . . . 3 -9
W h e e l In s p e c tio n
3 -9
U p p e r B a ll J o in t In s p e c tio n

.3 -1 0 L o w e r B a ll J o in t In s p e c tio n. . . . . . . . . . . . . . . . 3 -1 0 S h o c k A b s o rb e rs

3 -1 0
flu id

to ra is e th e le v e l to th e b a s e o f th e fille r n e c k . D o D o t o v e rfill th e re s - e rv o ir.

C heck
F o r
F lu id
L e a k s
1 . If th e p o w e r s te e rin g flu id
d o e s
n o t
a lre a d y
in c lu d e
y e llo w is h
g re e n
d y e , p re -m ix

o n e te a s p o o n fu l o f o il- s o lu b le a n ilin e d y e w ith 2 p in ts o f a u - to m a tic

tra n s m is s io n
flu id
C IA Z -
] 9 5 8 2 -A .
T h e n
re fill
th e
re s e rv o ir
w ith
th e d y e s o lu tio n .
2 . W ith
th e e n g in e ru n n in g
a t id le
s p e e d , tu rn

th e s te e rin g w h e e l a ll th e w a y to th e rig h t s to p a n d to th e le ft s to p

s e v e ra l tim e s
t o
d is trib u te
th e
d y e s o lu tio n th ro u g h o u t th e h y d ra u lic
s y s te m . D o n o t h o ld th e w h e e l a g a in s t
D
D IA G N O S IS
A N D
T E S T IN G
M A N U A L
S T E E R IN G
C heck
Pum p
B e lt
T a b le
1 lis ts v a rio u s s te e rin g g e a r
If th e p u m p b e lt is b ro k e n , g la z e d ,
a n d
lin k a g e
tro u b le
s y m p to m s
a n d
o r w o rn , re p la c e w ith a n e w b e lt. U s e
p o s s ib le
causes. Several
o f
th e s e
o n ly
th e
s p e c ifie d ty p e
o f b e lt.
s y m p to m s a re
a ls o c o m m o n
t o
s u s -
.
p e n s io n fra m e ,
a n d
wheel and
t ir e
C heck
T h e
B e lt
T e n s io n
tro u b le s . F o r th is re a s o n , b e s u re th a t
If th e b e lt is to o lo o s e o r to o tig h t,
th e
cause of
th e
tro u b le
is
in
th e
it
s h o u ld
b e a d ju s te d to
th e
p ro p e r
s te e rin g g e a r o r lin k a g e b e fo re a d ju s t-
te n s io n a s o u tlin e d
in
P a rt 3 -4 .
in g , r e p a ir in g , o r r e p la c in g a n y o f th e
A
"u s e d b e lt"
is o n e th a t h a s ru n
s te e rin g p a rts .
1 5 m in u te s o r lo n g e r.
PO W ER
S T E E R IN G
C heck
F lu id
L e v e l
S ta rt th e e n g in e , tu rn
th e s te e rin g
P R E L IM IN A R Y
T E S T S
w h e e l a ll
th e
w ay
t o
th e
le ft
a n d
T h e
fo llo w in g
p re lim in a ry
c h e c k s
rig h t
s e v e ra l tim e s , a n d s h u t o ff th e
s h o u ld
a lw a y s b e m a d e b e fo re
p e r-
e n g in e .
fo rm in g
a n y tro u b le -s h o o tin g
o p e ra -
C h e c k th e flu id
le v e l in
th e re s e r-
tio n s .
v o ir. If
th e le v e l is lo w , a d d e n o u g h
G R O U P
3 -
S U S P E N S IO N ,
S T E E R IN G ,
W H E E L SA N D T IR E S
3 -2
s e a ls . A
pow er
c y lin d e r
s e a l
k it
s h o u ld
b e
u s e d
t o

c o rre c t le a k a g e . D o n o t r e p la c e th e p o w e r c y lin d e r a s . s e m b ly u n le s s th e p is to n ro d is s c o re d o r h a s a d u ll g r a y fin is h in s te a d o f a

h ig h lu s te r c h r o m e fin is h .
C heck
T u rn in g
E ffo rt
W ith
th e
fro n t
w h e e ls
p ro p e rly
a lig n e d
a n d
t ir e
p re s s u re s c o rre c t,
c h e c k th e e ffo rt re q u ire d to tu rn
th e
s te e rin g w h e e l.
1 . W ith
th e
car on
d ry
c o n c re te ,
s e t th e p a rk in g
b ra k e s .
2 . W ith
th e e n g in e w a rm e d u p a n d
ru n n in g
a t id le s p e e d , tu rn
th e s te e r-
in g w h e e l to th e le ft a n d rig h t s e v e ra l
tim e s to w a rm
th e flu id .
3 . A tta c h
a to rq u e
w re n c h
t o
th e
s te e rin g w h e e l h u b . (F ig .
1 ). C h e c k
~ ;~ :~ ~ h
(In . L b .)~
C 1 2 7 0 -B
F IG .
1 -C h e c k in g T u rn in g
E ffo rt- T y p ic a l
th e e ffo rt re q u ire d to tu rn
th e w h e e l
a t le a s t o n e
c o m p le te
re v o lu tio n
in
b o th d ire c tio n s . S e e P a rt 3 -6 fo r
th e
s p e c ifie d to rq u e w h ic h
s h o u ld b e a p -
p ro x im a te ly
e q u a l in
b o th d ire c tio n s .
P u m p - F lu id
P re s s u re
T e s t
A
flu id
p re s s u re te s t
w ill

s h o w w h e th e r th e p u m p o r s o m e o th e r u n it in th e p o w e r s te e rin g s y s te m is c a u s - in g tro u b le

in
th e s y s te m . S te p s o u t-
lin e d b e lo w s h o u ld b e fo llo w e d
to d e -
te rm in e th e c a u s e o f th e tro u b le .
1 . M e a s u re th e p u m p b e lt te n s io n .

W h e n a d ju s tin g th e b e lt te n s io n o n th e p o w e r s te e rin g p u m p , d o n o t p ry a g a in s t th e p u m p to o b ta in th e p ro p - e r b e lt lo a d .

A
h a lf-in c h
c a s t b o s s h a s b e e n in -
c o rp o ra te d
o n th e fro n t
fa c e o f
th e
pum p
c o v e r p la te o n to
w h ic h
a 9 /1 6
in c h o p e n e n d w re n c h c a n b e fitte d
t o
p ry
th e p u m p a n d o b ta in th e p ro p e r
b e lt te n s io n .
2 . D is c o n n e c t
th e
p re s s u re
lin e
h o s e fro m
th e p u m p o u tle t, a n d in s ta ll

a 0 -2 0 0 0 p s i p re s s u re g a u g e a n d s h u t o ff v a lv e b e tw e e n th e e n d o f th e h o s e a n d

th e p u m p
o u tle t (F ig . 2 ).
B e s u re th a t th e p re s s u re g a u g e is
b e tw e e n th e p u m p
a n d th e
s h u t o ff
v a lv e , a ll c o n n e c tio n s a re tig h t,
a n d
th e s h u t o ff v a lv e is fu U y o p e n .
3 . C o n n e c t a ta c h o m e te r.

4 . S ta rt th e e n g in e a n d o p e ra te it a t id le s p e e d fo r a t le a s t tw o m in u te s to w a rm u p th e flu id .

S . C y c le
th e
s te e rin g w h e e l fro m
s to p -to -s to p s e v e ra ltim e s to e x p e l a n y
e a c h w h e e l s to p fo r
m o re th a n
3 to
5 seconds.
3 . S h u t o ff th e e n g in e , a n d c h e c k
fo r
le a k s .
F ittin g
a n d T u b e S e a t L e a k . S in c e
m o s t flu id
le a k s o c c u r a t th e fittin g s
a n d c o n n e c tio n s in
a p o w e r s te e rin g
h y d r a u lic
s y s te m , th e s e p a rts s h o u ld
b e c h e c k e d b e fo re
a n y o th e r p a rt is
re p la c e d .
1 . W ith
th e e n g in e ru n n in g
a t id le
s p e e d , ra is e th e c a r o n a h o is t.
2 . C le a n
th e
o u ts id e
o f
th e
c o n -
tro l v a lv e a n d th e p o w e r c y lin d e r, th e
b o tto m
s u rfa c e s o f th e p u m p , a n d a ll
lin e s a n d fittin g s . D irt,
o il, a n d g r e a s e
s h o u ld
b e
re m o v e d
fro m
a ll
a re a s
w h e re le a k s m a y e x is t.
3 . T ig h te n
a ll fittin g s , u s in g a s p e -
c ia l 5 -fla t tu b e w re n c h . D o n o t tig h t-
e n th e
fittin g
w ith
a
s ta n d a rd o p e n
e n d w re n c h . If
a p ro p e rly
tig h te n e d
fittin g
le a k s , re p la c e th e s e a t.
P u m p , C o n tro l

V a lv e , a n d P o w e r C y lin d e r L e a k . If th e fittin g s a n d c o n - n e c tio n s d o n o t le a k , c h e c k th e o th e r p a rts o f th e s y s te m .

C h e c k th e h o s e c o n n e c tio n
a t th e
p u m p fo r le a k s , a n d tig h te n th e h o s e
c la m p if n e c e s s a r y .
Pum p
L e a k s . If

le a k a g e o c c u rs a t th e p u m p re s e rv o ir s e a l, p u m p o u tle t v a lv e s e a ls , o r th e s u p p o rt s tu d s e a l, c h e c k th e to rq u e

o f th e o u tle t v a lv e
n u t
a n d
th e
s u p p o rt
s tu d
n u t.
I f
to rq u e is w ith in
s p e c ific a tio n s , r e p la c e
th e re s e rv o ir s e a l, o u tle t v a lv e
s e a ls ,
o r th e s u p p o rt s tu d s e a l, w h ic h e v e r is
re q u ire d
if
le a k s a re
e v id e n t
o th e r
th a n th e lin e s .
C o n tro l V a lv e L e a k s . If th e c o n tro l
v a lv e
is
le a k in g
(s o m e w h e re
o th e r
th a n
th e
tu b e

s e a ts ), re p la c e a ll th e s e a ls , u s in g a c o n tr o l v a lv e s e a l k it. U s e a ll th e

p a rts in
th e
k it,
and be
s u re
th e y
a re
c o rre c tly
in s ta lle d .
W h e n a s s e m b lin g th e n e w s e a ls in th e
v a lv e ,
a n
a p p lic a tio n
o f
s ilic o n e
g re a s e to
th e in te rn a l p a rts w ill
h e lp
to p ro v id e a b e tte r s e a l a g a in s t fu tu re
le a k a g e . A p p ly
g re a s e to
th e c e n te r-

in g s p r in g a r e a , e s p e c ia lly o n th e c a p a n d s p a c e r m a tin g s u rfa c e s . C o a t th e th re a d s

o f
th e
c a p
re ta in in g
b o lts
w ith
g re a s e . T h e
ru b b e r
b o o t s e a ls ,
th e
a c tu a to r a s s e m b ly , a n d th e m e t-
a l
c u p
s e a ls in
th e
c o n tro l
v a lv e
s h o u ld
a ls o b e c o a te d w ith
s ilic o n e
g re a s e .
S o m e o il re m a in in g fro m
th e m a n -
u fa c tu rin g

p ro c e s s e sm a y b e fo u n d in th e s le e v e n e a r th e b a ll s tu d . D o n o t c o n fu s e

th is
o il
w ith
le a k in g
flu id
fro m
th e h y d ra u lic
s y s te m .
P o w e r C y lin d e r L e a k s . T h e p o w e r
c y lin d e r
m a y le a k a t th e
p is to n
ro d
P A R T
3 -1
-
S U S P E N S IO N ,
S T E E R IN G .
W H E E L SA N D T IR E SG E N E R A L
S E R V IC E
3 -.1
a fo re a n d c a u s e u n d u e p u m p a n d / o r
s te e rin g
g e a r
w e a r.
E n g in e
rp m
s h o u ld
n o t
e x c e e d fa s t
id le
d u rin g
th is te s t.
s u re is h ig h e r, in s p e c t th e h o s e s fo r
k in k s
a n d
o b s tru c tio n s .
7 . In c re a s e
th e
e n g in e
s p e e d to
1 0 0 0
rpm ;
th e n ,
s lo w ly
c lo s e
th e
g a u g e s h u t-o ff v a lv e . W ith
th e v a lv e
fu lly
c lo s e d ,
th e
pum p
p re s s u re
s h o u ld b e 7 5 0 to
9 0 0 p s i.
D o
n o t c lo s e th e
v a lv e
fo r
m ore
th a n a fe w
s e c o n d s (m a x im u m
5 sec-
o n d s ), a s th is
w o u ld
a b n o r m a lly
in -
c re a s e th e
lu b r ic a n t
(flu id )
te m p e r-
a ir fro m
th e s y s te m ; s to p th e e n g in e .
R e m o v e th e
r e s e r v o ir fille r
c a p
a n d
c h e c k th e flu id
le v e l in
th e re s e rv o ir.
I f
necessary, add
lu b r ic a n t
C IA Z -
1 9 5 8 2 -A to
th e
p ro p e r
le v e l.
6 . W ith
th e e n g in e ru n n in g
at ap-
p ro x im a te ly 5 0 0 rp m
a n d n o s te e rin g
e ffo rt a p p lie d ,
a n d
th e
lu b r ic a n t
a t
n o rm a l
o p e ra tin g
te m p e ra tu re ,
th e
p re s s u re g a u g e s h o u ld
s h o w
a p re s -
s u re o f le s s th a n S O p s i. If
th e p re s -
I f
p re s s u re is
m ore
o r
le s s th a n
s p e c ific a tio n ,
re p la c e
th e
pum p
a s -
s e m b ly . If p re s s u re is a s s p e c ifie d a n d
s te e rin g
e ffo rts
a re
h e a v y , th e
g e a r
a n d ! o r c o n tro l v a lv e c o u ld b e a t fa u lt.
S T E E R IN G
T R O U B L E
D IA G N O S IS
G U ID E
B IN D IN G
O R
P O O R
R E C O V E R Y
c h e c k th e s p o o l a d ju s tm e n t. If th e a d -
ju s tm e n t is
c o rre c t, o v e rh a u l o r re -
p la c e th e c o n tro l v a lv e .

C h e c k th e c o n tro l v a lv e tra v e l re g - u la to r s to p a d ju s tm e n t. If th e s to p is d ra w n

u p
to o
tig h tly ,
th e

b a ll s tu d w ill b in d in th e s e a ts .A d ju s t th e s to p a s re q u ire d .

C h e c k th e c o n tro l v a lv e s le e v e a n d
th e s o c k e t tu b e fo r

d a m a g e . R e p la c e p a rts th a t s h o w s ig n s o f d a m a g e , a n d a d ju s t th e tra v e l re g u la to r s to p .

C h e c k fo r p o s s ib le in te rfe re n c e b e -
tw e e n
th e
s te e rin g
w heel
a n d
th e
s te e rin g c o lu m n .
If th e s te e rin g w h e e l b in d s o r s tic k s
w h e n tu rn e d , o r if p o o r re c o v e ry
t o
th e
s tra ig h t-a h e a d
p o s itio n
o c c u rs ,
c h e c k th e P itm a n a rm
b a ll s tu d in th e
c o n tro l v a lv e s le e v e . If
th e b a ll s tu d
is
ru b b in g
a g a in s t th e
edge of
th e
s le e v e s lo t, th e r o ll p in
m a y b e m is s -
in g .
If e ith e r o f th e id le r a rm
b u s h in g s
a re
w o rn
o r
d a m a g e d , re p la c e b o th
b u s h in g s .
C h e c k th e s te e rin g g e a r a d ju s tm e n t
(S e c tio n 2 ).
C h e c k th e o p e ra tio n o f th e c o n tro l
v a lv e s p o o l in
th e
v a lv e h o u s in g . If
th e
s p o o l is b in d in g
in
th e h o u s in g ,
te rin g s p rin g a d ju s tm e n t. A d ju s t if re -
q u ire d
(S e c tio n 2 ).
C h e c k th e c o n tro l v a lv e s p o o l fo r
m o v e m e n t.
I f
th e
s p o o l
d o e s

n o t m o v e fre e ly , c h e c k fo r, a n d e lim in a te , in te rfe re n c e b e tw e e n th e s o c k e t tu b e a n d th e v a lv e s le e v e . If

th e s p o o l is
s tic k in g
in
th e

h o u s in g , re m o v e th e s p o o l a n d c h e c k th e s p o o l la n d s fo r b u rrs . S m a ll b u rrs

m a y b e re m o v e d
w ith
c ro c u s c lo th
if th e e d g e s o f th e
v a lv e
la n d s a re
n o t
ro u n d e d
in
th e
p ro c e s s . If
th e
s p o o l c a n n o t b e re -
p a ire d , re p la c e
th e
c o n tro l v a lv e .
C heck
th e c o n tro l v a lv e b a ll s tu d
fo r
fre e
m o v e m e n t in
th e
b a ll s tu d
s e a ts . If
th e
s tu d
is
b in d in g
in
th e
s e a ts , a d ju s t th e tra v e l re g u la to r s to p .
I f
th e
h a rd
s te e rin g s till
p e rs is ts ,
c h e c k th e
fro n t
e n d a lig n m e n t.
H A P .D
S T E E R IN G
I f
th e
e ffo rt
re q u ire d
t o
tu rn

th e s te e rin g w h e e l is g re a te r th a n n o rm a l fo r

th e
e n tire
tra v e l
o f
th e
fro n t
w h e e ls , c h e c k th e tire
p re s s u re th e n ,
te s t th e flu id

p re s s u re . B e s u re th a t th e re a re n o le a k s , th a t th e re s e rv o ir is p ro p e rly

fille d , a n d th a t th e b e lt is p ro p e rly a d ju s te d . If th e p u m p o u tp u t p re s s u re is lo w , th e p u m p m a y b e d e - fe c tiv e a n d s h o u ld b e re p la c e d .

I f

th e p re s s u re te s t s h o w s th a t th e tro u b le is in th e c o n tro l v a lv e o r p o w - e r c y lin d e r, re m o v e a n d in s p e c t th e s e u n its . R e p a ir o r r e p la c e a n y d a m a g e d

p a rts .
I f
th e p re s s u re te s t in d ic a te s th a t
th e p re s s u re s th ro u g h o u t th e
s y s te m
a re
w ith in
s p e c ific a tio n s , c h e c k
th e
fo llo w in g
ite m s in th e o rd e r g iv e n :
C h e c k th e c o n tro l v a lv e s p o o l c e n -
v a lv e
tra v e l
re g u la to r
s to p
C h e c k th e c o n tro l v a lv e c e n te rin g
s p rin g
a d ju s tm e n t. If
th e
s p rin g a d -

ju s tm e n t n u t is lo o s e , tig h te n th e n u t u n til it is s n u g , a n d th e n b a c k o ff th e n u t n o t m o re th a n 1 /4 tu rn . E x c e s s iv e tig h te n in g

m a y d a m a g e th e s to p p in .
E X C E S S IV EFREE PLAY
I f
e x c e s s iv e fre e
p la y
o r lo s t m o -
tio n
is n o tic e d w h e n
s te e rin g , c h e c k
th e
s te e rin g g e a r p re lo a d
a n d
m esh
a d ju s tm e n t.
C h e c k fo r
e x c e s s iv e c le a r a n c e b e -
tw e e n th e s te e rin g a rm
b a ll s tu d a n d
th e b a ll s tu d s e a ts . If
th e b a ll s tu d is
lo o s e in
th e s e a ts , a d ju s t th e c o n tro l
C O N T IN U E D
O N
N E X T
P A G E

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