Ford - Falcon - Workshop Manual - 1960 - 1970

FORD BOLT-IN IFS INSTRUCTIONS FITS THE FOLLOWING FORD CARS: Mustang ‘64-73, Cougar ‘67-73, Ranchero ‘60-71, Torino ‘68-71, Cyclone ‘64-71, Montego ‘68-71, Mavrick ‘70-77, Falcon ‘60-70, Fairlane ‘60-70, Comet ‘60-67 & ‘71-77 FRONT VIEW Upper shock bracket features about 3” of adjustable stance Upper A-arm features a L & R threaded adjuster for easy alignment New lower A-arm bracket bolts to stock holes Both sides of sway bar bolt to stock holes on frame MADE IN USA by American craftsman from top quality US materials BOTTOM VIEW Removable steering arms www.jimmeyerracing.com Bolts to original front strut rod holes Lower balljoint comes pressed in Lower A-arm holes feature 3/4” dia. shaft & bronze bushings 2795 SE 23rd • Lincoln City, OR 97367 Tech: 1-541-994-7717 • Order: 1-800-824-1752 • Fax: 1-541-994-2397 1 2 IFS Torque Specs All specs are in foot pounds = ft. lbs. Torque specs common to both sides FRONT VIEW Upper A-arm 3/4” pivot bolts 60 ft. lbs. Upper balljoint nut 60 ft. lbs. Lower balljoint nut 70 ft. lbs. Upper & Lower 1/2” shock mount bolts 50 ft. lbs. End caps 10 ft. lbs. 3/4” strut rod hole 70 ft. lbs. Top 2 holes 1/2” 50 ft. lbs. Bottom 2 3/8” 30 ft. lbs. BOTTOM VIEW Forward support tubes 3/8” 30 ft. lbs. Upper tower Looking at the upper A-arm balljoint, torque the 4 - 1/4” 20 ft. lbs. Antisway bar to frame brackets 3/8” 30 ft. lbs. R/P mounting bolts 5/16”, 3/8” or 10mm 30 ft. lbs. 1/2”-50 ft. lbs. www.jimmeyerracing.com 1 - 1/2” - 50 ft. lbs. 1 - 3/8” - 30 ft. lbs. Cross shaft setscrew is installed in bottom of crossmember 5/16” 10 ft. lbs. both sides Tie rod ends - both sides 1/2” 50 ft. lbs. 2795 SE 23rd • Lincoln City, OR 97367 Tech: 1-541-994-7717 • Order: 1-800-824-1752 • Fax: 1-541-994-2397 Parts Inventory Lists & Replacement Parts 1st thing to do is read over the entire instructions 1964-73 Mustang Hardware Kit Also Fits: Comet ‘60-67 & ‘71-77, Cougar ‘67-73, Cyclone ‘64-71, Fairlane ‘66-71, Falcon ‘60-70, Mavrick ‘70-77, Montego ‘68-71, Ranchero ‘60-71, Torino ‘68-73 Quantity Fastener Size Fastener Location Quantity Upper Control Arm and Shock Tower 2 2 1/2NF x 3” Gr8 Hex Bolt 1/2NF Nylock Nut 4 4 4 8 4 2 2 2 2 2 3/4” x 3/8” Clevis 3/4” Jam Nut Gr5 3/8NC x 1-1/2” Gr8 Hex Bolt 3/8 AN960 Washer 3/8NC Nylock Nut “L” Bracket 3/4NF x 1-3/4” Gr8 Hex Bolt Aluminum Shouldered Bushings 3/4” USS Washer 3/4NF Thin Nylock Nut 2 2 2 6 4 1” Urethane Bushing and Saddle Clamp 3/8NC Nylock Nut Front 3/8NC x 4” Gr8 Hex Bolt Anti-Sway Urethane Bushing Bar Bushing Washer 1 2 1 2 1 6 3 1 1 1/2NC x 1-3/4” Gr8 Hex Bolt 1/2” SAE F436 Struct. Washer 1/2NC Thin Nylock Nut 3/8NC x 1-1/4” Gr8 Hex Bolt 3/8NC x 1-3/4” Gr8 Hex Bolt 3/8” SAE F436 Struct. Washer 3/8NC Nylock Nut 10mm - 1.5 x 25 10mm Split Lock Washer 2 2 8 8 5/16NC x 1” Gr8 Hex Bolt 5/16NC x 1-1/2” Gr8 Hex Bolt 5/16” SAE F436 Struct. Washer 5/16NC Nylock Nut 4 4 4 8 8 1/2NC x 1-1/4” Gr8 Hex Bolt 1/2” SAE F436 Struct. Washer 1/2NC Nylock Nut 3/8NC x 1” Gr8 Hex Bolt 3/8NC Nylock Nut 4 2 2 2 4 2 2 4 2 3/4NF x 2” Gr8 Special Pivot Bolt 3/4” Spherical Rod End 3/4” Sph. Rod End Left Hand Thread 3/4” x 1/2” Clevis 3/4” Jam Nut Gr5 3/4” Jam Nut Gr5 Left Hand Thread 1/2NC x 1-1/4” Socket Cap Screw 1/2” AN960 Washer 1/2NC Thin Nylock Nut 8 8 2 2 2 4 1/4NC x 1” Hex Bolt 1/4NC Lock Nut Urethane Boot Castle Nut Cotter Pin Shim Washers 4 4 2 4 2 4 4 1/2NC x 1-1/4” Socket Cap Screw 1/2” Ext. Tooth Lock Washer 1/2NC x 2-1/4” Gr8 Hex Bolt 1/2” SAE Ex. Thick Washer 1/2NC 4-1/2” Sock Cap Screw 1/2NC Thin Nylock Nut Shock Spacers 2 8 4 4 4 Pivot Shaft Urethane Bushing Lower 3/4” Stainless AN960-L Thrust Washer Control Aluminum Pivot Caps Arm 5/16NF x 3/4” Flat Head Socket Cap Screw 2 2 2 2 2 2 2 4 4 2 2 2 Urethane Boot Castle Nut Cotter Pin Spindle Assembly 5/8NF x 1” Gr8 Hex Bolt 5/8” Int. Tooth Lock Washer 1/2NF x 3-1/2” Gr8 Hex Bolt 1/2NF x 2-3/4” Gr8 Hex Bolt 1/2” SAE Ex. Thick Washer 1/2NF Nylock Nut Spindle Nut Spindle Washer Cotter Pin www.jimmeyerracing.com Upper Control Arm Upper Ball Joint Shock Mount Lower Ball Joint Fastener Size Fastener Location Crossmember Crossmember Support Tubes Rack & Pinion Power Steering Manual R&P Spindle 67-72 Chevelle Disc Brake Rotor 67-72 Chevelle 11” (8200) Replacement Caliper 67-72 Chevelle (4059/60) Parts Lower Ball Joint 67-72 Chevelle (5103) Upper Ball Joint 67-72 Chevelle (5208) Coil-over Shock 9-1/2”-10” Ride Height QA1 (3855B) Coil Spring 2-1/2” ID x 7” x 650# Rack and Pinion Power 85-92 Buick Electra (RP5279) 17mm DD Manual Flaming River Omni (FR1507-2-5) 9/16” x 26 Spline 2795 SE 23rd • Lincoln City, OR 97367 Tech: 1-541-994-7717 • Order: 1-800-824-1752 • Fax: 1-541-994-2397 3 Drill 8 Holes & Install Upper Tower Bolt this template, provided in the kit, to the 2 top holes and drill the 2 bottom holes 3/8”. Then go to page 3 and find the correct size fasteners under upper control arm and shock tower. 1 2 The 2 upper holes (not using center hole) held the stock tower support on both sides. To anchor the lower end of the new upper tower brackets, drill two 3/8” holes in the lip of the frame doubler plate. Install nuts/bolts and torque to specs. 3 www.jimmeyerracing.com 2795 SE 23rd • Lincoln City, OR 97367 Tech: 1-541-994-7717 • Order: 1-800-824-1752 • Fax: 1-541-994-2397 4 Install Upper A-arm and Shock Bracket Upper balljoint bolts in from the top as shown using 4 1/4x20 bolts & lock nuts 4 5 INSTALLING THE UPPER SHOCK BRACKET. 6 Like two gears meshing together, make sure the external star washers mesh flat before tightening the 2 Allen bolts to 60 ft. lbs. Start in middle as shown. The upper A-arms can be installed now or later. Make sure the L/R adjuster is toward the front, then install the 1/2” bolts in the front legs of A-arm. The upper coilover shock bracket offers four 1/2” holes for 3 adjustment settings, for additional settings flip the shock bracket. The top 2 holes will lower the car to the max. The 2 bottom holes raise it to the max, while the 2 center holes can be used for a medium stance. 7 www.jimmeyerracing.com 2795 SE 23rd • Lincoln City, OR 97367 Tech: 1-541-994-7717 • Order: 1-800-824-1752 • Fax: 1-541-994-2397 5 Lower Crossmember & Support Rods Find the new IFS crossmember and the two 1/2” grade-8 bolts and lock nuts and install to chassis. 8 9  FRONT Note: The rack goes on last.  FRONT On each side of the pan are the stock lower A-arm holes. Install the 1/2” bolts and bracket to these original holes. 10 11 Slip the new crossmember into the original lower A-arm brackets using two 1/2” grade-8 bolts and locknuts 12 The new support rods use the stock forward hole. Load the forward clevis as shown. The large washer and nut go on the front side of stock hole.  Load forward clevis as shown. The aluminum centering washer goes on rear of the hole. 13 14 www.jimmeyerracing.com The rear clevis mounts to the front of the new IFS crossmember. The support rods go under the antisway bar. As shown in #13. 2795 SE 23rd • Lincoln City, OR 97367 Tech: 1-541-994-7717 • Order: 1-800-824-1752 • Fax: 1-541-994-2397 6 7 Installing the Lower A-arms  Grease all (4) bushings inside and out, along with the cross shaft and the holes in A-arms and in the crossmember on each side. Install the 4 urethane bushings as shown. 15  FRONT You can install the lower A-arm before you install crossmember or after it is installed. Be sure the antisway mount hole is pointing forward on each side. As the pivot shaft meets the other side of the crossmember, install another 3/4-inch diameter washer. You should have one washer on each side of the crossmember. 16  17 18 19 Continue tapping the shaft through the last 2 bushings, then stop with about 1/4-inch of shaft sticking out. Use the aluminum capshaft screw (5/16NF X 3/4 countersunk) to tap the shaft through the last 1/4-inch. 20 Install the aluminum end caps and Loctite both 5/16 NF countersunk flathead screws in each end. Using an Allen wrench on each end of the shaft (end caps) will keep the shaft from turning. www.jimmeyerracing.com 21 Looking at the bottom of the R&P crossmember, you’ll find the lower cross shaft has a 5/16” set-screw with all weight on tires, tighten the setscrew to 10 ft. lbs. 2795 SE 23rd • Lincoln City, OR 97367 Tech: 1-541-994-7717 • Order: 1-800-824-1752 • Fax: 1-541-994-2397 Mounting the Front Coilover Shocks Check the spring pre-load on your assembled coilovers. With the top of the spring seated into the upper collar, thread the lower collar with stainless washer against the spring. Using the spanner wrench enclosed, thread the lower collar 3/4 to 1-inch up the threads and tighten the collar lock nut against the lower collar. 22 23 Find these bolts to install the coilover between the lower A-arm & upper tower. Refer to page 3 for fastener size and location. Be sure to add a thick washer on each side of the upper coilover bushing inside the mounting bracket as shown. 25 24 Now you can install the coilover in the lower Aarm. Be sure to install a bushing on either side of the coilover when installing the 3/8-inch bolt. Install the Nylock nut. Torque to 30 ft. lbs. Bolt goes thru the inner hole on lower A-arm. Installing Power R&P to Bracket 26 Now you can install the rack to the crossmember www.jimmeyerracing.com 27 2-Left side bolts 1-1/2 x 1 3/4 and 1-3/8 x 1 3/4 28 2-Right side bolts 2-3/8 x 1 1/4 and 1-10mm x 25mm 2795 SE 23rd • Lincoln City, OR 97367 Tech: 1-541-994-7717 • Order: 1-800-824-1752 • Fax: 1-541-994-2397 8 Connecting R & P to Steering Arms - con’t The rod ends mount on the bottom of the steering arms. Place a hat washer on each side of the rod end-ball as shown. 29 Installing the Sway Bar to Chassis 30 A concave washer goes on the top and bottom of the sandwich. 32 Install the raised end of the urethane bushings into the holes as shown. 31 With the weight of the car on the tires and the ends of the sway bar connected to the lower A-arms, install the urethane bushings and sway bar brackets around the 1-inch diameter sway bar. Lift the assembly up to the frame and mark the holes. Torque to 30 ft. lbs. Connecting the Optional Steering Linkage This is how your new steering linkage hooks up to the bottom of your column. Either your old stock column modified, new ididit or Flaming River column will need a double “D” U-joint to mate with the standard linkage shown below. Only 2 U-joints are required for SB applications. Our IFS is compatible with patroit headers, block huggers stock SB exhause manifolds. 33 34 When installing your steering linkage U-joints, make all U-joint connections as shown! The connecting shafts that enter the Ujoints should be mounted flush on the inside! Your steering can be severely limited or lock-up if the connecting shaft protrudes into the U-joint travel area! Loctite and tighten all set screws in the U-joint as tight as possible and lock in place with the jam nut and check them occassionally. www.jimmeyerracing.com 35 2795 SE 23rd • Lincoln City, OR 97367 Tech: 1-541-994-7717 • Order: 1-800-824-1752 • Fax: 1-541-994-2397 9 Connecting the Brake System 36 As you noticed in the brake kit photo on this page, a 1/4-inch union and 1/4-inch plug are included. The original 1/4-inch supply line from the original master cylinder should be installed in the front port of the new dual chamber master cylinder. In the rear master cylinder port, install the short 1/4-inch line with 2-90-degree bends in it and attach the proportioning valve to the end of this short line (like the photo) to the port marked “IN”. NEXT, install a length of brake line in the “OUT” port of the proportioning valve and route it to the left side of the frame just behind the rear of the upper A-arm. Follow the old brake line path to the right side of the frame. Find the “T” fitting and remove the original rear line and plug it with the 1/4-inch inverted flare plug provided. Next, attach the new line to the rear line with the union provided. In review, the front line of the master cylinder should go to the front brakes and the rear line from the master cylinder should be going to the rear brakes. Optional Steering & Brake Installation Tips OPTIONAL DUAL CHAMBER M/C KIT The optional brake kit provides all you’ll need to change to a disc/drum system. Notice, the proportioning valve goes in the line to the rear drums. Replumb the brake lines by plugging the rear of the original “T”. The new line to the rear goes from the rear port of the M/C through the proportioning valve and reconnects into the old rear brake line. 37 Plug goes here 38 Connects to original rear brake line POWER STEERING PUMP KIT The gear box pump (provided) works excellent with our power rack. The same pump can be used with this rack if you are converting a 605 system over to the rack. The optional pump kit show does not include the (optional) double-groove V-belt crank pulley, however it will be needed if you now have a single crank pulley. All kit components are available separately. www.jimmeyerracing.com 2795 SE 23rd • Lincoln City, OR 97367 Tech: 1-541-994-7717 • Order: 1-800-824-1752 • Fax: 1-541-994-2397 10 11 Front End Alignment 39 FRONT FIRST - set camber to get to the alignment shop. Align the upper A-Arms after the car is assembled and has all the weight on the chassis. Using any type of vertical level (examples in photo), on the rotor face, adjust upper A-Arm rod ends until rotor is vertically level. 40  Left/Right adjuster for caster. Rod ends thread in&-out for camber adjustment. The goal is to align correct enough to get to the alignment shop. 42 41 LAST - Set the toe-in. Always measure between the same tread on each tire. We recommend setting about an 18-inch toe-in when you’re finished with the installation. First, you’ll have to measure the back (of tires) between the treads and then the front using the same tread as the rear. When the measurements match, then you can set the front tread 18-inch in. ALIGNMENT SHOP SPECS: TOE IN: 1/16” to 1/8” total CHAMBER: 0 to 1/4 positive CASTER: 1 1/2” to 4” set both the same above www.jimmeyerracing.com Looking at the bottom of the chassis with IFS installed, you can see that all components are level with or above the oil pan, note the support rods going between the crossmember and into the stock forward strut holes. 2795 SE 23rd • Lincoln City, OR 97367 Tech: 1-541-994-7717 • Order: 1-800-824-1752 • Fax: 1-541-994-2397 JIM MEYER RACING PRODUCTS WARNING: Installation of any component or kit should only be performed by persons experienced in the installation and proper operation of SUSPENSION SYSTEMS. 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If, and in the event that purchasers expressly or impliedly cause representations, or statements or affirmations of fact contrary to this disclaimer of all warranties, expressed or implied, then purchasers agree to indemnity and hold harmless Jim Meyer Racing Products in the event of any claim, demand, or legal action against Jim Meyer Racing Products by any purchaser. Purchasers understand and agree that no officer, director, employee, or salesman of Jim Meyer Racing Products has any authority to make any statement contrary to the terms of this agreement. On the contrary, Jim Meyer Racing Products disavows any statement contrary to what is herein above written. www.jimmeyerracing.com 2795 SE 23rd • Lincoln City, OR 97367 Tech: 1-541-994-7717 • Order: 1-800-824-1752 • Fax: 1-541-994-2397