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Ford COUGAR 1968, Shop Manual

The Ford COUGAR 1968 Shop Manual is a comprehensive guide for owners looking to maintain or repair their classic vehicle. This manual can be downloaded for free from manualshive.com, providing detailed instructions and illustrations to help you keep your COUGAR running smoothly. Don't miss out on this essential resource.

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Summary of Contents for COUGAR 1968

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Page 2: ...oduction or distribution of the Ford Motor Company material is allowed without the express written permission of Ford Motor Company Disclaimer Although every effort was made to ensure the accuracy of...

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Page 4: ...ording to the cype of work being performed such as diagnosis and testing frequently performed adjust ments and repairs invehick adjustments overhaul etc Spscjfications and recommended special tools ar...

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Page 6: ...4C 65C 63A 65F 63C 65G Each model year each assembly plant begins production with number 500001 Montego or Cougar or 100001 Fairlane Falcon Mustang and continues on for each u n t built 1 Bucket Seat...

Page 7: ...i a 17 Washington 21 Atlanta 22 Charlotte 24 Jacksom lle 25 Richmond 27 Cincinnati 28 Louisville 32 Cleveland 33 Detroit 34 Indianapolis 35 Lansing 37 Buffalo 38 Pittsburgh 41 Chicago 42 Fargo 43 Milw...

Page 8: ...l Cou ar 7A Black Cloth and back Vinyl Fairlane Montego Code 1 Trim Scheme 78 Lt Blue Vinyl Cougar 78 Med Blue Cloth and Lt BlueVin I Fairlane 78 Dk Blue Cloth and Dk Blue Vin I ontego 70 Dk Red Cloth...

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Page 10: ...ake lining outside diameter to the approximate inside diameter of the _brake drum withRotunda Tool H R E 8650 Figs IIand 12 Part 2 2 7 If all the brake adjusters brake drums and linings are function a...

Page 11: ...tall Tool T66L 4204 L on the rear wheel Fig 3 4 Turn the locking adjustment nut forward against the cable guide on the equalizer Fig 4 until there is 100 ft lbs break away torque at the rear wheel whe...

Page 12: ...l air is expelled MANUAL BLEEDING The primary and secondary front and rear hydraulic brake systems are individual systems and are bled sep arately Bleed the longest line first on the individual system...

Page 13: ...Clean all dirt from the master I I When the bleeding operation cylinder reservoir cover is completed close the bleeder tank valve and remove the tank hose from 2 Remove the master cylinder re the adap...

Page 14: ...kage is evident it should be replaced Slight leakage around the piston or a seized piston indicates the need for removal and disassembly 8 If upon disassembly the cali per is found to be distorted or...

Page 15: ...PART 2 1 General Brake Service 2 7 FIG II Front Wheel Disc Brake Trouble Symptoms and Possible Causes...

Page 16: ...ses Of Trouble Trouble Symptoms g n m 2 M E CI a 2 P m Q s z L g g x e E z h u l L 6 3 e 9 0 3 6 M B Q 8 z I Q u l a o o o i 0 B 0 ra 0 u l 3 h L3 o a Z o m E S w Z m B B c l 8 a 5 n e 8 2 z u n I E a...

Page 17: ...ntego vehi cles equipped with power brakes have the master cylinder outlet ports for the rear brake system located on the bot tom of the master cylinder body Master cylinder hydraulic system bleed scr...

Page 18: ...e valve toward the low pressure area to illuminate the brake warning light Fig 3 A mechanically operated electrical switch is located on the side of the pressure differential valve assembly The inner...

Page 19: ...y and an anchor plate The anchor plate is bolted to the wheel spindle arm by two bolts The floating caliper is at tached to the anchor plate through a spring steel stabilizer The floating caliper slid...

Page 20: ...onal View PISTON SEAL DISTORTED PISTON SEAL RELAXED I CALIPER HOUSING BRAKES APPLIED FIG 6 Function of Piston Seal cylinder forces the piston out of the bore The inboard shoe and lining being attached...

Page 21: ...anner premature rear wheel The cable is routed along the webb of the secondary brake shoe by means of the cable guide The adjuster spring is hooked to the primary brake shoe and to the lever The autom...

Page 22: ...on a brake MONTEGO FAIRLANE booster The booster unit is to be AND FALCON exchanged when it is inspected check ed and found to be defective An independent foot operated park ing brake control actuates...

Page 23: ...590 B Grc se 3 Rotate Tool H R E 8650 around the hrake shoes to be sure of the settine the wheel cover or hub cap and re move the wheel and tire from the drum 2 Remove the grease cap from the huh Remo...

Page 24: ...s not cocked or binding on the anchor pin when installed All parts should be flat on the anchor pin Remove the brake cylinder clamp 07 Apply a small amount of high temperature grease Part Number C IAZ...

Page 25: ...any other foreign material must be kept off the Caliper assembly surfaces of the rotor and external surfaces of the hub during service operations Handling of the rotor and caliper assemblies should b...

Page 26: ...Remove the wheel and tire from the hub and rotor assembly Fig 16 Be careful to avoid damage or inter ference with the caliper splash shield or bleeder screw fitting 2 Remove the caliper assembly from...

Page 27: ...screw from the cylinder I Wash I1 parts in clean speci fied hrake fluid Dry with compressed LIlr 2 Check all the internal parts for excessive wear or damagc Replace scored pistons Always replace the...

Page 28: ...em after a primary or secondary brake system hose or line replacement Centralize the differential valve after bleeding the brake system because vi bration will cause tube failure When bending brake tu...

Page 29: ...RDAND POWER DRU TUBE 2263 R H 4 REQUIRED VlEW I N CIRCLE U METAL METALREBOUNDANDFULL TYPICAL 4 PLACES INSIDE AND OUTSIDE TURNS BOLT 401 2562 TUBE 2263 R H 2264 L H VIEW I N CIRCLE Y TUBE 2263 R H TYPI...

Page 30: ...ION ON POWER DRUM AND STANDARD BRAKES ONLY CHECKBRAKE HOSECLEARANCE T O A L L COMPONENTS IN METAL METAL JOUNCE AND METAL METAL REBOUND 1 4 MINIMUM CLEARANCE BETWEEN TUBES BEND CLlP TO RETAIN TO A L L...

Page 31: ...the master cylinder 2 Remove the two nuts attaching the master cylinder to the brake booster assembly 3 Slide the master cylinder forward and upward from the vehicle I N S T A L L A T I O N I Before i...

Page 32: ...rake system outlet tube to the pressure differential valve assembly Tighten the tube nut to the specified torque 5 Connect the front brake system inlet tube to the pressure differential valve assembly...

Page 33: ...ult Connect the manifold vacuum hose to the booster I f the vehicle is equipped with an automatic transmission connect the transmission vacuum unit hose 4 Before installing the master cylinder check t...

Page 34: ...e the pedal assembly from the support bracket INSTALLATION 1 Apply a coating of SAE 10 en gine oil to the bushings and locate all the bushings in their proper places on the pedal assembly and pedal su...

Page 35: ...cure the insulator to the dash panel with two attaching screws REMOVAL FAIRLANE MONTEGO FALCON Refer to Fig 30 1 Working from inside the vehicle position the floor cover back and re move the retaining...

Page 36: ...ion of the cables since the parking brake rear cable assemblies supplied for these models is in one piece Removal and installation of both rear wheels tires and drums will also be required MUSTANG AND...

Page 37: ...f the braking surfaces are to be 85 15 micro inches The minimum limiting dimensions Fig I Part 2 1 from the inboard bearing cup to the outboard rotor face dimension A and from the inboard rotor face d...

Page 38: ...retainer on the push rod if so equipped lnstall NUT SHAFT AUTCMATICJRANSMlSSlCN STOP LITE SWITCH 1 3480 TUBE 28253 STANDARD AUTOMATIC TRANSMISSION TRANSMISSION 9s 9 H1558A FIG 28 Vacuum Brake Booster...

Page 39: ...the dust boot over the piston as it is instal led Seat the dust boot in the piston groove 4 Position the inner brake shoe so that the ears of the shoe rests on the top of the anchor plate bosses and...

Page 40: ...CONNECTOR 2A790 MUSTANG ONLY CABLE AND CONDUIT 2853 PARKING BRAKE BOLT 381877 52 WASHER 381629 S2 WASHER 352174 52 EQUALIZER LEVER 2 605 SPEEDOMETER CABLE CLIP 381821 S2 NO 1 CROSSMEMBER ABLE AND COND...

Page 41: ...PART 2 Bra ke System 2 33 FIG 30 Parking Brake Linkage Fairlane Falcon and Mercure Intermediate...

Page 42: ...hoe Rim Lln ngMax mumClearance t o Shoe Drum D ameter Self Adjustment Cable Length End Cable Anchor t o End of Cable Hook I Refer t o Part 2 1 Sectlon 1 Brake Pedal Free He ghtand Travel Measurements...

Page 43: ...S Color Code Yellow Black Blue Blue Yellow Black Blue Blue Red White Yellow Black Blue Blue Cougar Mustang Bonded FoMoCo 4 82 x 1 84 9 11 0 362 0 030 Car Line Thickness Mustang Cougar Fairlane Falcon...

Page 44: ...ut and retainer with cotter pin so that cotter pin end does not interfere with seating o wheel static collector in spindle hole Falcon 15 20 18 25 9 13 55 85 70 1 15 8 15 10 18 12 20 15 25 17 25 27 32...

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Page 46: ...cone grease Some oil remaining from the man ufacturing processes may be found in the sleeve near the ball stud Do not confuse this oil with leaking fluid from the hydraulic system Power Cylinder Leaks...

Page 47: ...ion 2 With the vehicle in position for the front end alignment inspection and adjustment install the alignment spacers as follows to establish the curb height Insert the pin in the spacer hole marked...

Page 48: ...rut front nut to specificat on TOE IN AND STEERING WHEEL ALIGNMENT ADJUSTMENTS Check the steering wheel spoke po sition when the front wheels are in the straight ahead position If the spokes are not i...

Page 49: ...FLUSHING THE POWER cleaning solvent and dry with a lint STEERING SYSTEM free cloth Seals must not be washed or soaked in cleaning solvent The Should a power steering pump be bearing should not be spu...

Page 50: ...ing exceeds specifications Part 3 6 replace the upper ball joint LOWER BALL JOINT INSPECTION 1 Raise the vehicle on a frame contact hoist or by floor jacks placed beneath the underbody until the wheel...

Page 51: ...ina Wheels And Tires General Service 3 7 FIG 12 Steering Trouble Symptoms and Possible Causes m E 0 E E a m c l P b W cl 2 0 Cr b POSSIBLE CAUSES OF TROUBLE C V m b 4 5 w o P O 2 0 b Z 9 O 2 4 2 d 4 E...

Page 52: ...ressure test shows that the crocus cloth if the edges of the valve trouble is in the control valve or pow lands are not rounded in the process er cylinder remove and inspect these If the spool cannot...

Page 53: ...stance the internal parts of the ten a loose pump belt power cylinder are broken or dam Test the fluid pressure to determine aged Replace the power cylinder if whether the trouble is in the pump broke...

Page 54: ...vacuum disconnect hose from pre ceding connection and check vacuum Repeat this test at each connection forward or backward until obstruc tion is located Check circuit continuity between left front do...

Page 55: ...eering Column Trouble Diagnosis Guide Action Indicated Check wiring connections Make certain that all slack is re moved from cable with vacuum re leased Disconnect the wires and connect an ohmmeter to...

Page 56: ...ings Check pivot pins for looseness in the locking index Disconnect vacuum motor from locking pawl cable Make sure that cable is not adjusted to tight If Defective Tighten attaching nut to specifica...

Page 57: ...A L S W I T C H Action Indicated Remove the switch and connect an ohmmeter to the switch terminals The gauge should read on the infinitive side of the scale when the plunger is depressed Check switch...

Page 58: ...ension lower arms D o not allow the adapters to contact the steering linkage UPPER BALL JOINT REPLACEMENT 1 Position a support between the upper arm and frame side rail as shown in Figs 3 and 4 then r...

Page 59: ...red The shaft will be properly cen tered when dimensions A and B in Fig 6 are equal 1 0 Fabricate a spacer from a sec tion of 3 4 inch diameter pipe or met al of comparable size and strength The space...

Page 60: ...in Arm Typical FIG 7 Torque Upper Arm Inner Shaft Bushings Typical 2 Raise the vehicle position safety stands and remove the wheel and tire 3 Remove the cotter pin caste lated nut and the adjustment n...

Page 61: ...d nut lock Adjust the wheel bearing as outlined in Part 3 5 TURN TO COMPRESS SHAFT THRUST RFARING Adopter Plote CAVITY FRONT SPRING REMOVING REPLACING TOOLS VEHICLE I BASIC TOOL NO I ADAPTER and insta...

Page 62: ...er F 1288 8 FIG 9 Spring Compressor Tool Installed Upper View Typical bolt 4 Remove the strut to lower arm attaching nuts and bolts 5 Remove the cotter pin from the nut on the lower ball joint stud an...

Page 63: ...n the upper arm and frame as shown in Figs 3 and 4 then raise the vehicle and position safety stands 2 Remove the hub cap or wheel cover 3 Remove the grease cap from the hub then remove the adjusting...

Page 64: ...the jack and remove the spindle UPPER MOUNTING BRACKET 9 Install the hub cap or wheel FIG 12 Removing or Installing Front Shock Absorber Typical Installation 1 Position the spindle on the low er ball...

Page 65: ...install the bush ing outer washer and new nut on the stud Be sure that spring clip plate is frqe of burrs Tighten the nut to specification MONTECO FALCON A N D FAIRLANE EXCEPT CONVERTIBLE Removal 1 Op...

Page 66: ...lower shock absor ber attaching nut and remove the shock absorber lnstallation 1 Position the washers and bush ings on the shock absorber and posi tion the shock absorber to the lower attachment Insta...

Page 67: ...in the front hanger slip the washer on the front hanger bolt and from the inboard side insert the bolt through the hanger and eye Install the lock nut on the hanger bolt and tighten finger tight 6 Low...

Page 68: ...n needle bearings that are pressed into the gear housing n e worm bearing preload is con trolled by the large bearing adjust er which is threaded into the housing The sector shaft mesh load is control...

Page 69: ...STRIPE 53 BLACK BLUE STRIPE 54 GREEN YELLOW S I P E 87 GREEN ORANGE SrRIPE 297 BLACK GREEN SrRlPE TO NEUTRAL SWITCH 375 YELLOW BLACK STRIPE VACUUMMOTOR AN0 STARTER SAFETY 1 RELEASEVALVE TO ACC TERMINA...

Page 70: ...be moved upward to indicate righ turns downward to indicate left turns and forward to release the steering col umn lock when adjusting the steering wheel to a desired driving position As the turn sign...

Page 71: ...o not use a hammer or knock off type wheel puller Striking the puller or shaft may cause damage to the bear ings and or collapsible column 4 Transfer all servicable parts to the new steering wheel 5 P...

Page 72: ...ng column tube and install 14 Secure the crash pad to the 6 Remove the turn signal and horn the three attaching screws steering wheel with the two attach wire shield from the side of the steer 3 Posit...

Page 73: ...he pul ler or shaft may cause damage to the bearings and or collapsible column 4 Remove the turn signal wire shield from the side of the steering column 5 Remove the turn indicator lever 6 Remove the...

Page 74: ...G COLOR CODE RED BLUE STRIPE BLACK BLUE STRIPE GREEN YELLOW STRIPE f J 7hmp FUSE RELAY l SWITCH I i s STARTER SAFETY SWITCH GREEN ORANGE STRIPE BLACK GREEN STRIPE TO NEUTRAL SWITCH YELLOW BLACK STRIPE...

Page 75: ...I downward on the steering column 4 Remove the turn signal wire retaining clip from the upper end of the steering column tube 5 Remove the screws that attach the upper cover to the tilt mechanism Slip...

Page 76: ...3 32 GROUP 3 Suspension Steering Wheels Tires...

Page 77: ...anism If one pin presses in before the other place a spacer washer over the head of the pin that has already positioned to pre vent over pressing while still pressing the other one into position 6 Mov...

Page 78: ...ove the upper cover attach ing screws and remove the cover 5 Slide the lower cover down on the steering collimn tube 6 Remove the turn signal switch wire plastic retaining clamp 7 Remove the two turn...

Page 79: ...nd install the flex coupling to steering shaft at taching bolt and nut 5 Torque the bolt to specification Part 3 6 6 Fill the steering gear with the specified lubricant to the correct level Part 3 1 A...

Page 80: ...her stop 2 After removing the sector ad justing screw locknut and the housing cover bolts remove the sector shaft with the cover Remove the cover from the shaft by turning the screw clock wise Keep th...

Page 81: ...oat the worm bearings sector shaft bearing and gear teeth with gear lubricant C3AZ 19578 A 10 Clamp the housing in a vise with the sector shaft axis horizontal and position the steering shaft lower be...

Page 82: ...time 5 Insert the stud in the part from which the old one was removed and install the stud nut Torque the nut to specification and install the cotter pin 6 Check and if necessary adjust toe in Part 3...

Page 83: ...ll cotter pin 3 Position the spindle connecting rod ends to the center link and install the attaching nuts Torque the nuts to the low end of the specification Con tinue to tighten each nut until the s...

Page 84: ...of the pump housing front plate and the pump b ody is in cased within the reservoir OPERATION The control valve operated by steering wheel movement directs the pressure developed by the pump When the...

Page 85: ...ERVOIR I I I I I 1 1 I I rll I RETURN PRESSURE _ 5 ____ FLUID FLOW LEFT TURN D RESERVOIR _ _ r _ 4 _ L J I RETURN PRESSURE G z x I REACTION PRESSURE I ___ FLUID FLOW RIGHT TURN ND RESERVOIR PRESSURE I...

Page 86: ...thus creating a pressure area The pressure or outlet port is located in this area While this u m i n e action is going on between O degrees and 180 FIG 1 Power Steering Pump Cycle degrees the same con...

Page 87: ...rt the engine and check the turning effort with a spring scale With the spring scale attached to the rim of the steering wheel the effort to turn the wheel in both directions should not exceed I 2 pou...

Page 88: ...gine and turn the steering wheel to each end of its travel several times to cycle the system and check for leaks Check the fluid level fill as required and install the filler cap MUSTANG AND COUGAR EQ...

Page 89: ...tion the ball stud in the sec tor shaft arm 3 Measure the distance between the center of the grease plug in the sleeve and the center of the stud at the inner end of the left spindle con necting rod F...

Page 90: ...ts in the power cylinder for nicks burrs or damage Replace the seats in the cylinder or the tubes as required INSTALLATION I Install the washer sleeve and the insulator on the end of the power cylinde...

Page 91: ...s with lubricant COAZ 19553 A I Install the reaction limiting valve the spring and the plug 2 Install the return port relief valve and the hose seat 3 Insert one of the ball stud seats flat end first...

Page 92: ...around the flange with a wood block Fig 20 4 Remove the reservoir O ring seal the outlet fitting gasket from the pump lN S T A L L A T I O N I N S T A L L A T I O N When replacing the power cylinder...

Page 93: ...ing and in the nut to specification Part 3 6 pump housing plate stall the outlet fitting hex nut Torque Do not exceed specification 6 Position the service identifica OUTLET FITTING TOOL GASKET WOOD BL...

Page 94: ...etainer is installed at the inner end of the hub to prevent lubricant from leaking in to the drum or on the rotor The entire assembly is secured to its spindle by the adjusting nut nut lock and cotter...

Page 95: ...rake pedal travel WITH WHEEL ROTATING BACK ADJUSTING TIGHTEN ADJUSTING INSTALL THE LOCK TORQUE ADJUSTING NUT NUT OFF 1 2 TURN NUT TO 10 15 IN LBS AND A NEW COTTER PIN TO 17 25FT LBS F 1138 C FIG 3 Fro...

Page 96: ...r outer bear If a 2 Post hoist is used to lift ing cones and rollers with solvent and the vehicle place the adapters under dry them thoroughly D o not spin the the front suspension lower arms DO beari...

Page 97: ...ent getting dirt on the spindle carefully remove the cloth from the spindle 11 If the inner and or outer bearing cup s were removed install the replacement cup s in the hub with the tool shown in Figs...

Page 98: ...ching the caliper to the spindle Remove the caliper from the rotor and wire it to the underbody to prevent damaee to the brake hose 3 Remove the grease cap from the hub Remove the cotter pin nut lock...

Page 99: ...nsion C Inches 6 50 6 30 TORQUE LIMITS FRONT SUSPENSION MONTEGO FALCON FAIRLANE MUSTANG AND COUGAR Dimension 0 Imhet 6 72 5 50 Mustang 6 35 Cougar Vehicle Model Montego and Fairlane Falcon Except Stat...

Page 100: ...rber t o Spr ng Clip Aate Spring t o Axle U Bolt Nut POWER STEERING GEAR Montego Falcon Fairlane 15 22 15 25 15 25 30 45 55 85 70 115 90 120 40 60 7 1 0 Wheel Lug Nut Mustang and Cougar 15 22 15 25 15...

Page 101: ...lbs 18 42 in lbs Manual Steerim 4240 in lbs 18 42 in lbs Reload Adjuster Locknut4anual Steering 60 80 o 45 60 Steeriw Column Steering Wheel Attaching Nut 20 30 20 30 Bracket t o Lower Clamp Under Hoo...

Page 102: ...d must not exceed full rated Max load 8 Engine 6 Cyl and 302 V 8 390 V 8 427 V 8 6 Cyl 302 and 390 V 8 427 V 8 6 Cyl and 302 V 8 390 V 8 302 and 390 V 8 427 V 8 Tires inflation Ressur e Cold Front Rea...

Page 103: ...CID V 8 6 Cyl 289 302 ClD V 8 390 ClD V 8 All Tires High Speed Capability Tires 2 May be inflated 28 psi for special handling requirements Engine 6 Cyl 289 302 V 8 390 V 8 289 H P 302 V 8 390 V 8 427...

Page 104: ...eal Remover and Replacer Adapter T64P 3590 F SteeringArm Remover TOOL3600 M SteeringWheel Remover T65P 3A733 A Power SteeringPump Pulley Replacer T63P 530A Front Coil Spring Remover and Replacer TOOL...

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Page 106: ...he fact that there are three different types of gear set hunting non hunting and partial non hunting Each type is determined by the num ber of teeth in the gears The non hunt ing and partial non hunti...

Page 107: ...in this is the point at which the indicator hand will reverse direction as the flange is rotated Record the flange bearing cup run out reading obtained from the indi cator Fig 5 Rotate the companion f...

Page 108: ...4 4 GROUP4 Rear Axle ACCEPTABLE TOOTH PATTERN LIMITS I L 3 ANY COMBINATION OF DRIVE AND COAST PATTERNS SHOWN PERMISSIBLE Toe Toe I Toe Toe DRIVE COAST FIG 2 Acceptable Tooth Pattern Limits All Axles...

Page 109: ...cate the pinion for correct contact with the ring gear When adjusting either type axle shim thickness should be increased or reduced only as indicated by the tooth pattern check described in the fore...

Page 110: ...preload the bearings from 0 008 to 0 0012 inch case spread Rotate the pinion gear several revolutions in each direction while the bearings are loaded to seat the bearings in their cups to be sure no b...

Page 111: ...ole Place the pinion retainer aisembly in the carrier so that the marked tooth on the pinion indexes between the marked teeth on the ring gear Fig 25 Part 4 2 In almost every case of improper assembly...

Page 112: ...of the pinion The pattern taken during disas sembly should be helpful in judging if gears can be re used Worn gears cannot be rebuilt to correct a noisy condition Gear scoring is the result of excess...

Page 113: ...essive wear is evident Bonded plates should be re placed as a set only Examine all thrust surfaces and hubs for wear Abnormal wear on these surfaces can contribute to a noisy axle Inspect the Bellvill...

Page 114: ...repair the unit remove it from the is in the vehicle If the torque required axle housing to rotate one rear wheel is less than Drive the vehicle in a fairly tight tion plates installed The axle hous...

Page 115: ...ured to all Ford produced axles under one of the rear cover to hous ing bolts The first five spaces on the top line are reserved for the model designation letters such as WCY E WDJ C or WEA B These le...

Page 116: ...t secure the wheel bearing retainer plate Then pull the axle shaft assembly out of the axle housing Fig 2 The brake back ing plate must not be dislodged In stall one nut to hold the plate in place aft...

Page 117: ...tegral pinion nut and washer 5 Clean the pinion bearing retain er around the oil sesl Place a drain pan under the seal or raise the front of the vehicle higher than the rear 6 Using the tool shown in...

Page 118: ...OUGAR FAIRLANE MONTEGO AND FALCON WITH FALCON WITH 8 CYLINDER ENGINE 6CYLINDER ENGINE FOR ADJUSTABLE BED PRESS PUSH PULLER OPERATION BEARING INSTALLATION INSTALLATION VlEW 6 BEARING REMOVAL VIEW 1 El2...

Page 119: ...e ing tightened I I Tighten the pinion shaft nut rotating the pinion occasionally to in sure proper bearing seating Fig 6 and take frequent preload readings until the preload is at the original record...

Page 120: ...cle 12 If the axle housing is being replaced transfer all the differential and pinion parts to the new housing See Section 4 Major Repair Oper ations I Raise the axle housing into po sition so that th...

Page 121: ...leak age Refer to the transmission group for the appropriate tool 9 Rcmove the differential bearing adjusting nut locks Fig 15 10 Mark one differential bearing cap and the case Fig 16 to help positio...

Page 122: ...damaged the correct shim thickness for the new ion and ring gear as outlined under If the pinion bearing cups are to gear set to be installed follow these be re laced drive them out of the steps Carr...

Page 123: ...ed to seat the bearings in their cups This step is important 5 Again loosen the right nut to release the preload Check to see that the left nut contacts the bearing cup Using the dial indicator set up...

Page 124: ...d a new collapsible spacer installed Do not decrease the preload by loosen ing the pinion shaft nut This will re move the compression between the pin ion front and rear bearing cones and the collapsib...

Page 125: ...Rear Axle 4 2 1 FIG 23 Pinion and Ring Gear Marking FIG 24 Differential Bearing Installation WHICH GEARS WERE LAPPED E1335 A FIG 25 Typical Gear Set Timing Marks FIG 26 Backlash and Bearing Pre load A...

Page 126: ...s adjusted by shims between the pinion retainer and the carrier housing The differential asiembly is mount ed on two opposed tapered roller bearings which are retained in the car rier by removable cap...

Page 127: ...conditions where one or both wheels may be on a low traction surface such as snow ice or mud the friction between the clutch plates will transfer a portion of the usable torque to the wheel with the m...

Page 128: ...on both the bearing and the inner retainer ring at the same time 10 Using the bearing installation tool press the bearing inner retainer ring on the shaft until the retainer seats firmly against the b...

Page 129: ...t preload readings until the pre load is at the original recorded reading established in step 3 16 After original preload has been reached tighten the pinion nut slowly until an additional preload of...

Page 130: ...t at the rear axle U joint remove the drive shaft from the transmission ex tension housing Install an oil seal re placer tool in the housing to prevent transmission leakage Refer to the transmission g...

Page 131: ...resistant sealer on the outer edge of each seal be fore it is installed Do not put any of the sealer on the sealing lip Install the oil seals in the ends of the rear axle housing with the tool shown...

Page 132: ...he slinger 3 Remove the pinion bearing and retainer assembly from the car rier housing Fig 26 Measure the shim thickness with a micrometer Record this original shim thickness If a new gear set is inst...

Page 133: ...aring Tool T62F 4625 A FIG 16 Removing Pinion Front Bearing Cone or 4625 AC 1 ond 2 FIG 19 lnstalling Pilot Bearing PINION BEARING CUPS D o not remove the pinion bearing cups from the retainer unless...

Page 134: ...G GEAR If the ring gear runout check be fore disassembly exceeded specifi cations the condition may be caused A X L E HOUSING VENT CONE AND R O L L E R by a warped gear a defective case or excessively...

Page 135: ...stall a new pinion oil seal in the bearing retainer Fig 27 On ve hicles with high performance engines use tool T58L 4676 A or tool 4676 F New seals should be soaked in SAE 10oil for 112hour before use...

Page 136: ...nstall the bearing cap bolts and alternately torque them to spec ification 14 If the adjusting nuts do not turn freely as the cap bolts are tight ened remove the bearing caps and again inspect for dam...

Page 137: ...ates are in proper alignment 4 Carefully set the differential case cover over the right hand case Fig 35 At this point no force or pressure should be applied to the cover l he cover contains two 3 16...

Page 138: ...ear turning with new clutch plates is 100 to 125 ft lbs integral carrier and 155 195 ft lbs removable carrier On re used clutch plates the torque required is a minimum of 50 ft lbs integral carrier an...

Page 139: ...tial Pinion Gear Thrust Washer Thickness Drive Pinion Bearirlg Solid Spacers Used w t h 9 318 rlng gear 6 Spacers jn increments of 0 002 jnch 14 Spacers i n increments of 0 001 n c h Differential Bear...

Page 140: ...14 Inch Conventional 3 8 Inch Conventional a 9 Inch Conventional 3 9 Inch Limited Slip a 7 114lnch Limited Slip a 8 Inch Limited Slip 8 Integral Carrier Type 50 100 125 50 Min With New Clutch Plates W...

Page 141: ...Bracket T65K 4204 Aor F067 Differential Bearing Adjuster Nut T59L 4204 A Wrench Ford Tool flo TOOL 42354 T57L 4614 A TOOL 4615 J TMK 4616A T57L 4616 A T57L 4616 A2 T55P 4616 A2 TOOL 4621 K T62F 4621...

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Page 143: ...ll the yoke on the transmission output shaft Install the driveshaft so that the index marks or the yellow mark if visible on the yoke is in line with the yellow mark on the axle pinion flange This pre...

Page 144: ...of the slip yoke If the bearing cannot be pressed all the way out of the yoke remove it with vise grip or channel lock pliers 4 Reposition the tool to press on the spider to remove the bearing from t...

Page 145: ...nting FIG 9 Drive Shaft Trouble Diagnosis and Possible Causes DRIVE SHAFT VIBRA I ION U JOINT NOISE Undercoating or other foreign ma Broken rear spring center bolt terial on shaft Broken rear spring U...

Page 146: ...hrough one revolution Note the indicator read ing and mark the maximum point of runout on the face of the housing MAXIMUM FACE RUN OUT 0 009 INCH UAXIMUM NEGATIVE BORE RUN OUT 0 015 lNCP C1017 C FIG I...

Page 147: ...FIG 2 Dia 1 lgner Gauge...

Page 148: ...r down without disturbing the lateral alignment When alignment is within limits torque the housing bolts and recheck bore alignment 5 If the flywheel housing cannot be moved enough to bring the align...

Page 149: ...e the plate on the floor being careful not to score or scratch the surface Force each individual finger down then release it quickly If the finger does not return quickly a bind ing condition is indic...

Page 150: ...SYMPTOMS LOSS O F OR EXCESSIVE CLUTCH PEDAL FREE PLAY AND OR INADEQUATE RESERVE CLUTCH PEDAL H A N G U P OR EXCESSIVE CLUTCH PEDAL EFFORT CLUTCH NOISY W H E N PEDAL IS DEPRESSED T O THE END O F FREE...

Page 151: ...and a series of mechanical linkage When the clutch pedal is in the engaged position the clutch disc fac ings are clamped between the friction surface of the engine flywheel and the face of the clutch...

Page 152: ...od to the clutch pedal Disconnect the rod from the pedal 2 Remove the lower bolt retain FIG 2 Fairlane and Montego Clutch Linkage Disassembled ing the assist spring bracket to the pedal support Then l...

Page 153: ...flat washers and nuts 9 Check and if necessary posi tion the clutch pedal release rod in the clutch release lever 10 Adjust the clutch pedal free travel as required EQUALIZER BAR AND OR BUSHING REPLA...

Page 154: ...g 8 Lower the vehicle Connect the clutch pedal equalizer rod to the equalizer bar and secure with the re taining pin 9 Adjust the clutch pedal free travel as required CLUTCH ASSIST SPRING REPLACEMENT...

Page 155: ...on for ward on the guide pins until it is po sitioned against the flywheel housing 9 Install the two upper mounting bolts Then remove the guide pins and install the two lower mounting bolts Torque all...

Page 156: ...the guide pins and PART 5 3 Clutch install the two lower mounting bolts Torque all bolts to specification 7 Raise the rear of the engine high enough to provide clearance for installing the crossmembe...

Page 157: ...Springs Orange Clutch Pink and Orange Springs Aluminum Clutch Pink and Orange Springs Aluminum Diameter Inches 9 9 10 9 10 11 11 5 SPECIAL TOOLS Engine 170 1V 200 1V 289 2V 200 1V 289 2V 390 2V 4V 390...

Page 158: ......

Page 159: ...ission case for being cracked worn or damaged bearing bores damaged threads or any other damage which could af fect the operation of the transmission 2 Inspect the front face of the case for small nic...

Page 160: ...cker ring and the clutch teeth on the gear must not be less than 0 010 inches 13 Replace the speedometer drive gear if the teeth are stripped or dam aged Make certain to install the correct size repla...

Page 161: ...kage interference 4 Lack of lubrication of shift linkage trunnions and external shift mechanism floor shift CLUTCH 1 Excessive engine idle speed 2 Inadequate clutch pedal reserve resuiting in excessiv...

Page 162: ...the nuts are loose check for bell mouthing of slots 3 Bent transmission shift rods or linkage interference 4 Lack of lubrication of shift linkage trunnions and external shift mechanism floor shift 5...

Page 163: ...and lubricate with Lith ium base grease no Polyethylene 1 Adjust to specification A B Replace worn or defec tive parts C D Install correctly replace defective parts if necessary 2 A Fill to bottom of...

Page 164: ...r coIumn alignment looseness binding and worn surfaces Make certain the toe plate at the base of the column is fastened se curely to the firewall 2 Alignment of column to steer ing gear pilot bushing...

Page 165: ...out of low gear detent prior to the column shift lever dropping through neutral crossover If the transmission shift lever is not completely out of low gear detent the shift interlock in the trans mis...

Page 166: ...clutch is engaged In the event that a bearing is defec tive the noise is more pronounced while engaged in gear under load or coast than in neutral When com plaints of this nature are encountered it w...

Page 167: ...ns mission incorporates a floating coun tershaft The countershaft floats in oversize countershaft bores in the transmission case The forward speed gears are heli cal cut and are in constant mesh Fig 2...

Page 168: ...NIZER INPUT SHAFT AN INPUT SHAFT BEARIN REZRSE IDLER GEAR COUNTERSHAn GEAR FIG 2 Power Flow 3 Speed Transmission 2 IN VEHICLE ADJUSTMENTS A N D REPAIRS GEAR SHIFT LINKAGE ADJUSTMENT MONTEGO FALCON FAI...

Page 169: ...s the speedometer cable retainer to the extension hous ing Pull the speedometer cable out of the extension housing 5 Remove the cotter pin flat washer and spring washer that se cure the shift rods to...

Page 170: ...8 Insert the speedometer cable and driven gear in the extension housing and secure with a cap screw and lock washer 9 Remove the tool shown in Fig 2 Part 6 1 from the extension hous ing Slide the fro...

Page 171: ...the expansion plug Fig 9 from the front of the case Remove the shift rail 16 Remove the second and third detent plug and spring from the de tent bore 17 Pull the input gear and shaft FIG 70 Rotating...

Page 172: ...ap ring from the end of the selector shaft with pointed snap ring pliers Fig 14 2 Remove the flat washer and spring 3 After removing two bolts pull the retainer selector levers and spacer from the sha...

Page 173: ...oller bearings and the two bearing retainer washers from the counter shaft gear Fig 21 2 Coat the bore in each end of the counter shaft gear with grease 3 Hold the dummy shaft in the gear and install...

Page 174: ...the first speed position Place the first and re verse shift fork in the groove of the first and reverse synchronizer Rotate the fork into position and install the first and reverse shift rail Move the...

Page 175: ...ershaft bore at the front of the case 23 Coat a new extension hous ing gasket with sealer and position it on the case 24 Install lock washers on the five attaching screws Dip the threads of the cap sc...

Page 176: ...6 5 lists the transmission model numbers and vehicles in which they are used A transmission service identifica tion tag is located on the right side of the case at the front The first line on the tag...

Page 177: ...mesh reverse idler Splines then carry the power through the re verse sliding gear to the first and sec ong speed synchronizer sleeve which is locked to the output shaft As the re verse sliding gear i...

Page 178: ...t to the extension housing and allow the assembly to hang by the shift lever 6 Support the engine with a transmission jack and remove the two nuts securing the transmission rear support to the crossme...

Page 179: ...the case as shown in Fig 5 Remove the spring and the plug with a magnet 8 Remove the attaching screw from the third and fourth speed shift fork Tap on the inner end of the shift rail to unseal the exp...

Page 180: ...the retainer is not inter fering with free movement of the shaft Tighten the bolts 18 Install the spring flat washer and snap ring 19 Position the shift assembly to the transmission extension housing...

Page 181: ...nd of the countershaft gear 2 Coat the bore in each end of the countershaft gear with grease 3 Hold the dummy shaft in the gear and install the 21 roller bear ings and the retainer washer in each end...

Page 182: ...ion the two thrust washers Fig 18 in place 7 Position the reverse idler gear sliding gear dummy shaft and the roller bearings in place making sure that the shift fork groove in the slid ing gear is to...

Page 183: ...all the heavy thrust washer on the rear of the output shaft 22 Support the thrust washer and first speed gear to prevent them from sliding off the shaft Carefully lower the output shaft assembly into...

Page 184: ...s shown in Fig 22 Align the countershaft gear bore and thrust washers with the bore in the case Install the countershaft 34 Use a new gasket and secure the extension housing to the case with the attac...

Page 185: ...712l 2 WASHER 378559 5 FIG 17 Countershaft Gear Disassembled REVERSE IDLER GEAR SHAFT 7140 REVERSE SLIDING GEAR iD223 W L R 7149 C 1528 8 FIG 18 Reverse Idler Gear Disassembled INPUT SHAFT BEARING RE...

Page 186: ...Ford Design Four Speed Transmission 6 29 C DETAIL 4 FORD AND MERCURY I l b i DETAIL 5 COUGAR FAIRLANE FALCON MONTEGO AND MUSTANG DETAIL 3 FIG 22 Installing Countershaft FIG 21 Installing Output Shaft...

Page 187: ...nge to Output Shaft Engine Rear Support t o Extension Housing Bolts or Bracket Nut Transmission Cover Bolts o 14 19 for Cylinder Models Gear Ratios s p e d Trtnsmissions 42 50 19 25 3 04 5 Filler Plug...

Page 188: ...tion T 70258 Rear Main Shaft Bearing Remover T 702 Main Shaft Bearing Remover Replacer T57L 7111 A Cluster Gear Roller Retainer Shaft T60K 7111 A Cluster Gear Roller Retainer Shaft T62K 7111 A Cluster...

Page 189: ......

Page 190: ...ring seal may cause fluid to be deposited on the outside lower part of the converter housing as shown in Fig I 5 Fluid leakage from the con verter drain plugs will appear at the outside diameter of th...

Page 191: ...peed using the pro cedure given in Group 10 If the idle speed is too low the ANTI STALL DASHPOT CLEARANCE CHECK After the engine idle speed has been properly adjusted check the anti stall dashpot clea...

Page 192: ...er positions Transmis sion control pressure should agree with the specifications shown in Figures 9 and 10 1 TO VACUUM GAUGE D1515 A FIG 5 Typical Vacuum Test Line Connections FIG 6 Vacuum Diaphragm a...

Page 193: ...ped Idle As Required As Required I Barometric 29 5 I SeaLeveI 1 5662 71 86 1 7 10 1 100 115 I 4 0 4 4 I IKl 190 240 3001 77 84 Pressure I 3 At altitudes above sea level it may not be possible to obtai...

Page 194: ...L SYSTEM TESTS C6 TRANSMISSION In general diagnosis and test pro cedures which apply to the C4 trans mission will also apply to the C6 One of the most important aspects of diagnosis is understanding t...

Page 195: ...to a seized stator assembly If the stator is defective replace the converter INITIAL ENGAGEMENT CHECKS Initial engagement checks are made to determine if initial band and clutch engagements are smoot...

Page 196: ...ly air pressure into I ODY GOVERNOR PRESSURE L mu REVERSE SERVO PRIMARY THROTTLE VALVE EXHAUST CONTROL PRESSURE T O GOVERNOR D1494 8 FIG 13 l id Pressure Passage Holes the intennediate servo P P J Pas...

Page 197: ...ble resulting in fluid contamination be put back into service without first flushing the transmission oil cooler I After installing a new or re built automatic transmission and converter assembly in t...

Page 198: ...02 A D 1 E FIG 14 Converter Checking Tool TURBINE AND STATOR END PLAY CHECK 1 Insert the tool into the con verter pump drive hub until it bot toms 2 Install the guide over the con verter pump drive hu...

Page 199: ...ion Service 7 11 STATOR ONE WAY CLUTCH n END PLAY CHECK Torave Wrench Splif FIG Bushing Torque Wrench M a 6 I Toal T63P 79i C4 and C6 T O O T L W A C4 TRANSMISSION STATOR CLUTCH CHECK FIG 15 Converter...

Page 200: ...ine lnterference FORWARD CLUTCH ASSEMBLY I Inspect the compositon clutch plates for damage These plates should be flat If the plates are not flat they must be replaced If the old plates are to be re u...

Page 201: ...o piston and seals for defects that would cause hydraulic leakage 2 lnspect the cover seal and gas ket cover sealing surface for defects CASE 1 lnspect the case Tor cracks 2 With an air hose check all...

Page 202: ...OUT OF VEHICLE a Forward Clutch b Reverse High Clutch c Leakage in Hydraulic System d Front Pump B Parking Linkage h Planetary Assembly I Planetary One way Clutch j Engine Rear Oil Seal m Front Pump O...

Page 203: ...r E Valve Body G Intermediate Band H Low Reverse Clutch J Intermediate Servo K Engine Idle Speed L Downshift Linkage Including Inner Lever Position M Converter Drain Plugs N Oil Pan Gasket Filler T u...

Page 204: ...arts Repair or Replacement 7 39 Assembly of Transmission 7 50 1 DESCRIPTION AND OPERATION DESCRIPTION Figure I shows the location of the converter front pump clutches gear train and most of the intern...

Page 205: ...ain consists of an input shaft that is splined to the turbine of the converter and the forward clutch cylinder Fig 5 The forward clutch cylinder rotates the steel internal clutch plates of the forward...

Page 206: ...of the piston stem and then to the apply side of the piston The piston moves against the return spring to tigh ten the intermediate band around the reverse high clutch drum To release the servo piston...

Page 207: ...gear is splined to the output shaft and rotates the output shaft clockwise The output shaft rotation is at a reduced speed compared to the in put shaft rotation but at an in creased torque The output...

Page 208: ...Front Pump Low Reverse Band Off On Off Off Off On A gear type pump mounted or the front of the transmission case sup plies the fluid for the operadon of the hydraulic control system Pump intake is thr...

Page 209: ...FORWARD CLUTCH APPLIED a REVERSE HIGH CLUTCH FORWARD CLUTCH E I APPLIED OUTPUT SHAFT I INPUT SHAFT ONE WAY CLUTCH HOLDIN G REVERSE PLANET CARRIER AGAINST ROTATION PUT SHAFT OUTPUT SHAFT FIRST GEAR D H...

Page 210: ...7 22 GROUP 7 Automatic Transmission FIG 10 Hydraulic Control System...

Page 211: ...added to the main regu lator valve spring force transmitted to the regulator valve This will pro vide increased line pressures required to compensate for increased throttle openings and engine torque...

Page 212: ...throttle opening Cut Back Valve Increased line pressure is required to prevent clutch and band slippage under stall conditions As vehicle speed increases the requirements for increased line pressure...

Page 213: ...ft valve train also closes at the same time This will provide a 3 1 downshift when coast ing in D range Throttle Pressure Increased If throttle pressure is increased sufficiently it will move the thro...

Page 214: ...t to 2 or 1 range is made from high gear This is accomplished by directing 2 or I R oil pressure to the end of the manual low valve when 2 or 1 range is selected Intermediate Band Accumulator Valve Tr...

Page 215: ...ing link from the throttle shaft at point B Fig 18 2 Disconnect the stabilizer rod from the stabilizer at point A 3 Insert a 114 inch diameter pin through the stabilizer and the brack et Fig 18 4 Adju...

Page 216: ...ACCELERATOR ACCELERATOR SHAFT LEVER DOWNSHIFT CONTROL CABLE 7A186 LUBRICATION POINTS FIG 15 Throttle Linkage Mustang with 6 Cylinder Engine ACCELERATOR CONNECTING LlNK ACCELERATOR SHAFT LEVER I PA702...

Page 217: ...B R I C A T I O N POINTS FIG 77 Throttle Linkage Mustang and Cougar with 8 Cylinder Engine PEDAL STABILIZER ROD PEDAL HEIGHT SETTING ACCELERATOR POSITION 9825 STABILIZER ROD POINT B POINT A q70B no W...

Page 218: ...Lift the handle off 1 Raise the vehicle on a hoist or the selector lever jack stands 5 Remove the console trim panel 2 Remove the retainer that se from the top of the console Remove TRANSMISSION SELE...

Page 219: ...1 Install the handle and the 2 Raise the vehicle and loosen the Selector Lever Removal button on the selector lever Secure manual lever control rod retaining Adjustment a n d Installat ion the handle...

Page 220: ...except park and neutral 2 Set the parking brake and place the transmission selector lever in neutral Be sure that the selector lever is tight against the neutral stop 3 Disconnect the neutral start sw...

Page 221: ...or lever housing Lift the retainer from the housing 5 Remove the two screws securing the neutral start switch to the se lector lever housing Disconnect the neutral start switch wires at the plug conne...

Page 222: ...o servo cover attaching bolts Remove the two 1 I 4 inch bolts and install two at taching bolts Torque the bolts to specification 7 Adjust the intermediate band Lower the vehicle and check the trans mi...

Page 223: ...specification 10 Install a new extension hous ing gasket on the case Install the extension housing and six attaching bolts Torque the bolts to specifica tion 11 Install the transmission mount ing pad...

Page 224: ...bered I through 10 Number 1 is the first thrust washer located at the front pump The last thrust washer No 10 is located at the parking gear DISASSEMBLY OF TRANSMISSION 1 Remove the converter from the...

Page 225: ...driver behind the input shell Fig 40 Move the input shell and the front part of the gear train forward 6 Record the dial indicator read ing The end play should be 0 008 to 0 042 inch If the end play i...

Page 226: ...it in a vapor degreaser or with a detergent solu tion Clean the band with a lint free cloth 5 Using a screwdriver between the input shell and rear planet carrier Fig 45 lift the input shell upward an...

Page 227: ...nd retaining pin from the case Fig 54 26 Remove the parking gear and thrust washer No 10from the case 27 Remove the six one way clutch outer race to case attaching bolts with the tool shown in Fig 55...

Page 228: ...l Lubri cate the seals with clean transmis sion fluid Install the piston into the cover Be careful not to damage the piston seal 6 Install the piston return spring in the servo bore of the case 7 Plac...

Page 229: ...r retaining ring flat washer FIG 54 Parking Pawl Mechanism and link from the toggle rod Fig C O V E R SEAL 64 5 Remove the manual lever link lower retaining ring and link from SERVO PISTONSTEM the tog...

Page 230: ...s to be replaced press the bush ing out of the case with the tool shown in Fig 68 2 Install a new transmission case bushing with the tool shown in Fig 68 UPPER RETAINING 2NG PARKING LEVER LINK FIG 62...

Page 231: ...2 Remove the lower valve body attaching screws and separate the lower valve body separator plate gasket and hold down plates Fig 70 from the upper valve body Be care ful not to lose the check valves a...

Page 232: ...ove the spring and the line pressure coasting boost valve Fig 72 16 Carefully pry the downshift valve retainer from the body then remove the spring and valve 17 Depress the throttle booster valve plug...

Page 233: ...2 3 SHIFT VALVE MANUALLOWVALVE 3 2 CONTROL VALVE THROTTLE MODULATOR VALVE THROTTLE BOOSTER VALVE UPPER BODY MAIN REGUL VALVE NUAL VALVE OETENT PLUG SPRING AN0 RETAINING PIN LINE COASTING BOOSTVALVE ON...

Page 234: ...the slot and groove positioned to the rear of the pump body and 60 degrees below the horizontal center line 7 Install the drive and driven gears in the pump housing Each gear has an idehtification mar...

Page 235: ...4 0 078 and 0 060 0 064 11 When new composition clutch inch Install the correct size snap ring plates are used soak the plates in and recheck the clearance transmission oil for fifteen minutes before...

Page 236: ...or transmissions having four internal splined clutch plates and 0 026 0 042 inch for transmissions having five internal splined clutch plates 11 If the clearance is not with in specifications selectiv...

Page 237: ...l Pry the loose ends of the bushing up with an awl and remove the bushing 2 lnstall a new bushing with the tool shown in Fig 98 GOVERNOR AND OIL DISTRIBUTOR I Remove the rings from the governor oil di...

Page 238: ...oil distributor ASSEMBLY O F TRANSMISSION W e n assembling the transmis sion sub assemblies Fig lo make sure that the correct thrust washer is used between certain subassemblies Vaseline should be use...

Page 239: ...rust washer on the back face of the case Fig 104 6 Place the two fluid distributor tubes in the governor distributor sleeve Install the distributor sleeve on the case As the distributor sleeve is in s...

Page 240: ...the tabs of the carrier with the slots in the low reverse drum 22 On the bench install the for ward clutch in the reverse high clutch by rotating the units to mesh the reverse high clutch plates with...

Page 241: ...TOR 6 THRUST WASHER NO 2 5 PLANET SLEEVE 7 FRONT PUMP GASKET 16 INPUT SHELL SUN GEAR 25 LOW AND REVERSE DRUM 35 SNAP 8 INTERMEDIATE BAND AND THRUST WASHER NO 5 26 CLUTCH 36 GOVERNOR VALVES 6 9 BAND ST...

Page 242: ...ve body THRUST WASHER NO 10 D1441 A Fig 38 As the valve body is in stalled engage the manual and down NG 105 Number 10Thrust Washer Location Install all but one front pump to case attaching bolts and...

Page 243: ...T 7 2 C4 Automatic Transmission 7 55 INNER RACE I 1 INSTALL SPRING RETAINER INTO OUTER RACE I I INSTALL INNER RACE I INSTALL 12 SPRINGS FIG 707 O n e W a y Clutch Installation INSTALL 12 ROLLERS D l55...

Page 244: ...on THRUST W S H E R NO 6 D1444 A FIG 709 Numbers 6 and 7 Thrust Washer Location FORWARD CLUTCH Hub FORWARD CLUTCH D l 4 3 9 A FIG 7 70 installing Clutch Units THRUST WASHER NO 3 FORWARD CLUTCH CYLINDE...

Page 245: ...tic Transmission 7 57 FRONT PLANET FORWARD CLUTCH Tool FCO 24 INPUT SHELL AND SUN GEAR FIG 7 76 InstallingVacuum Unit DRIVE LUG CLUTCH ENGAGEMENT FIG 7 74 Installing Front FIG 7 75 Installing Input Sh...

Page 246: ...ment 7 72 Neutral Start Switch Replacement 7 73 Band Adjustment 7 74 Fluid Pan and Control Valve Body Replacement 7 74 I Section Page Intermediate Servo Repair 7 74 Extension Housing and Governor Repl...

Page 247: ...r The only adjustments on the trans mission proper are for the inter mediate band and on Mustang and Cougar the neutral safety switch The fluid is drained from the transmission by loosening the pan FI...

Page 248: ...s as an efficient fluid coupling as long as the turbine speed remains greater than 9 10 impeller speed A constant flow of fluid into and out of the converter is maintained The fluid coming out of the...

Page 249: ...Y CLUTCH Dl RANGE IS HOLDING THE REVERSE UNlT PLANET CARRIER STATIONARY FIRST GEAR THE REVERSE AND HlGH CLUTCH IS APPLIED THE INPUT SHAFT IS LOCKED TO THE REVERSE AND HlGH CLUTCH DRUM THE INPUT SHELL...

Page 250: ...dy through a hole in the case to the hole in the servo piston stem The pressure passes through the center of the piston stem and then to the apply side of the piston The piston moves against the retur...

Page 251: ...fer ential for regulation Fluid pressure in this area tends to move the valve against spring force Spring force 1s such that at approximately 60 psi front pump pressure the main vaive will move so tha...

Page 252: ...7 64 GROUP 7 Automatic Transmission X EXHAUST D18i6 A FIG 9 Hydraulic Control System...

Page 253: ...g on the out er end of the primary governor valve holds the primary governor valve inward blocking further flow of the fluid in the line leakage pas sage This causes pressure in the line leakage passa...

Page 254: ...vehicle speed at constant vac uum values Line Pressure Coasting Regulator Valve When the selector lever is moved from D to 2 or I to force a 3 2 closed throttle downshift in order to use the engine a...

Page 255: ...hrough the manual valve and opening the D passage to al low D fluid to apply the reverse high clutch and release the inter mediate servo With the shift valve open down the throttle modulator valve is...

Page 256: ...ified idle speed in D T o make sure that the carburetor throttle lever is against the idle adjusting screw refer to Group 10 for the carburetor adjusting procedures MONTEGO AND FAlRLANE LINKAGE 390 CI...

Page 257: ...TI0t I LUBRICATION POINTS FIG 73 Throttle Linkage Montego and Fairlane with 390 and 427 CID Engine ACCELERATOR CONNECTINGLINK PEDAL HEIGHT SETTING ACCELERATOR WIDE OPEN ACCELERATOR SHAFT LEVER DOWNSHI...

Page 258: ...ing screws 1 8 Install the cover and dial in dicator 1 9 Place the console in position and install the retaining bolts Tigh ten the selector lever housing attach ing bolts 20 Position the console trim...

Page 259: ...NSULATOR WASHER NUT FLAT WASHER 372285 58 I ENGAGE LATS OF STUD IN SLOT OF ROD BEFORE APPLYING 7343 TORQUE FIG 16 Manual Linkage Console Montego and Fairlane PLUG COUGAR FLOOR SHII DIAL HOUSING HWSING...

Page 260: ...the gague pin align the two holes in the switch at point A and reinstall the gauge pin 9 Position the neutral start switch on the steering column and in v ADJUSTMENT SCREWS FIG 20 Starter Neutral Swi...

Page 261: ...uring the neuGal start switch to the steer ing column and remove the switch Remove the actuator lever from the steering column if equipped with a Type I1 switch Fig 19 3 Position the neutral start swi...

Page 262: ...the vehicle on a hoist or jack stands 2 Clean the threads of the inter mediate band adjustment screw 3 Remove and discard the lock nut 4 Install a new lock ntit and tighten the adjusting screw to 1 0...

Page 263: ...h to remove the weight from the cross member 9 Remove the cotter pins and nuts that attach the crossmember to the frame side supports Remove the crossmember 1 0 Remove the engine rear sup port to exte...

Page 264: ...under the vehicle 24 Remove the converter from the transmission Mouht the trans mission in a holding fixture if repairs are necessary INSTALLATION I Mount the transmission in a transmission jack and s...

Page 265: ...gear train as an assembly as FIG 29 Transmission Mounted in Holding Fixture shown in Fig 34 13 Remove the large snap ring that secures the reverse planet car rier in the low reverse clutch hub Lift t...

Page 266: ...the switch and case as close as possible to the shaft Gently pry the switch from the case 3 Slide the downshift lever out from the inside of the case Fig 38 Remove the seal from the recess in the man...

Page 267: ...tall a new cupped washer Fig 40 to retain the shaft 8 Install the parking pawl shaft in the case Slip the parking pawl and spring into place on the shaft 9 Position the guide plate on the case making...

Page 268: ...press the manual valve de tent spring with the tool shown in Figdre 44 Remove the retaining pin from the upper valve body Remove the spring and detent plunger 5 Slide the manual valve Fig 45 out of th...

Page 269: ...e body 16 Place the valve body on a clean surface wi h the passage side facing up Place the converter relief valve spring in its bore Fig 46 Coat the converter relief valve check valve with vaseline a...

Page 270: ...MULATOR VALVE a 3 2 SHIFT TIMING VALVE MANUAL LOW 2 1 SCHEDULING VALVE THROTTLE PRESSURE MANUALVALVE DETENT PI UG SPRING AN0 PIN THROTTLE PRESSURE 2 3 SHIFT GELIFF SPRING 3 VALVE CHECK b S S ThRCTTLE...

Page 271: ...tes alternately starting with a steel drive plate and a composition plate Fig 52 6 After all clutch plates have been installed position the pressure plate in the clutch drum with the chamfered side fa...

Page 272: ...from the ring gear Assembly I Position the hub in the ring gear 2 Secure the hub with the retain ing snap ring Make certain that the snap ring is fully engaged with the groove ONE WAY CLUTCH Disassem...

Page 273: ...6 REVERSE HIGH CLUTCH IS NUMBER 6 THRUST WASHER 25 ONE WAY CLUTCH INNER RACE ASSEMBLY 16 SNAP RING 26 SNAP RING 7 NUMBER 2 THRUST WASHER 17 NUMBER 7 THRUST WASHER 27 LOW REVERSE CLUTCH 8 FORWARD CLUTC...

Page 274: ...he springs firmly into the piston to prevent them from falling out 5 Position the spring retainer over the springs and position the retainer snap ring in place on the one way clutch inner race 6 Insta...

Page 275: ...to seat i t on the inner race 15 lnstall the low reverse clutch plates starting with a steel plate and following with friction and steel plates alternately Refer to the Speci fications Section for th...

Page 276: ...sufficiently to retain the band 23 Place the selective thickness bronze thrust washer on the rear shoulder of the stator support and retain it with vaseline If the end play was not within specificatio...

Page 277: ...n the case 21 I n s t a l l a new pan g a s k e t and the pan 29 I n s t a l l the c o n v e r t e r a s s e m b l y 30 I n s t a l l the t r a n s m i s s i o n in the v e h i c l e SNAP SEAL TG GOVE...

Page 278: ...lar Fuel Premium Fuel M i n e w e d Idle As Required As Required Stall Ratio 2 10 1 2 02 1 Nominal Size 12 12 Identification No o 44 46 Stall Ratio 2 05 1 2 00 1 6 At altitudes above sea level i t may...

Page 279: ...n back off 3 turns 0 1024 106 0 0884 092 0 0744 078 0 0604 064 Intermediate Band Adjustment Forward Clutch ReSsure Aate tfiSnap Ring Clearance Select veSnap Rihg Thicknesses Reverse High Clutch Ressur...

Page 280: ...VALVE SPRING IDENTIFICATION44 TRANSMISSION Free Pack Clear Inches 0 020 0 0366 0 026 0 042 External Spline 3 4 0 4 Internal Spline bmp 3 3 0 4 Steel Plates 5 6 Forward Clutch Plates P GA P GB Interna...

Page 281: ...x 14 F70 x 14 3 3 20 1 6 95 x 14 185R x 14 E70 x 14 2 7 35 x 14 7 75 x 14 F70 x 14 FR70 x 14 3 3 00 1 7 35 x 14 FR70 x 14 185R x 14 4 7 75 x 14 F70 x 14 5 2 83 1 All 6 Range D D D 1 D D D D D D D D S...

Page 282: ...O Detent Torque Demand Thru Detent W O T 1 8 10 11 20 10 16 25 19 31 36 52 32 18 28 37 53 68 69 27 2 9 10 13 21 10 18 27 22 33 39 57 34 19 31 40 58 73 73 29 Range c D D D 1 D D D D D D D D Vehicle Axl...

Page 283: ...sed Above 17 Vacuum To Detent Torque Demand Through Detent W O T Throttle Closed Above 17 Vacuum To Detent Torque Demand Through Detent W O T 2 6 9 620 6 9 23 34 34 50 59 80 26 42 45 56 77 92 70 82 34...

Page 284: ...dy t o Collector Body Cooler Line Fittings A R E 29 05 TOOL FCO 24 1501 100 A T58L 101 A T53L 200 A T57L 5004 TOOL 1175 AB 1501 100 Aand TOOL 1175 AB TOOL 35524 TOOL4201 C 55 75 12 18 80 120 80 120 80...

Page 285: ......

Page 286: ...controlling the amount of contam inants emitted through the exhaust sys tem to an acceptable minimum air pollution is reduced When making carburetor idle fuel mixture and speed adjustments follow the...

Page 287: ...nition switch OFF Bump the crankshaft over until the tappet or lifter is on the base circle of the camshaft lobe At this point the push rod will be in its lowest position 5 Zero the dial indicator Con...

Page 288: ...e to distribute the oil and repeat the compression test The oil will temporarily seal leakage past the rings If approximately the same reading is obtained the rings are satisfactory but the valves are...

Page 289: ...t the other end of the hose to the tester adapter 3 Use the dipstick hole plug to plug the opening in the dipstick tube 4 Insert the tester adapter in the iiller cap opening and turn the selec tor kno...

Page 290: ...ve plate inside the valve body It should be lightly positioned against the valve seat away from the air manifold 5 Insert a probe Into the hose con nection on the check valve and depress the valve pla...

Page 291: ...hat crankshaft NG 11 Typical Crankshaft End Play end play will not be indicated as fly wheel runout If the clutch face runout exceeds the specifications remove the fly wheel and check for burrs betwee...

Page 292: ...SIDE FORCE L E S E OUT MEASURE D STANCEB DEFLECTION IS A MINUS B FIG 75 Typical Timing Chain Deflection FIG 74 Typical Camshaft End Play slack on the right side of the chain Force the left side of the...

Page 293: ...k stud nut Replace the stud nut if the FIG 79 Typical Valve Clearance the available clearance with a feeler break away torque does not meet spe d i 2 8 9 and 302 V 8 gauge between the rocker arm and c...

Page 294: ...n the valve and the piston To replace a push rod it will be necessary to remove the valve rock er arm shaft assembly following the procedure in Part 8 4 Upon replacement of a valve push rod valve rock...

Page 295: ...ch reamer with a 0 015 inch O S pilot When going from a standard size valve to an oversize valve always use the reamers in sequence Always reface the valve seat after the valve guide has been reamed a...

Page 296: ...scuffs scores or nicks from the camshaft machined surfaces with a smooth oil stone CRANKSHAFT Dress minor imperfections with an oil stone If the journals are severely marred or exceed the wear limit...

Page 297: ...nishing Cylinder Walls Honing is recommended for refin ishing cylinder walls only when the walls have minor imperfections such as light scuffs and scratches or for fitting pistons to the specified cle...

Page 298: ...ired area to blend with the general contour of the surrounding surface 6 Paint the surface to match the rest of the block CORE PLUG REPLACEMENT To remove a large core plug drill a 112 inch hole in the...

Page 299: ...r arms make sure the oil passage in the push rod end of the rocker arm is open INSPECTION On rocker arm shaft assemblies check the clearance between each rocker arm and the shaft by check ing the ID o...

Page 300: ...ply tube air hole or orifice with a 5116 inch diameter stiff wire brush With the valves installed to pro tect the valve seats remove deposits from the combustion chambers and valve heads with a scrape...

Page 301: ...es while installed in the engine must not be used to determine good and or bad valve springs Weak valve springs cause poor engine performance there APPLY TORQUE UNTIL CLICK IS HEARD READ Torque Wrench...

Page 302: ...amper or sleeve with solvent to remove any corrosion sludge or varnish deposits Excess deposits that are not readily removed with solvent may be removed with crocus cloth Use crocus cloth to re move a...

Page 303: ...r 8 3 It is not necessary to ream or hone the pin bore in the connecting rod Replace defective connecting rod nuts and bolts If the connecting rod has been removed from the piston it should be checked...

Page 304: ...all machined gasket sur faces for burrs nicks scratches and scores Remove minor imperfections with an oil stone Check the flatness of the cylinder block gasket surface following the procedure and spec...

Page 305: ...rator and wash in in a low volatility petroleum base solvent Shake the cap dry and install it Do not dry with compressed air as air pressure may damage the filter element Clean the crankcase ventilati...

Page 306: ...he buretor Use a suitable container to trouble is probably in the distributor catch the fuel Crank the engine to cap rotor or spark plug wires see if fuel is reaching the carburetor If there is no spa...

Page 307: ...ar cylinder perform a spark test on Worn distributor cam the ignition lead of that cylinder Defective coil rotor condenser If a good park does not occur the breaker points ignition wiring or trouble i...

Page 308: ...ON SYSTEM Worn camshaft lobes Perform a manifold vacuum or Improperly adjusted or defective compression test to determine which breaker points mechanical component is at fault Remove air cleaner actua...

Page 309: ...or more camshaft lobes worn beyond wear limit Incorrect valve clearance Worn valve guides TRANSMISSION Improper band adjustment auto matic transmissions EXCESSIVE FUEL CONSUMPTION Determine the actual...

Page 310: ...ncorrect Radiator fins obstructed Thermostat defective Thermostat improperly installed Cooling system passages blocked Water pump inoperative Faulty fan drive Distributor vacuum control valve defectiv...

Page 311: ...king contact with body EXHAUST SYSTEM parts Defective centrifugal air filter fan Air bypass valve vacuum line col Defective air pressure relief valve lapsed plugged di connected or leak Wrong pressure...

Page 312: ...fter troubles are dirt to 318 inch diameter hose of sufficient gum varnish carbon deposits and length to direct the oil discharge into alr bubbles the oil filler pipe Close the valve Dirt in the lifte...

Page 313: ...00 cubic inches and the pat ent plate symbol is T The 170 and 200 Series engines use either the Thermactor or the Imco ex haust emission control system to keep exhaust gas contaminants at an accep tab...

Page 314: ...sion chamber becomes filled 1 5 t with oil the pressures in the two chambers are equalized The oil flow t ceases and the discvalve spring seats i t A2746 A I I a FIG 2 3 4 Right Front View the disc va...

Page 315: ...flows into the main oil gallery The oil gallery supplies oil to all thc camshaft and main bearings through a drilled pas sage in each main bearing web The timing chain and sprockets are splash lubrica...

Page 316: ...the coolant outlet elbow to increase distri butor advance under hot conditions This will temporarily increase the idle speed and reduce the engine oper ating temperature If the thermostat is closed a...

Page 317: ...st emission system is used on engines in combination with automa tic transmissions Vehicles with stan dard transmissions have engines with a Thermactor exhaust emission system Both the Imco and Therma...

Page 318: ...i r under pressure from the pump flows through the bypass valve to the air manifold that distributes the air A 2707 A to the air delivery tube i n each ex haust Port A check valve i n the in FIG 10 S...

Page 319: ...e engine and install the inhla tor to engine bolts and washers finger tight 2 Lower the engine carefully to make sure the insulator stud engages the hole in the support bracket 3 lnstall the insulator...

Page 320: ...oraue the nuts that is too tight places a severe strain on the air pump bearings Properly tensioned drive belts minimize noise and also prolong serv ice life of the belt Therefore it is recommended th...

Page 321: ...P P INSTALLATION Before installing the pump be sure that the correct pressure setting plug is installed in the pressure relief valve The correct pressure setting plug for these engines should be colo...

Page 322: ...d the gasket FIG 76 Closed Crankcase Ventilation System Components 4 Remove the rocker arm shaft support bolts by loosening the bolts two turns at a time in sequence Re move the rocker arm shaft assem...

Page 323: ...tify them for proper connection 6 Disconnect the distributor vac uum line at the distributor Discon FIG 19 Valve Push Rod Removal INSTALLATION 1 Clean the head and block gas ket surfaces Refer to Part...

Page 324: ...lve Fig 23 in the valve guide from which it was removed or to which it was fitted Install a new stem seal on the valve 3 Install the valve spring assem bly over the valve Install the spring retainer a...

Page 325: ...conditioner and Thermactor drive belts if so equipped 2 Disconnect the radiator lower hose at the water pump Remove the drive belt fan or fan and drive clutch and water pump pulley 3 Disconnect the he...

Page 326: ...or upper and lower hoses 7 Fill and bleed the cooling sys tem Fill the crankcase with the pro per quantity and grade of engine oil 8 Start the engine and check the ignition timing Operate the engine a...

Page 327: ...shaft until oil emerges from the outlet opening Install the pump inlet tube Install the oil pump and oil pan Install the oil level dipstick 5 Install the fan fan pulley and drive belt Adjust the belt...

Page 328: ...ith a screwdriver Remove the check valve and spring ASSEMBLY A typical hydraulic valve lifter as sembly is shown in Fig 36 I Place the plunger upside down on a clean work bench 2 Place the check valve...

Page 329: ...llation cut the ends of the seal flush Apply a thin coating of oil resist ant sealer to the rear main bearing cap at the rear of the top mating surface Fig 38 D o not apply sealer to the area forward...

Page 330: ...were fitted The connecting rod and bear ing caps are numbered from 1 to 6 beginning at the front of the engine The numbers on the connecting rod and bearing cap must be on the same side when installe...

Page 331: ...nds have high steps the piston should be re placed 6 Be sure the bearing inserts and the bearing bore in the connecting rod and cap are clean Foreign material under the inserts will distort the bear i...

Page 332: ...r bar and pull it downward out of the way Remove one bolt and loosen the other on the No 2 cross member and lower it out of the way 4 Remove the oi pan and gasket 5 Remove the oil pump inlet tube and...

Page 333: ...he chassis and in sembly and remove the outer race FIG 57 Typical Oil Pump Assembly 3 Insert a self threading sheet metal screw of the proper diameter into the oil pressure relief valve chamber cap an...

Page 334: ...emove the engine lifting hooks Install the flywheel or con verter housing upper retaining bolts 5 Remove the jack from the transmission Raise the vehicle 6 Remove the guide pin and in stall the flywhe...

Page 335: ...inserts and bearing bores are axis is parallel to the axis stand Fkmove the flywheel clean Foreign material under the in i 59 the oil pan and gasket Remove the will distort the bearing and oil pump 18...

Page 336: ...oil pump and oil pump screen 27 Prime the oil pump by filling the inlet opening with oil and rotating the pump shaft until oil emerges from the outlet opening Install the oil pump following steps 1 2...

Page 337: ...14 inches from the face of the camshaft EXPANDING MANDREL THRUST BEARING DETAIL I 2 or 3 EXPANDING COLLET I BACK UP NUT DETAIL 5 PULLERSCREW DETAIL 4 PULLER SCREW EXTENSION PULLING PLATE thrust plate...

Page 338: ...tep 15 under Camshaft Removal Check timing chain deflection by following steps 4 and 5 under Cylinder Front Cover Removal 14 Remove the camshaft sprock et retaining bolt and washer Slide both sprocket...

Page 339: ...lt to specifications Install the accessory drive pulley if so equipped 31 Install the water pump alter nator fan pulley and fan Install and adjust all belts to specifications 32 Prime the oil pump by...

Page 340: ...he coil on the block and connect the coil high ten sion lead Install the distributor vac uum advance control valve decelera tion valve 54 Position the exhaust manifold on the cylinder head Install the...

Page 341: ...l dipstick mount ing bracket washer Refer to Part 8 1 Section I for engine tag code The 289 and 302 V 8 engines use either the Thermactor or Imco exhaust emission control system to keep ex haust gas c...

Page 342: ...and one oil control ring The top compression ring is chrome plated and the lower compression ring is phosphate coated The oil con trol ring assembly consists of a ser rated spring and two chrome plat...

Page 343: ...l Intake Manifold Fuel Passages When the valve is closed the lifter assembly is on the base circle of the camshaft lobe and the valve push rod is in its lowest position With the lifter assembly in thi...

Page 344: ...ough the pressure type lubrica tion system Fig 10 by a rotor oil pump A spring loaded relief valve in the pump limits the maximum pres sure of the system Oil relieved by the valve is directed back to...

Page 345: ...ossibility of car buretor icing The air duct shroud and tube assembly together with the air duct and thermostat assembly di rect warm air into the air cleaner and carburetor If the temperature of the...

Page 346: ...s For a description of this valve see Part 9 1 Section I of this manual The water pump has two outlet ports one for each cylinder bank to provide uniform coolant circulation in both banks of the engin...

Page 347: ...o on most automatic transmission vehicles and Thermactor on all others Both the IMCO and Thermactor ex huast emission control systems are designed to reduce the hydrocarbon and carbon monoxide content...

Page 348: ...art 8 1 Section 1 for test procedures ENGINE FRONT SUPPORT INSULATORS The front supports are located on BOLT 20386s each side of the cylinder block Figs 16 and 17 The procedures given ap ply to either...

Page 349: ...ct the air hoses and vacuum line at the air bypass valve body Fig 15 2 Be sure the valve is positioned properly Fig 15 and connect the air hoses and vacuum line THERMACTOR CHECK VALVE REPLACEMENT 1 Di...

Page 350: ...sassemble the air pump to replace the relief valve but remove it from the engine 1 Position Tool T66L 9A486 D on the air pump and remove the relief valve with the aid of a slide hammer T59L 100 B 2 Po...

Page 351: ...Remove the carburetor fuel in let line and the automatic choke heat tube 6 Disconnect the distributor vac uum hoses from the distributor Re move the distributor hold down bolt and remove the distribut...

Page 352: ...o the air bypass valve 14 Fill and bleed the cooling sys tem 15 Start the engine and check and adjust the ignition timing Con nect the distributor vacuum hoses to the distributor 16 Operate the engine...

Page 353: ...air hose s from the check valve s Remove the check valve s Remove the air bypass valve air pump and bracket if the right cylinder head is being removed 3 If the right cylinder head is to be removed r...

Page 354: ...bolts Adjust the drive belt to specifications 10 Install the intake manifold and related parts following the pro cedure under Intake Manifold In stallation DISASSEMBLY 1 Remove the exhaust manifolds...

Page 355: ...3 A NG 32 Valve Stem Seal Removal or Installation 12 Install the push rod Apply Lubriplate to the tip of the valve stem 13 Apply Lubriplate to the ful crum seat and socket and install the valve rocker...

Page 356: ...cover gasket Remove the crankshaft front oil slinger 12 Check the timing chain de flection refer to Part 8 1 Section 2 13 Crank the engine until the timing marks on the sprockets are positioned as sh...

Page 357: ...the ignition timing CAMSHAFT The camshaft and related parts are shown in Fig 40 REMOVAL 1 Remove the cylinder front cov er and the timing chain following the procedure under Cylinder Front Cov er and...

Page 358: ...que the bolts to the same speci fications 14 Clean and install the crank case ventilation system 15 On Thermactor engines in stall the air pump and connect the air bypass valve Install check valves an...

Page 359: ...I Disassembly Disassemble and assemble each lifter spearately Keep the lifter assem blies in proper sequence so they can be installed in their original bores I Grasp the lock ring with needle nose pl...

Page 360: ...the journals and thrust faces thrust bearing for nicks burrs or bearing pick up that would cause premature bearing wear When re placing standard bearings with new bearings it is good practice to fit...

Page 361: ...e bearing to the minimum specified clearance and to first try to obtain the proper clearance with two blue bearing halves 5 Install the bearing inserts in the connecting rod and cap with the tangs fit...

Page 362: ...with engine oil and rotating the pump shaft to distribute the oil with in the housing Install the oil pump and the oil pan 12 Install the cylinder heads fol lowing steps 1 thru 9 under Cylinder Head I...

Page 363: ...ting in the slots provided FLYWHEEL R E M O V A L I On a vehicle with a manual shift transmission remove the transmis sion clutch pressure plate and disc following the procedures in Group 5 On a vehic...

Page 364: ...r tight Rotate the filter slightly in each direction to make sure the gasket is seated even1y 7 Torque the center bolts to spec ifications D o not overtighten the cen ter bolt 8 Add oil to the crankca...

Page 365: ...Insert a self threading sheet metal screw of the proper diameter into the oil pressure relief valve INLET TUBE ASSEMBLY 6622 ROTOR A N D SHAFT ASSEMBLY 660R IDENTIFICATION MARKS PLATE FIG 60 Oil Pump...

Page 366: ...r the clutch disc I f the engine hangs up after the shaft enters turn the crankshaft slowly transmis sion in gear until the shaft splines mesh with the clutch disc spline 4 Install the flywheel or con...

Page 367: ...t cov er and water pump as an assembly 5 Remove the crankshaft front oil slinger Check the timing chain deflection then remove the timing chain and sprockets by following steps 12 through 14 under Cyl...

Page 368: ...into place Be careful not to damage the bearing surfaces 11 Check the clearance of each main bearing as follows Place a piece of Plastigage on the crankshaft journal the full width of the journal and...

Page 369: ...he specified distance below the front bearing bore plug recess thoroughly face of the cylinder block Fig 67 Coat the flange of a new plug with 7 Clean out the camshaft rear oil resistant sealer and in...

Page 370: ...in der front cover retaining bolts Re move the cylinder front cover retain ing screws Remove the cylinder front cover and water pump as an assembly Discard the gasket and re move the crankshaft front...

Page 371: ...et surface of the block and cover and the cover bolt threads with oil resistant sealer Po sition a new gasket on the block 23 Install the alignment pilot tool on the cylinder front cover so that the k...

Page 372: ...k with the rotor at the No I firing position and the points open Install the hold down clamp 49 lnstall the ignition coil Posi tion and install the alternator shield and mounting bracket On Thermactor...

Page 373: ...gnition coil bracket refer to Part 8 1 Section I for engine identification tag codes The 390 and 427 V 8 engines use either the Thermactor or Imco exhaust emission control systems to keep ex haust gas...

Page 374: ...rome plated and the lower compression ring is phosphate coated The oil con trol ring assembly consists of a serrat ed spring and two chrome plated steel rails The pistons are the slipper type Indentat...

Page 375: ...ers are equalized The oil flow ceases and the disc valve spring seats the disc valve and closes the disc valve port As the camshaft rotates the lifter assembly is raised by the camshaft lobe This incr...

Page 376: ...the valve push rod chamber floor except on th 427 en gine The oil gallery supplies oil to each individual camshaft bearing through drilled passages in the block Passages are drilled from each cam sha...

Page 377: ...Oil from here feeds the valve lifter assemblies A reservoir at each valve lifter bore b oss traps oil so that oil is available for valve lifter lu brication as soon as the engine starts VALVE OPEN LIF...

Page 378: ...rocker arm The excess oil spirals head flows through the water pas down the rotating push rods and The coolant is drawn from the sages in the intake manifold past the lubricates the push seats The bo...

Page 379: ...nder hot idle conditions Under these conditions the distri butor vacuum is increased thereby increasing engine speed and reducing engine operating temperatures A vane type impeller supplies cool ant t...

Page 380: ...r carburetor spacer through the crank case vent hose tube and fittings During idle intake manifold vac uum is high The high vacuum over comes the tension of the spring pres sure and moves the valve to...

Page 381: ...back pres sure exceeds the air pump delivery pressure The pressure air from the air supply pump is connected to the air bypass valve Fig 20 Normally the valve is closed and the air is directed t o the...

Page 382: ...stall the retaining bolts washers and nuts On a right insulator position the starter cable and its retaining brack et before installing the retaining bolts washers and nuts Torque to specifi cations 2...

Page 383: ...d tighten the adjusting arm bolt D o not pry against the pump housing Adjust the belt tension refer to Part 8 5 as necessary Al ways use a belt tension gauge Tool T63L 8620 A to check belt tension 3 T...

Page 384: ...k plug wires at the spark plugs Remove the wires from the bracket on the valve rocker arm cover s and position the wires out of the way To remove the right valve rocker arm cover remove the carburetor...

Page 385: ...he plug s in straight and be sure it does not become cocked at any time during installation 4 Install the rocker arms sup ports and springs in the order shown in Fig 27 Be sure the oil holes in the sh...

Page 386: ...a non harden ing sealer Be sure the holes in the gaskets are aligned with the holes in the cylinder heads 5 Install the eye bolts in the in take manifold and attach the engine lifting sling 6 Use a ho...

Page 387: ...the frame Raise the engine approximately I or 2 inches to provide necessary clearance to remove the right manifold 3 Disconnect the muffler inlet pipe at the exhaust manifold and re move the exhaust m...

Page 388: ...ry for accessibility Remove the in take manifold crankcase ventilation system components carburetor and thermostat housing as an assembly following the procedure under In take Manifold Removal 2 On th...

Page 389: ...514 SPRING DAMPER 65 3 SPRING OIL SEAL 6 5 7 428 POLICE INTERCEPTOR INTAKE VALVE ENGINES ONLY 6507 EXHAUST VALVE 6505 A1427 F FIG 32 Compressing Valve Spring On Bench FIG 33 Typical Valve Assembly ins...

Page 390: ...stem seal identified by yel ow paint is approximately 0 025 inch shorter i n overall height than the intake valve stem seal therefore be sure the proper seal is installed 10 Install the valve springs...

Page 391: ...If the cylinder front cover is be ing removed to replace the gasket or to replace the fuel pum p drive eccentric it is not necessary to check the timing chain deflection For cylin der front cover gas...

Page 392: ...ces follow ing the procedures in Part 8 1 4 Coat the gasket surface of the block and cover and the cover bolt threads with sealer Position a new gasket on the block 5 Lubricate and install the align m...

Page 393: ...he oil pan and oil pump screen by following the pro cedure under Oil Pan and Oil Pump Removal 7 Remove the timing chain and sprockets following steps 12 thru 15 under Cylinder Front Cover and Tim ing...

Page 394: ...install the clutch pres sure plate disc flywheel housing transmission following the procedure in Group 5 On a vehicle with an automatic transmission install the transmission and converter housing foll...

Page 395: ...o Part 8 1 Section I for the test pro cedure CRANKSHAFT REAR OIL SEAL REPLACEMENT SPLIT LIP TYPE Replacement of a crankshaft rear oil seal to correct for oil leaks re quires replacement of both the up...

Page 396: ...place the plain end of the bear ing over the shaft on the locking tang side of the block and partially install the bearing so that tool 6331 E can be inserted in the oil hole in the crankshaft Fig 54...

Page 397: ...seals The seals are designed to expand when dipped in oil Using sealer may re tard this expansion It may be neces sary to tap the seals into place for the last 112 inch of travel Do not cut the seal...

Page 398: ...he crankshaft until the connecting rod being removed is down 5 Remove the connecting rod cap 6 Push the connecting rod and piston assembly out of the top of the cylinder with the handle end of a hamme...

Page 399: ...Part 8 1 Lubricate all parts with light engine oil Position the con necting rod in the piston and push the UPPER COMPRESSION r 1 L O I L ASSEMBLY R I N G BEARING INSERTS 6211 I 7 FIG 60 Typical Piston...

Page 400: ...Place the filter in posi tion on ttie adapter Fig 65 Hand tighten the filter until the gasket con tacts the adapter face Then advance it 112turn 3 Operate the engine at fast idle and check for leaks...

Page 401: ...l Pan Installation DISASSEMBLY 1 Remove the oil inlet tube from the oil pump and remove the gasket 2 Remove the cover retaining screws and cover plate Remove the inner rotor and shaft assembly and the...

Page 402: ...engine slightly and carefully pull it from the transmis sion Lift the engine out of the en gine compartment INSTALLATION 1 Attach the engine lifting brack ets and sling Fig 68 2 Lower the engine care...

Page 403: ...ni fold the alternator wires at the al ternator and the water temperature sending unit at the sending unit 7 Disconnect the wire loom at the distributor and ignition coil Re move the wire loom from th...

Page 404: ...an automatic transmission connect the kickdown rod to the carburetor Install the kick down rod retracting spring Connect the transmission vacuum line Install the oil level dipstick Install the ac cele...

Page 405: ...he following diameters No I Bearing 7 64 inch No 2 Bearing 9 64 inch No 3 Bearing 9 32 inch No 4 Bearing 5 32 inch No 5 Bearing 9 32 inch If the rod passes through both the bearing and the block suffi...

Page 406: ...and brackets on the right cylinder head lk THRUST BEARING PRY CAP BACKWARD TIGHTEN CAP 179 A 30 Remove the engine from ihe work stand CAMSHAFT BEARING REPLACEMENT Camshaft bearings are available pre f...

Page 407: ...arances Install thc manifolds and cylinder head as an assembly ENGINE DISASSEMBLY I Install the engine on the work stand 2 Remove the distributor cap and spark plug wire assembly 3 Remove the vacuum h...

Page 408: ...ng the journals and lobes 35 Remove the camshaft rear bearing bore plug Remove the cam shaft bearings Fig 72 36 Clean inspect and repair or replace all parts following the pro cedures in Part 8 1 ENGI...

Page 409: ...Remove the pilot 29 Apply Lubriplate to the outer surface front oil seal contact surface of the crankshaft sleeve and install the sleeve 30 Apply a white lead and oil mixture to the inside diameter o...

Page 410: ...the mani fold bolts in sequence to specifica tions 56 Remove the engine lifting sling and eye bolts 57 Refer to Valve Rocker Arm Shaft Assembly Installation and in stall the valve rocker arm shaft as...

Page 411: ...10 5 1 10 9 l 170Six 1 V 200 Six 1 V 289V 8 2 V 302 V 8 2 V 302 V 8 4 V 390 V 8 2 V 390 V 8 2 v o 390V 8 4 V0 427 V 8 4 V Curb Idle R W 0 EIhaust Emission EMne Idk Manifold Vacuum o 17 18 17 15 Cou l...

Page 412: ...0 117 0 150 3 Head GasketSurface Fin sh R M S 90 150 Combustion Chamber Volume 51 5 54 0 60 5 63 5 52 0 55 0 67 1 70 1 72 7 75 7 Dwell Angle At Idle Speed Valve Guide Bore Diameter Standard Intake and...

Page 413: ...t collapsed Wear limit 0 0047 I Valve face runout All Engines M a x i m 0 0020 J Wear limit 0 0055 a Hydraulic valve lifter adjustment turns down after contact 289 and 302 1 Valve Spring Out 01 Square...

Page 414: ...0 2320 0 2320 0 2303 0 2470 0 2780 0 2780 170 200 1 8095 1 8105 1 8115 1 8125 No 1 Wear Limit 0 0060 Exhaust 0 2320 0 2320 0 2375 0 2490 0 2830 0 2830 Theoretical Valve Lift CAMSHAFT DRIVE MECHANISM C...

Page 415: ...nectine rod and main bearing iournal out of roundmaximum 0 0004 all engines 2 4380 2 4388 Engine 170 200 289 302 390 427 Main Bearing Journal Thrust Face Runout 0 001 0 0003 Per Inch 0 0004 Per Inch 1...

Page 416: ...od Bearing Bore Diameter Blue 2 5911 2 5915 Diameter oil 170 200 289 302 390 427 0 003 Oversize 3 50013 5005 3 68023 6808 4 00084 0014 4 05084 0514 4 23174 2323 Coded Red 3 49823 4987 3 67783 6784 3 9...

Page 417: ...0 9 6 1 53 8 0 13 0 a 1 56 Flywheel TORQUE LIMITS CONTINUED Relief Valve Clearance 0 0015 0 0029 Drive Shaft To Housing Bearing Clearance 0 00154 0029 Imperial Measure 3 112quarts 3 112quarts 4 quarts...

Page 418: ...Rocker Shaft Support To Cylinder Head 30 35 4 0 4 5 Fuel Pump To CylinderBlock Or Cylinder Front Cover 12 15 20 25 Valve Rocker Arm Adjusting Nut Removal torque Break away counterclockwise 289 302 4...

Page 419: ...ble disagree with any of those listed i n the preceding tables the limits listed in the preceding tables prevail Size Inches Torque Ft Lbs Size Inches Torque Ft Lbs 1 4 20 6 9 7 16 14 45 50 1 4 28 6 9...

Page 420: ...Valve Installer Relief Valve Remover Use With T59L 100 B Slide Hammer LUBRICANTS Ford Part No Exhaust Control Valve Lubricant COAZ 19A501 4 R 149 A Ford Tool No T59L 100 B SEALERS Ford Part No Loct i...

Page 421: ......

Page 422: ...TEST r b u b l e Isolation 1 Disconnect the brown wire from the starter relay I terminal and the red and blue wire from the starter relay Sterminal 2 Remove the coil high tension lead from the distri...

Page 423: ...ed pickup over the coil to distributor high tension wire 6 If the engine timing is to be checked plug the timing light into its socket 7 On the ARE 881 tester dis connect the battery positive and nega...

Page 424: ...stributor vacuum line s if so equipped 5 With the timing light pointed towaids the timing marks accel erate the engine to see if the timing advances ARE 881 Tester 1 Turn the RPM selector to the 800 p...

Page 425: ...IRING OSCILLATION I I PARTIALLY SHORTED CONDENSER LUG FIRING OSCILLATIONSMISSING c PRIMARY CIRCUIT RESISTANCE DWELL TOO SHORT CONDENSER NOT FULLY DISCHARGED DWELLTOOLONG DWELL VARIATIONS C D V OWELL V...

Page 426: ...nection poor ground connection to breaker plate or engine block or a loose connection to breaker points If the scope pattern is still the same af ter the above ignition parts have been checked and pr...

Page 427: ...PRIMARY OSCILLATIONS OSCILLATIONS NORMAL ARCING POINTS _I REVERSED COlL POLARITY SHORTED COlL I SHORTED COlL MULTAPLE SPARK LlNE OSCILLATIONSBELOW n REFERENCE LlNE I BOUNCING POINTS HIGH SECONDARY RE...

Page 428: ...ern is like the 15 KV pat tern with the exception of the height The height has been reduced to al low for checking the coil output reserve The secondary circuit 30 KV pat tern will indicate excessive...

Page 429: ...K PLUG RESISTANCE 7 FlRlNG SPIKE I NORMAL EXPANDEDPATTERN I I SPARK PLUG CIRCUIT RESISTANCE NORMAL FlRlNG SPIKE_ AN0 SPARK LINE SHORT FlRlNG SPIKE SPARK PLUG SHORTED FOULEDORGAPPED TOO CLOSE UNEVEN Fl...

Page 430: ...igh tension lead at the distributor 3 With the ignition switch off crank the engine by installing a jumper wire between the battery and the S terminal of the starter relay while observing the voltage...

Page 431: ...rvice 9 11 I I NORMAL PARADEDPATTERN TOTAL COlL OUTPUT COlL OUTPUT I O CILLATIONS LOST I INTERMITTENTLY I ACCELERATION PATTERN Z J G WIRE 1 GROUNDED I t ROTORAIR CAP TEST CROSS FIRING FIG 8 Normal Sec...

Page 432: ...lgnition Switch Test Clean and inspect the secondary wiring by following the procedure under Cleaning and Inspection Sec tion 3 of this part These wires are the radio resist ance type which filter out...

Page 433: ...tributor Gear Backlash Test Connections The distributor gear backlash can not be accurately checked on the dual advance or centrifugal advance distributor 1 Mount a dial indicator on the distributor s...

Page 434: ...ERS 1 Tuln the OFF SET CAM SYNC switch to the SET position 2 Adjust the SET TACH control so that tachometer pointer is on the SET line 3 Turn the OFF SET CAM SYNC switch to the SYNC posi tion 4 On an...

Page 435: ...not connect the vacuum line to the distributor Remove the vacuum line from the distributor Adjust the vacuum pres sure of a distributor tester to its maximum position Hold your hand over the end of th...

Page 436: ...e is shown in Fig 17 2 C O M M O N ADJUSTMENTS AND REPAIRS GENERAL PROCEDURES Accurate ignition system adjust ments are of great importance in the control of hydro caibon and carbon monoxide emissions...

Page 437: ...used to check the gap of new breaker points A scope or a dwell meter can be used to check the gap of used break er points Due to the roughness of used points it is not advisable to use a feeler gauge...

Page 438: ...the No 1 cylinder spark plug wire In stall an engine speed tachometer 4 Start the engine and adjust the initial ignition timing to speci fications by rotating the distributor in the proper direction...

Page 439: ...ignition for these engines spark plugs wiring i stallation 2 Install the boots on the dis is shown in Fig 26 tributor end of the wires and install the wires in the correct sockets in the Removal dist...

Page 440: ...rallel surfaces on both the center and side elec trodes Examine the plug carefully for cracked or broken insulators badly pitted electrodes and other signs of failure Replace as required DISTRIBUTORS...

Page 441: ...ributor cap with a soft bristle brush and mild cleaning solvent or mineral spirits Dry the cap with compressed air Inspect the cap for cracks burned contacts per manent carbon tracks or dirt or cor ro...

Page 442: ...f the coil Ignition condenser of improper capacity Extended operation of the engine at speeds other than normal FIG 37 Breaker Point Inspection RE STRIPE YELLW STRIPE ACCESSORY CUTLET OR CAPPED INTAKE...

Page 443: ...AGM DISTRIBUTOR FIG 33 Ignition Vacuum Schematic 170 Engine With Thermactor and Manual Shift Transmission Falcon RED STRIPE I DUAL DIAPHRAGM DISTRIBUTOR B3OW A FIG 34 lgnition Vacuum Schematic 200 Eng...

Page 444: ...IPPLE 2 V CARBURETOR DUAL DIAPHRAGMDISTRIBUTOR FIG 35 lgnition Vacuum Schematic 289 2 V and 302 2 V With lmco and Automatic Trans mission Without Air Conditioning AIR CLEANER VACUUM OVERRIDE DUAL DIAP...

Page 445: ...PE SINGLE DIAPHRAGM DISTRIBUTOR FIG 37 lgnition Vacuum Schematic 302 4 V with Imco Automatic Transmission and Air Conditioning 0ptional Except Fairlane FIG 38 Ignition Vacuum Schematic 289 and 302 V 8...

Page 446: ...m Schematic 390 2 V Premium Fuel With Imco Automatic Transmission and Air Conditioning Cougar RED STRIPE II I I 83096 A FIG 40 lgnition Vacuum Schematic 3 90 2 V With Imco Automatic Transmission and A...

Page 447: ...tic 390 GT With Thermactor and Automatic Transmission Without Air Conditioning Except Falcon REAR INTA KE MANIFOLD FITTING OR CAPPED FIG 42 lgnition Vacuum Schematic 390 4 V and GT With Ther rnactor M...

Page 448: ...BYPASS VALVE SINGLE DIAPHRAGMDISTRIBUTOR 03099 A FIG 43 lgnition Vacuum Schematic 427 HP With Thermactor and Automatic Transmission Without Air Conditioning Except Falcon STRIPE YELLOW ACCESSORY OUTLE...

Page 449: ...phragm Vacuum Advance Distributor Distributor Vacuum Control Valve All distributors are equipped with both vacuum and centrifugal advance units The vacuum advance governs the ignition timing spark adv...

Page 450: ...toward the distributor This allows the advance diaphragm spring to move the advance diaphragm causing the movable breaker plate to pivot in the same direction as dis tr butor rotation This retard of t...

Page 451: ...N T ASSEMBLY GROUND IRE COND NSER I DISTRIBUTOR SING BREAKER O I N T AND CONDENSER PLATE FIG 3 Breaker Plate Installed 6 Cylinder Engine Dual Diaphragm Distributor exhaust system When the vehicle slow...

Page 452: ...ion 2 for distributor push the primary wire the adjustment procedures 3 REMOVAL AND INSTALLATION REMOVAL INSTALLATION 1 Disconnect the primary wire at the coil Disconnect the vacuum ad vance line at t...

Page 453: ...nt assembly DRIVE GEAR 12390 HOUSING 12130 QIL SEAL 12143 DIAPHRAGM ASSEMBLY WEIGHT RETAINER RETAINER 12177 STATIONARY SUB PLATE 12151 MOVEABLE BREAKER PLATE 12151 A S P R I N G 1 2 1 9 1 or 12192 CAL...

Page 454: ...er and the spring washer secur ing the breaker plate to the sub plate 8 Remove the sub plate retaining screws and lift both plates out of the distributor 9 Mark one of the distributor weight springs a...

Page 455: ...re through the opening in distributor 20 Slide the diaphragm into the opening in the distributor and place the link in its position 21 Install the spring clip that se cures the diaphragm link to the m...

Page 456: ...U H INCH HOLE THROUGH Toal TIGHTEN SCREW T571 12390 A ENOUGH TO 81387 D FIG 77 New Shaft and Gear Installation V 8 Engines play Remove the feeler gauge and allow the shaft to rest on the back ing scre...

Page 457: ...02 390 3 390 4 390 5 390 b 427 Point Voltage Drop Max Coil Primary 1 40 1 54 Resistance Ohms 75 F Secondary 76004800 Resistance Ohms 75 F Amperage Draw 4 5 Engine Stopped Amperage Draw 2 5 Engine Idli...

Page 458: ...000 1500 2000 Automatic Transmission Crankshaft Advance At 2000 Engine RPM With Distributor Vacuum Line Disconnected 12 1 2 16 1 2 7 1 2 11 1 2 13 17 9 1 2 13 1 2 7 1 1 12 16 1 2 to 0 at 250 of Mercur...

Page 459: ...1 112 8 1 2 11 112 0 314 1 4 314 7 10 9 1 2 12 112 10 12 112 0 314 1 3 4 4 314 6 314 9 112 7 4 112 7 4 112 0 1 1 4 314 7 10 8 1 1 Distributor rpm Max Adv Camshaft Degrees 10 112 9 12 112 11 112 12 112...

Page 460: ...emover Distributor Puller Distributor Puller Adapter Distributor Holding Clamp Tool Description Distributor Testers Drive Gear Installing Fixture Drive Gear Remover Kit Ignition Oscilloscopes Pin Remo...

Page 461: ......

Page 462: ...y condi tions in addition to the loss of fuel A restricted fuel tank vent can cause low fuel pump pressure and volume may in some instances re sult in collapsed inlet line hoses or a collapsed fuel ta...

Page 463: ...Fig 3 2 If the plate is not in the heat on position check for possible interference of plate and duct which would cause the plate to bind in its given travel Correct if interference is present by rea...

Page 464: ...FOLD VACUUM CLOSED POSITION FIG 5 390 G T Air Valve a n d Varuum Motor Assembly AIR FIG 6 Duct a n d Valve Assembly in Partial Heat On Position Cold Acceleration terference of plate uum motor which pl...

Page 465: ...hin approximately 15 seconds or after the air has been removed from the sys tem If no bubbles are seen the pow er valve gaskets and cover are sealing properly Holley Model 4 150 C 4 V Carburetor 1 Rem...

Page 466: ...ew carter 1 V IDLE MIXTURE ADJUSTING SCREW 83133 A FIG 13 Idle Fuel Mixture Adjusting Screws Holley 4 V 4 Turn the idle speed adjusting screw inward until it just makes the contact with the screw stop...

Page 467: ...b Ignition system wiring contin uity c Spark plugs d Distributor breaker point dwell angle e Distributor point condition f Initial ignition timing I n certain instances i t nay be pos sible that the i...

Page 468: ...or idle fuel system Refer to the procedures in a Removal and Installation of Idle Limiter Caps All Autolite and Carter 4 V Carburetors b Remove and Installation of Lead Seal and Readjustment of ldle L...

Page 469: ...r running when the engine is cold during choke operation As the choke plate is moved through its range of travel from the closed to the open position the fast idle cam pick up lever rotates the fast i...

Page 470: ...turned to alter the adjustment Turn ing the housing in a counterclock wise direction will require a higher therm ostatic spring temperature cold weather operation to fully open the choke plate Turnin...

Page 471: ...accelerating pump has been adjusted the fuel bowl vent valve should be checked and if re quired adjusted Part 10 10 Autolite Model 1100 I V The pump stroke is controlled by changing location of the r...

Page 472: ...ALVE ROD TO ALIGN WITH EDGE Autolite Model 4300 4 V The fuel bowl vent valve Fig 35 must be adjusted to the specified clearance The adjustment can be made with the carburetor on or off the engine I Se...

Page 473: ...tment until the specified level is achieved 6 Install a new air horn gasket the air horn assembly carburetor identification tag and the retaining screws Tighten the retaining screws Install the air cl...

Page 474: ...ove the carburetor air horn and gasket from the carburetor Re fer to Air Horn to Main Body Gasket Replacement in this section for the proper procedure 2 Fabricate a float level gauge Fig 42 to the spe...

Page 475: ...the bending SECONDARY THROTTLE tool shown in Fig 44 PLATE ADJUSTMENT HOLLEY MODEL 4150 C 4 v TWO 3 16 HOLES 1 Hold the secondary throttle TWEEN CENTERS plates closed 2 Turn the secondary throttle sha...

Page 476: ...he carbu retor To remove the thermostatic spring housing with the carburetor installed on the engine refer to Ther mostatic Spring Housing and Gas ket Replacement in this section 2 Bend a wire gauge o...

Page 477: ...ne adjust the engine idle speed and fuel mixture Adjust the anti stall dashpot if so equipped DECHOKE CLEARANCE Autolite Model 4300 4 V 1 Open the throttle plate to the wide open throttle position and...

Page 478: ...hould contact the lifter link at the lifting lug and at the diaphragm shaft 3 If iecessary bend the metering rod pin flange on the metering rod arm up or down to properly position the metering rod 4 I...

Page 479: ...engthen or shorten the assembled crank Secure the stabilizer into po control shaft rod assembled length length of the accelerator shaft to bell sition with the retaining clip Make to obtain the specif...

Page 480: ...PAD ASSEMBLY 9A799 PREVENTING PROPER OPERATIO RICATE HINGE POINTS WITH OF THE ACCELERATOR CONTROL LUBRIPLATE WlTH A DROP OF LIGHT ENGINE OIL FIG 56 Throttle Linkage Adjustment Falcon Montego Fairlane...

Page 481: ...ET 9 D 7 9 SCREW 55876S2 2 REQUIRED ACCELERATOR SHAFT TO ACCELERATOR SHAFTTOCARBURE LCRANK ROD ASSEMBLY PA702 ASSEMBLY BELLCRANK 9A729 INSERT 25 DIA ADJUSTMENT PIN THESE 3 HOLES ADJUSTING THE BELLCRAN...

Page 482: ...60 Throttle Linkage Adjustment Fairlane Fairlane Ranchero and Montego 390 V 8 ACCELERATOR RETRACTING SPRING 9737 COTTER PIN 720034 ACCELERATOR SHAFT TO LCRANK POD ASSEMBLY 9A702 RUBBER GROMMET 377406...

Page 483: ...st the idle fuel mixture and idle speed Autolite Model 2100 2 V idle speed and the dashpot as outlined in this section 6 Install the carburetor air cleaner assembly Part 10 7 Section 2 Autolite Model...

Page 484: ...FLOAT NEEDLE VALVE AND SEAT INLET SCREEN OR MAIN JET REPLACEMENT AUTOLITE MODEL 2100 2 V 1 Remove the carburetor air horn to main body gasket by follow ing the procedure under Air Horn to Main Body G...

Page 485: ...K VALVE REPLACEMENT AUTOLITE MODEL 43004 V 1 Remove the air horn assembly from the main body of the carburetor 2 Remove the accelerator rod re tainer and rod from the accelerator pump lever then remov...

Page 486: ...olite Model 1 100 1 V JET 1 Remove the air cleaner assem bly Part 10 7 Section 2 2 Remove the retaining nut and the dashpot from the mounting brack et 3 Install the new dashpot and re taining nut on t...

Page 487: ...the choke housing onto the lower body connecting the rod to the choke plate shaft Start the re taining screws into the body 15 Insert the end of the choke pull down rod into the throttle shaft lever...

Page 488: ...t lever as the choke housing is placed in position on the main body Be sure the projection on the choke rod is placed under the fast idle cam so that the cam will be lifted when the choke plate is clo...

Page 489: ...the accelerator shaft to bellcrank rod retaining clip Disconnect the accelerator shaft to bellcrank rod from the accelerator shaft assembly Remove the retaining clip On a Mustang Six engine discon nec...

Page 490: ...tabilizer Adjust ment Fairlane and Montego 289 or 390 V 8 in this section for the proper procedure Accelerator Bellcrank Replacement Assembly Refer to Figs 55 through 61 for views of the accelerator l...

Page 491: ...ads Replace all distorted or broken springs Inspect all gasket mating surfaces for nicks and burrs Repair or re place any parts that have a damaged gasket surface On Autolite Model 2100 2 V carburetor...

Page 492: ...ry diaphragm or secondary A LEAN MIXTURE ON throttle lever ACCELERATION C A N BE Secondary vacuum passage ball check stuck on its seat CAUSED BY Secondary vacuum probe restrict 1ncorrect accelerating...

Page 493: ...en Secondary throttle plate operating Faulty choke operation rod binding Improper throttle linkage adjust Secondary vacuum passage ball ment check sticking on its seat 4 V CARBURETORS Secondary damper...

Page 494: ...ged low volume Main body retaining screws loose Diaphragm spring too strong or tensioned improper spring Diaphragm vent hole is plugged or Diaphragm surface too tight over omitted Diaphragm stretched...

Page 495: ...retor on its way to enter the cylindcrs low pressure is created at the fuel dis charge outlets of the cerburetor The fuel bowl is vented to atmospheric and to carburetor air inlet pressure through a v...

Page 496: ...nt regulations idle mixture limiter caps are installed The caps prevent the enrichment of the idle mixture however the adjust ment screws can be turned approxi mately 415 turn toward the lean side inw...

Page 497: ...ure for this brief period of time The accelerating pump is actuated by linkage connected to the throttle shaft When the throttle is opened on acceleration the diaphragm forces fuel from the accelerati...

Page 498: ...vercomes the spring tension The piston and rod move up and the grad ient valve closes the power jet channel AUTOMATIC CHOKE SYSTEM The automatic choke system Fig 8 provides the proper choking ac tion...

Page 499: ...to warm up Tension of the thermostatic spring gradually de creases as the temperature of the air from the heat chamber rises allowing the choke plate to open The air in the choke housing is exhausted...

Page 500: ...askets and position them on the intake manifold 2 Install the carburetor and tight en the retaining nuts evenly and al ternately to specification The vent control valve Fig 9 is at the inward position...

Page 501: ...crews are flared excessively file off the flared portion to avoid damage to the threads i n the choke shaft Be careful not to damage the choke shaft or venturi while filing the screws Remove the choke...

Page 502: ...10 42 GROUP 10 Fuel System I AIR CLEANt R BRACKET 98672 RETAINER 9C631 I FIG 1l Autolite Model 1100 1 V Carburetor Assembly...

Page 503: ...ragm plunger facing the lever and line up the holes Position the cover and diaphragm over the return spring and onto the body In stall the cover retaining screws fin ger tight Push the diaphragm assem...

Page 504: ...adjusting nut 5 Position the short end of the choke control rod into the keyhole in the choke housing choke lever 6 Insert the choke assembly re taining screws into the choke hous ing Position the ch...

Page 505: ...needle a high speed air bleed and the main discharge nozzle The throttle body contains the throttle plate throttle shaft and lever idle mixture adjusting screw and discharge slot and choke connec tor...

Page 506: ...adjustment screw inward rkduces the quantity of fuel air mixture supplied by the idle circuit The idle port is slot shaped As the throttle valve is opened more of the idle port is uncovered allowing a...

Page 507: ...for smooth engine operation during acceleration c c e l e r a t i n pump action is con trolled both mechanically and by manifold vacuum in the same man ner as the metering rod When the throttle is cl...

Page 508: ...up period the corresponding drop in manifold vacuum allows the thermostatic spring to momentarily close the choke providing a richer mixture During the warm up period it is necessary to provide a fast...

Page 509: ...s for com pletely overhauling the carburetor houever certain components of the carburetor may be serviced without LI complete disassembly of the entire unit A disassembled view of the car buretor is s...

Page 510: ...LINK COlL HOUSING RETAINER UPPER PUMP SPRING METERING ROD ARM ASSEMBLY PUMP DIAPHRAGM SPRING RETAINER FUEL BOWL BAFFLE PLATE DIAPHRAGM HOUSING ATTACHING SCREW BOOY FLANGE PUMP DIAPHRAGM HOUSING ASSEMB...

Page 511: ...hragm shaft and housing assembly Install the spring retainer Install the pump lifter link metering rod arm and spring assem bly and upper pump spring on the diaphragm shaft Depress the spring and inst...

Page 512: ...P 10 Fuel System ket between the baffle and coil hous tainer on the fast idle link Install the ing Be sure the thermostatic spring choke connector rod on the throttle engages the choke lever tang Inst...

Page 513: ...e main body The two barrels each contain a main and booster venturi main fuel discharge accelerating pump discharge idle fuel discharge and a throttle plate OPERATION FUEL INLET SYSTEM The amount of f...

Page 514: ...rod and the inward movement of the vent rod opens the vent p u_g a specifi ed distance from the air horn at the fuel bowl vent opening AUTOMATIC CHOKE SYSTEM The choke plate located in tht air horn ab...

Page 515: ...e lever and the throttle shaft is designed so that the choke plate will partially open when the accelerator pedal is During off idle when the throttle fully depressed This permits unload plate is move...

Page 516: ...ifference in pressure between the main discharge port and the fuel bowl causes fuel to flow through the main the main ell The fuel moves up the main well tube past air bleed holes Filtered air from th...

Page 517: ...s The contents of the bowls may then be examined for contamination as the carburetor is disassembled 1 Remove the air cleaner Part 10 7 Section 2 Remove the choke shield retaining screws and remove th...

Page 518: ...and gasket 3 Remove the choke housing as sembly retaining screws If the air OVER TRAVEL LEVER I R E T I N E R FAST IDLE SCREW FAST IDLE ADJUSTING LEVER 2 6 0 4 FIG 10 Fast ldle Cam a n d Fast ldle Le...

Page 519: ...Hold the throttle plates closed and FIG 18 Power Valve Removal or tighten and stake the retaining screws Installation When staking the screws support the shaft and plate on a block of wood or SCRIBEL...

Page 520: ...RI ASSEMBLY ATE SHAFT 9546 GASKET 9A536 OASHPOT 98549 OASHPOT BRACKET 90550 CHOKE CLEAN AIR FLOAT 9550 SHER 359555 5 ROD LUBRICATOR 98501 LEVER ASSEMBLY LEVER 9A753 FAST COLD ENGIN IDLE ADJUSTING SCRE...

Page 521: ...the choke piston on the choke thermostatic spring lever link and install the retaining pin Fig 21 2 Position the fast idle cam lever on t h e thermostatic choke shaft and lever assembly Fig 21 The bot...

Page 522: ...stall the air horn re taining screws arid the carburetor iden clearance pull down vent valve ad tification tag Tighten the retaining justment if so equipped and fast idle screws Install the choke plat...

Page 523: ...ure tor The correct fuel level is impor tant for proper carburetor operation A fuel level below the specified set ting will result in lean fuel air mix tures while high fuel levels produce cich fuel a...

Page 524: ...s syphoning vent at high engine speeds or when the engine is shut down The fuel air mixture passes down the idle channel into an idle cavity in the throttle body The idle cavity has an upper and lower...

Page 525: ...g hot engine shut down ACCELERATOR P U M P SYSTEM For smooth acceleration the ac celerator pump system Fig 7 in jects a metered amount of fuel direct ly into the air stream flowing through the carbure...

Page 526: ...orce applied by the vacuum piston spring As the piston moves downward the stem on the piston contacts the stem on the power valve Continued downward movement of the piston opens the power valve When t...

Page 527: ...is then discharged from the secondary main discharge tubes The anti syphon bleed and the high speed air bleeds act as anti percolator vents during idling periods and when a hot engine is shut down Th...

Page 528: ...opened to a defi nite distance but no farther When the engine reaches its normal operating temperature the bimetallic spring exerts torque to hold the piate for a brief moment This action provides a...

Page 529: ...4 Remove the accelerator pump rod retainer from the pump rod Sep arate the rod from the throttle lever 5 Remove the air horn to fuel bowl retaining screws one of the I I screws also retains the fuel...

Page 530: ...lightly with the end of a screw driver handle or similar tool so that the plates are properly and fully seat ed in the throttle bores when viewed with a light behind the plates little or no light sho...

Page 531: ...VE SPRING HOUSING AIR VALVE SPRING 9H556 SCREW 3540984 10 REQUIRED AIR HORN BODY SERVICED IN 9510 ELERATOR PUMP CHECK VALVE DISC SEMBLY POWER VALVE PC553 SERVIC 9576 E IN 9500 ASSEMBLY AND SE AUXILIAR...

Page 532: ...inlet seat 14 Position float and lever assem bly between hinge post and over fuel inlet valves lnsert the float hinge pin through the post and float lever The pin must be inserted from the pump plunge...

Page 533: ...lo cated within the primary metering block The primary barrels each con tain a primary and booster venturi main fuel discharge nozzle throttle plate and an idle fuel passage The choke plate mounted o...

Page 534: ...UM PICK UP ADJUSTMENT SCREW SECONDARY STAGE THROTTLE PLATES SECONDARY FUEL BOWL 82715 8 B n l s B air horn above the primary barrels when closed provides a high vacuum above as well as below the throt...

Page 535: ...per mits a faster engine idle speed for smoother running when the engine is cold As the choke plate is moved through its range of travel from the closed to the open position the choke rod rotates the...

Page 536: ...directions one through the idle discharge pas sage and the other to the idle trans fer passage Fig 6 The fuel in the idle discharge pas sage flows past the idle adjusting needle which controls the fue...

Page 537: ...e pump operating lever is actuated by throttle movement When the throttle is opened the accelerating pump link age actuated by a cam on the pri mary throttle shaft forces the pump diaphragm up As the...

Page 538: ...tR SECONDARY THROTTLE OPERATING DIAPHRAGM HOUSING SECONDARY OPERATING LEVER A t VACUUM B1408 C FIG 10 Typical Holley 4 V Secondary Stage Main Fuel System sion of the power valve spring and holds the d...

Page 539: ...n the carbu retor and to prevent damage to the throttle plates install carburetor legs on the base If the legs are unavail able install four bolts about 2 114 in ches long of the correct diameter and...

Page 540: ...t Disassemble the fuel bowl and the metering block by following Steps 3 5 6 7 and 8 under Primary Fuel Bowl and Metering Block MAIN BODY 1 Remove the air cleaner anchor stud and remove the secondary d...

Page 541: ...TlDN TUBE FITTING SECONDARY METERING BODY LOCK SCREW PRIMARY METERING BLOCK DISTRIBUTOR VACUUM FITTING FLOAT FAST IDLE CAM LEVER THROTTLE BODY SECONDARY THROTTLE PLATES FLOAT PIN SHAFT ECWDARYTHROTTLE...

Page 542: ...ottle plates and hold FAST IDLE CAM CHOKE HOUSING SHAFT AND LEVE FIG 20 Choke Housing Linkage Installed Holley 4 V the throttle body up to the light Little or no light should show between the throttle...

Page 543: ...the cover screws After the carburetor is assembled refer to Common Adjustment and Re pair for the correct adjustment of the accelerating pump 2 Install the gasket and fuel inlet and filter fitting 3 I...

Page 544: ...vent entry of dirt and unfiltered air into the engine The air from the engine compart ment enters the air cleaner assembly through the hot and cold air intake duct and valve except 427 4 V on the side...

Page 545: ...ing cold acceleration periods additional carburetor intake air is provided by the vacuum override mo tor control The decrease in intake manifold vacuum during acceleration causes the vacuum override m...

Page 546: ...and valve assembly to the air cleaner 2 Remove the air intake duct and valve assembly from the engine DIAGNOSIS AND TESTING Refer to Part 10 1 Section I for the air intake duct and valve testing proc...

Page 547: ...7 V 8 Engine of one piece construction and does not contain a cleanable filter element The fuel pumps are mechanically actuated by means of the fuel pump rocker arm and an eccentric on the camshaft A...

Page 548: ...filter if so equipped and screw the filter into the carburetor inlet port Tighten the filter 5 Position the fuel line hose clamp and crimp the clamp securely 6 Start the engine and check for fuel lea...

Page 549: ...he rocker arm pin to fall out If the pin does not come out freely use needle nose pliers Fig 6 6 Press the diaphragm into the fuel pump body and pull the rocker arm out to release the rod from the roc...

Page 550: ...the top of the fuel tank forms the luggage compartment floor On Montego and Fairlane station wag Venting on all Fairlane models ex on models a fuel tank guard in the cept station wagons is through a t...

Page 551: ...PART 10 9 Fuel Tank And Fuel Lines 10 91 FIG 2 Fuel System Mustang and Cougar HOSE CAP FILLER CAP NECK UPPER FILLER 82678 C FIG 3 Fuel System Fairlane Ranchero and Falcon Station Wagon Models...

Page 552: ...10 92 GROUP 10 Fuel System FIG 4 Fuel System Montego and Fairlane Station Wagon Models FIG 5 Fairlane and Montego Convertible...

Page 553: ...he end of the upper filler pipe and slide it through the body side panel and over the lower filler pipe Install the filler pipe neck retaining screws and tighten the hose clamp 5 Place the siphoned fu...

Page 554: ...all the left rear wheel and lower the vehicle 6 Fill the fuel tank and install the filler cap 7 Check all connections for leaks FUEL LINES The various fuel lines Figs 1 thru 5 are not serviced as asse...

Page 555: ...Fairlane Montego Mustang Falcon Fairlane Mustann 302 4V 390 2V 390 2V CARTER MODEL YF 1 V Carburetor Type Carter YF Autolite 1100 Autol ite 2100 Cougar Falcon Montego Mustang Fairlane Montego 390 4V...

Page 556: ...Throttle Bore Diameter 1 687 1 562 1 687 1 562 1 687 Power Valve Timing In Hg 12 5 to 13 5 10 5 t o 11 5 Main Meter Jet CHOKE SYSTEM Venturi Diameter 1 231 1 080 1 231 1 080 1 231 CHOKE SYSTEM Power V...

Page 557: ...M EX FUEL INLET SYSTEM Idle Cornpen sator Opens 148 F Fuel Press psi 5 0 ACCELERAT1NG I CHOKE SYSTEM PUMP FUEL lNLET SYSTEM Throttle Screw Setting 112 Turn after contact with lever Pump Jet 0 028 Pis...

Page 558: ...ODEL Fairlane Car and Station Wagons Falcon Station Wagon and Montego Mustang and Falcon Car Cougar Eccentric Total Lift lnches Wire Gauges Specified Clearance Sizes k Required I Throttle Shaft Bendin...

Page 559: ......

Page 560: ...d hose connec Cracked cylinder head or block tions or warped cylinder head or block Water pump leaking gasket surface Cylinder head gasket defective Radiator pressure cap defective Improper tightening...

Page 561: ...just the Strobe Light until it is synchro nized with the fan blade 10 The fan speed must not be greater than the specified minimum fan test speed at 2000 water pump rpm Part 1 1 5 11 Turn the engine o...

Page 562: ...R HOSE REPLACEMENT Radiator hoses should be replaced whenever they become cracked rotted or have a tendency to collapse I Drain the radiator then loosen the clamps at each end of the hose to be remove...

Page 563: ...washers retaining the connections to the tank 7 Remove the defective oil cooler 8 Clean the soldered surface areas and inspect and tin as necessary to assure proper solder bonding 9 Install the replac...

Page 564: ...e cooling system Dis connect the radiator upper and lower hoses at the radiator 2 On a car with automatic trans mission disconnect the oil cooler lines at the radiator 3 Remove the radiator support bo...

Page 565: ...is filled with a given amount of silicon base oil Centrifugal force resulting from the rotation of the clutch coupled with the constant pumping action designed into the unit forces the silicon base oi...

Page 566: ...with heavy to light traffic terrain Gc the fan clutch operates within the high and low rpm positions modulating as re quired as ambient air flow through the radiator core changes HIGH SPEED SUSTAINED...

Page 567: ...Flex Blade Fan assembly is part of an integrated design which includes the radiator engine heater and air conditioner if supplied Because the blades flex as engine rpm increases thereby reducing effe...

Page 568: ...et Metal All Engines 8 13 Radiator to EngineHoseClamps All Engines 1 0 2 5 Transmission OilCooler Tube Hoseto Radiator Fairlane 8 12 Transmission OilCooler Tube But to Bottomof Itadintor All Except Fa...

Page 569: ...ngine Option 289 302 289 302 302 302 302 Cooling Package A C A C A C A C A C A C A C Fan Assembly 68600 CBSE B USE B USE B USE B C8SE B C8SE B C8SE B D Fan Description No of Blades 5 5 5 5 5 5 5 Dia 1...

Page 570: ...11 1 2 GROUP 11 Cooling System RADIATOR AND COOLING FAN IDENTIFICATION...

Page 571: ...PART 11 5 Specifications 11 13 RADIATOR AND COOLING FAN lDENTlFlCATlON Continuod Radiator Identification...

Page 572: ...11 14 GROUP 1 1 Cooling System RADIATOR AND COOLING FAN IDENTIFICATION Continued...

Page 573: ......

Page 574: ...roper pipe connections Be sure that the inlet and outlet pipes and mufflers are aligned so that all clearances are within the limits shown on the illus trations in Part 12 2 Then torque the clamps to...

Page 575: ...consists of an H type inlet pipe and inlet pipe extension muffler and out let pipe assemblies Fig 9 The location and type of exhaust system gaskets retaining clamps and support brackets are shown in t...

Page 576: ...s Be sure to maintain the specified clear ances for the clamp s and locating tab s Tighten the clamp snug but not tight 4 Align the exhaust system to conform to the clearance specifications Figs 2 thr...

Page 577: ...go Mustang Cougar Hardtop GT Optional Dual Exhaust System Control Valve no no no no no no no no no Yes 80 no no no no no Yes no no no no no Yes no no no no no Yes Resonator no no no no no no no no no...

Page 578: ...ONLY VlEW V FOR FAIRLANE B MONTEGO BRACKET AND INSUL FAIRLANE B MONTECO FLOOR PAN REF CONVERTIBLE SUPPORTBRACKET 289 B 302 V 8 ONLY BE HORIZONTAL ALLOWABLE VARIATION VIEW Z VIEW Y TO VEHICLE IN CLAMP...

Page 579: ...RVICE CLAMP LOWERBRACKETOFHANGER ASSEMBLY 8 CLAMP TO BE CENTRALLYLOCATEDON SCREW MUST BE POINTING UPWARD AWAY MONTEGO g FAIRLANE FROM TIRE RVlCE C L W P 5A272 OWER BRACKET OF HANGER ASSY NDCLAMPTOBE L...

Page 580: ...12 8 GROUP 12 Exhaust System...

Page 581: ...SSMEMBER SECTION A A REF VERTICAL CENTERLINE MAINTAIN THIS VERTICAL DIMENSION WHILE ALLOWABLE VARIATION IN SECTION 8 0 VIEW I VlEW X 2331 D A DIM TRANS 2 1 16 3 SPD 8 4 SPD 1 5 8 MANUAL FIG 5 Fairlane...

Page 582: ...SUPPORTBRACKET AND INSULATOR 5A246 A DIM TRANS 2 1 16 3 SPD B SPD 1 S 8 MANUAL 1 3 8 FIG 6 Fairlane and Montego Single Exhaust System 390 V 8 Station Wagon and Ranchero...

Page 583: ......

Page 584: ...T BRACKET AND 318 CONSTANT TOVALANCEPANEL OF RESONATOR R H L H BOTH OUTLF T EXTENSIONS G T ONLY TOBE PARALLELTOGROUND VIEW Z OUTLE G T ONLY VlEW P STOP IS COMPLETELY OF RESONATOR UNTIL VIEW V ENGAGED...

Page 585: ...FIG...

Page 586: ...Inlet Pipe t o Exhaust Manifold Mustang 390 4V GT Resonator or Support Bracket t o Mounting Plate and Resonator Mustang 390 4V GT Resonator Inlet Pipe Flanges Mustang 289 4V H P 390 4V GT Muffler Insu...

Page 587: ......

Page 588: ...tem Trouble Diagnosis Guide b DISCHARGED BATTERY CHARGE INDICATOR LIGHT STAYS ON OR CHARGE INDICATOR G A U G E INDICATES CONSTANT DISCHARGE LIGHTS FAIL PREMATURELY BATTERY USES EXCESSIVE WATER CHARGE...

Page 589: ...e and adjust the speed to 1000 1500 rpm for all tests use a tachometer Part 9 1 Section I 3 With the Test Switch Fig 3 in the A position observe the pattern of lights on the tester 4 Slide the Test Sw...

Page 590: ...ustments as shown in Fig 7 Start the engine and run it at 1000 rpm use a tachometer Part 9 1 Sec tion I Turn off all lights and ac cessories Rotate the field rheostat clockwise until at least 6 volts...

Page 591: ...s are made to deter mine if the stator coil is defective Dis assemble the stator from the alterna tor and rectifier assembly Part 13 2 Section 4 for these tests Open Stator Test On Bench Set the Rotun...

Page 592: ...FIELD COIL THE ALTERNATOR TO REGULATOR HAR NESS TESTER MAY MAKE BUZZING NOISE CAUTION THESE CONDITIONS DAMAGE THE REGULATOR I I 1 m 1 SHORTED DIODE OR GROUNDED STATOR a a G i n 2 p GROUNDED OR MISCON...

Page 593: ...THE IGN GREEN LlGHT IS LIGHTED THE CHARGE INDICATOR BULB SOCKET OR WIRING IS SHORTED GROUNDED WlRE GREEN RE0 TRACER B E T W E E N REGULATOR PLUG AN0 CHARGE INDICATOR LIGHT REG LlGHT MAY BE ON CAUTION...

Page 594: ...adapt er switch Increase the engine speed to 2000 rpm Allow the battery to nor malize for about one minute then read the voltmeter upper scale Com pare the voltmeter reading with the voltage given in...

Page 595: ...to verform individual cell tests One battery cell has a special vent cap The center of the cap will glow if the electrolyte level is low Wipe the top of the cap clean before checking for the glow effe...

Page 596: ...ry is full charged when the cells are all gassing freely and the specific gravity ceases to rise for three successive readings taken at hourly intervals Additional battery testing will not be necessar...

Page 597: ...IS O K I LESS THAN 50 POINT 0 0 5 0 BETWEEN CELLS I MORE THAN 50 POINTS 0 0 5 0 BETWEEN CELLS I ADD WATER I F NECESSARY AND CHARGE BATTERY PER CHARGING SCHEDULE AND REPEAT CAPACITY TEST TOTAL VOLTAGE...

Page 598: ...O M M O N ADJUSTMENTS A N D REPAIRS BELT ADJUSTMENT the adjusting arm bolts 3 Check the belt tension using ALTERNATOR 2 Apply pressure on the alterna tool T63L 8620 A Adjust the belt I Loosen the alte...

Page 599: ...PART 13 3 Autolite Alternators 13 13 Block Red S t r p e FIG I Wiring Harness Connections Typical Except 65 Ampere FIG 2 Wiring Harness Connections 65 Ampere Alternator...

Page 600: ...ripped or damaged threads lnspect the hex hole in the end of the shaft for damage 6 Check both the front and rear housings for cracks Check the front housings for stripped threads in the mounting ear...

Page 601: ...12 Position the rear end housing and stator assembly over the rotor and align the scribe marks made during disassembly Seat the ma chined portion of the stator core into the step in both end housings...

Page 602: ...13 16 GROUP 13 Charging System DISHED WASHER STEEL FIG 8 Rectifier Assembly FIG 9 Alternator erminal Locations...

Page 603: ...PART 13 3 Autolite Alternators 13 17 FIG 70 Disassembled 65 Ampere Autolite Alternator...

Page 604: ...g iron 3 If the rear end housing bearing was removed press in a new bear ing from the inside of the housing 4 Install the BAT GRD insulator Fig 10 Position the stator and diode plate assembly in the r...

Page 605: ...resistor supplies adequate starting field current When the alternator builds up enough voltage to close the field re lay contacts full voltage is applied to the field and the charge indicator light g...

Page 606: ...80 F Charge at 5ampere rate only until the specific gravity reach es 1 250 at 80 F At no time during the charging operation should the electre lyte temperature exceed 130 F Qlarge Rate Amperes 35 35...

Page 607: ......

Page 608: ...from the battery positive terminal to the starter terminal of the starter relay If the starter will not crank the engine the starter is defective Repair or replace the starter If starter cranks check...

Page 609: ...Check Battery Check Cables Check Starter Drive and Starter In addition make the lollow ing checks Examine the dipstick for con gealed engine oil Check the car owner regarding the viscosity and grade...

Page 610: ...d to the open circuit winding passes under a brush ARMATURE A N D FIELD GROUNDED CIRCUIT TEST ON TEST BENCH This test will determine if the wind ing insulation has failed permitting a conductor to tou...

Page 611: ...of the relay The voltage drop in the circuit will be indicated by the voltmeter 0 to 2 volt range Maximum allowable volt age drop should be 1 With the voltmeter negative lead connected to the starter...

Page 612: ...quarely against its mount 8 cyl engine only frame ing surface and fully inserted into the 4 Remove the starter mounting hole Torque the bolts to speci 2 Disconnect the starter cable at bolts Remove th...

Page 613: ...er band retaining screw and remove the brush cover band and the starter drive plung er lever cover Observe the lead posi tion for assembly and then remove the commutator brushes from the brush holders...

Page 614: ...Screw Removal FIG 4 Commutator u n tCKeck 3 Install the solknoid coil and re tainer and bend the tabs to retain the coils to the frame 4 Solder the field coils and sole noid wire to the starter termi...

Page 615: ...mal engine temperature is 0 5 volt lhrough Bolt Torque Inlh 55 75 55 75 Starter Yotor Mountill Bdt Torque FtiLbs J ln Bolt Two Hole Mtg 15 20 15 20 Starter Brushes Mfg Lemth Inches 0 50 0 50 Dia Inche...

Page 616: ......

Page 617: ...erating com ponents aid installation Note the vacuum hose routing connections and color codes The headlight switch when pulled fully out actuates a distribution valve located on the back of tne headli...

Page 618: ...the switch actuating pin It is this move ment of the switch with respect to the actuating pin and master cylinder push rod that closes the switch contacts completing the circuit to the stoplights Whe...

Page 619: ...ator connections Group 13 2 Excessive vibration Verify the complaint 3 Both low beam filaments burn 1 Defective beam selector switch ed out 2 Loose or broken wire to the bulbs Verify the complaint Che...

Page 620: ...cuum At Point E Not OK Repair or replace the hose between points D and E If Vacuum At Point E OK Perform a leak test at the headlight switch Refer to Headlight Cover Vac uum System Leak Test in this s...

Page 621: ...servoir Turn the engine off and check for a minimum of 14 inchesof steady vacuum Perform a leak test at connector K El If Yellow Hose At Cover Motors Not OK F1 If Leak Test At Point K Not OK Check for...

Page 622: ...replace the check valve C1 If Leak Test At Connector K Not OK If Right Cover Motor Leak Test Not OK Perform a leak test on the hose at Point L If Leak Test At Point B Not OK Replace the right cover m...

Page 623: ...f Yellow Hose Check OK If Cover Check At Point G Not 0K Check the yellow hose between the cover motor and the tee in the close circuit for plugged conditions or kinks Replace the headlight sw itch If...

Page 624: ...Vacuum Check OK Perform a leak test on the head light switch If The Green Hose Vacuum OK Repair or replace the hose between the manifold and the check valve Repair the plugged venting holes in the he...

Page 625: ...engine intake manifold to the most remote component in the vacuum sys tem Call the epds of the hose the manifold end and the working end 2 Insert a 4 way connector into the working end of the hose 3...

Page 626: ...HICLE HORIZONTAL 4 OF HEADLIGHTS C I q OF L E F T NO 1 HEADLIGHT 1 t 20 LlNE tQ OF RIGHT NO 1 HEADLIGHT HEADLIGHTS25 FEET NO 1 LIGHT HIGH BEAM DIAGRAM WALL 1 DIMENSION A w 4 LlNE OF ADJUSTMENT HEADLIG...

Page 627: ...15 12 GROUP 15 Lighting System Horns And Instruments...

Page 628: ...nder Disconnect the lead wire and remove the light body and re tainer 3 If a new light body is to be installed transfer the body seal and bulb 4 Position the light body and retainer to the fender and...

Page 629: ...he full ON position Then press the knob release button on the switch assembly Pull the knob and shaft out of the switch assembly 3 Unscrew the mounting nut re move the bezel and switch then re move th...

Page 630: ...ter switch plug and the multiple plug to the printed circuit 3 Position the cluster to the in strument panel and install the five re taining screws 4 Install the instrument panel pad 5 Connect the bat...

Page 631: ...ER HOUSING BACK VIEW PRINTED CIRCUIT FUEL GA INSTRUMENT M4SK COVER LENS RETAINING BUTTON FIG 12 Fairlc INSTRUMENT VOLTAGE REGULATOR ILLUMINATION BULB SOCKET INSTRUMENT CLUSTER HOUSING FRONT VIEW UGE S...

Page 632: ...bulb lens and two retaining screws to the light assembly 3 Route the wire lead through the fender Position the assembly to the fender and install the two re taining nuts 4 Position the wire lead in t...

Page 633: ...ROUP 15 Lighting System Horns And Instruments _INSTRUMENTVOLTAGE 4 1 b i SPEEDOMETER ASSEMBLY INSTRUMENT COVER LEN FUEL GAdGE INSTRUMENT MASK d P k INSTRUMENT C I I n b FIG 13 Falcon InstrumentCluster...

Page 634: ...CONVENIENCE CONT INSTRUMENT CLUSTER HOUSING BACK VIEW LIGHT OPENINGS INSTRUMENT CLUSTER HOUSING FRONT VIEW INSTRUMENT MASK HEATER CONTROL OPENING I_ l INSTRUMENT COVER LENS INSTRUMENT FINISH COVER FI...

Page 635: ...RGE INDICATOR GAUGE TERMINALS FUEL GAUGE TERMINALS INSTRUMENT CLUSTER HOUSING BACK VIEW INSTRUMENT CLUSTER HOUSING FRONT VIEW SPEEDOMETER ASSEMBLY FUEL AND CHARGE INDICATOR GAUGES COVER LENS AND MASK...

Page 636: ...RESSURE GAUGE TERMINALS TERMINALS FUE INSTRUMENT CLUSTER HOUSING BACK VIEW REGULATOR CHARGE INDICATOR GAUGE TERMINALS FUEL GAUGE AN0 CHARGE SPEEDOMETER ASSEMBLY INCICATOR GAUGE CLOCK OPENING OIL PRESS...

Page 637: ...ens seal to the light body 8 Position the lens and door as sembly to the light body and install the ten retaining nuts 9 Instali the rubber ring gaskets in the bulb openings Cement the outer seal to t...

Page 638: ...tment door TAILLIGHT AND OR BACK UP LIGHT BODY BULB DOOR AND OR LENS MONTEGO EXCEPT MODEL 71 1 Open the luggage compartment door and position the spare tire to the side if necessary 2 Unplug the back...

Page 639: ...it stops 10 Install the spare tire and check the operation of the lights TAILLIGHT LENS COUGAR 1 Remove the luggage compart ment rear trim panel 2 Remove the four bulb and socket assemblies from the...

Page 640: ...d turn the horn ring and remove the horn ring and spring 4 Remove the steering wheel Refer to Group 3 5 Remove the screw retaining the light socket to the steering column and position the socket out R...

Page 641: ...Signal Clock Turn Signal Indicator Courtesy Light Hand Brake Signal Radio AM I Console Linht 1 1816 1 3C 1 Montego I I I Low Fuel War ninn 1 1895 1 2C I Bulb No 194 194 194 194 1895 1178 A Bulb No 18...

Page 642: ...ts The turn indicator flasher is lo cated in the back of the instrument panel The emergency warning flasher is located on the right side of the upper steering column hub On the Mustang the flasher is...

Page 643: ...ed circuits combine to provide a constant feed circuit to the right or left coil in the turn signal relay This provides a constant feed to the indicator bulb of the turn selected The turn signal relay...

Page 644: ...HT TURN SIGNAL OR EMERGENCY FLASHER LEFT OR RIGHT INDICATOR BULB INOPERATIVE ONE INDICATOR BULB LIGHTS STEADY BUT DOES NOT FLASH BOTH INDICATOR BULBS LIGHT STEADY BUT DO NOT FLASH FIG 4 Sequential Tur...

Page 645: ...turn signal switch 2 Open connection at turn signal 6 Defective turn signal switch flasher 7 Broken shorted or loose wires 3 Loose or broken wire frdm from switch to lights ignition switch to flasher...

Page 646: ...turn signals for proper operation 10 Install the quarter panel well cover and floor mat TURN SIGNAL EMERGENCY WARNING FLASHER SWITCH FIXED STEERING COLUMN REMOVAL 1 Disconnect the battery ground nega...

Page 647: ...t from the connector block Tape the wires together and attach a piece of heavy cord to the wires to help pull the wires through the steer ing column during installation 10 Remove the plastic cover fro...

Page 648: ...ct the wiring connector from the flasher unit Connect the wiring connector to the replacement unit and replace the unit in its holder TURN SIGNAL FLASHER UNIT MUSTANG 1 ing ing If equipped with air co...

Page 649: ...48 Low Fuel Level Warning System 15 41 Mustang Cougar and Cougar XR 7 15 49 Oil Pressure Indicator Gauge 15 42 Speedometer Shaft All 15 49 Oil Pressure Indicating Light 15 42 Speedometer Shaft and Ho...

Page 650: ...sating voltage from causing radio interference a ra dio suppression choke is connected in series with the instrument voltage reg ulator supplywire LOW FUEL LEVEL WARNING SYSTEM The low fuel level warn...

Page 651: ...open circuit in the wiring harness from the sender switch B R A K E LIGHer to the proof terminal of the ignition NOT GO O U T WITH THE switch Repair the circuit as required G N T O N O N A N D BRAKES...

Page 652: ...st light If Connections Not OK Repair the loose connection If Socket Voltage No OK If Connections0K Check and repair the power source lead to the socket If Light Check Not OK Replace the IVR Using a 1...

Page 653: ...If the gauge operates properly check the wiring harness for a possi ble short and repair as required If Prove Out Circuit OK If Light Prove Out Not OK Perform a continuity test on the ignition switch...

Page 654: ...e ignition switch Repair or re place the circuit as necessary If Voltage OK Check the bulb If Bulb Not OK Replace the bulb Check the continuity from the bulb to the oil pressure switch If Continuity N...

Page 655: ...s 2 Speedometer head out of cali bration 3 System is within normal pro duction tolerance no defect 1 Needle hangs up at zero due to grease or foreign material on speedo meter needle zero stop CHARGE I...

Page 656: ...ENT VOLTAGE REGULATOR GAUGE CALIBRATION TEST When the instrument voltage regu lator or gauge is suspected of being out of calibration having a fluctuating movement or a high or low reading both the ga...

Page 657: ...speedometer gears to use for various rear axle and tire size combinations TEMPERATURE COLD A N D HOT INDICATING LIGHTS TEST During the test procedure do not apply 12 volts directly to the tempera tur...

Page 658: ...stalling a new cable and housing it is necessary that extra care be taken to see that the new assembly is guided and routed properly to elim inate any kinks 4 Proper lubrication of the cable core is a...

Page 659: ...vers and four rubber spacers will come off with the mask and lens Fig 12 Part I 6 Remove the four screws and two nuts retaining the fuel gauge and hous ing to the cluster and remove the gauge and hous...

Page 660: ...l FUEL SENDING UNIT 1 Remove the fuel from the fuel tank 2 Disconnect the fuel gauge send ing unit wire from the sending unit 3 Loosen the hose clamp and dis connect the tank line at the sending unit...

Page 661: ...R 8 MUSTANG IGNITION SWITCH I CIGAR LIGHTER SOCKET AND RETAINER WINDSHIELD WIPER CONTROL 111 W l I WINDSHIELD WIPER CONTROL BEZEL NUT WINDSHIELD WIPER CONTROL RETAINING NUT WINDSHIELDWIPER CONTROL KNO...

Page 662: ...ve the instrument cluster assembly 9 To install position the cluster assembly on the steering column and connect the multiple connectors 1 0 Position the cluster assembly to the instrument panel and i...

Page 663: ...ition then position the switch to the lower end of the park ing brake control rod and loosely install the retaining nut and bolt 4 Connect the lead wire to the switch assembly 5 With the parking brake...

Page 664: ...speedometer the housing SPEEDOMETER MUSTANG COUGAR AND COUGAR XR 7 1 Disconnect the battery ground cable from the battery 2 Remove the instrument cluster assembly Remove the trip reset knob if so equi...

Page 665: ...15 50 GROUP 15 Lighting System Horns And Instruments LOCATICN AT ASSY STANDARD TRANS MUSTANG AND COUGAR SPEEDOMETER CABLE ROUTING K2183 A FIG 12 Mustang and Cougar Speedometer Cable Routing...

Page 666: ...ent Cluster Gauges And Controls 15 51 17260 ASSEMBLY AUTO TRANS ROUTING 17260 ASSY REF SPEEDOMETER DRIVEN GEAR SPEEDOMETER ASSY R SPEEDOMETER AIR COND DUCT FIG 13 Fairlane Falcon and Montego Speedomet...

Page 667: ...REGULATOR TACHOMETER BACK VIEW INSTRUMENT CLUSTER HOUSING FRONT VIEW ELECTRIC TACHCMETER ASSEMBLY FIG 74 Fairlane Instrument Cluster With Tachometer CLOCK 8 CONVENIENCE CONTROL LIGHTS ASSEMBLY FRONT V...

Page 668: ...retaining screws In stall the clock control knob 2 Connect the electrical connec tors to the clock or tachometer 3 Position the cluster to the instrument panel and install the eight retaining screws 4...

Page 669: ...pedal with a pumping action to eject a spray of water onto the windshield glass The washer pump system is co or dinated with the windshield wipers by means of a switch attached to the washer pump whic...

Page 670: ...SKETCH 1 START OF INTERMllTENT OPERATION SKETCH 2 WlPER IN OWELL INSTRUMENT PANEL CONTROL SELECTOR SKETCH 3 CONTINUOUS WlPER OPERATION WRING ENGINE ACCELERATION LOWERED VACUUM NORMALVACUUM 1 ATmsPHER...

Page 671: ...Windshield Washer System Trouble DiagnosisGuide WASHER DOES NOT OPERATE WHEN PEDAL IS ACTUATED WASHER OPERATES BUT WIPERS D O NOT Verifythe 3 Possible cracks in pump bel 1 Clogged windshieldjets lows...

Page 672: ...r correct linkage on the the wires and repair or replace the vehicle then disconnect the linkage defective wiring MONTECO INTERMITTENT SYSTEM WlPER SWI TCH CIRCUIT BREAKER TEST Connect the variable re...

Page 673: ...n g chort Reploce the switch i f it does not meet the specified requirements 9 SWITCHPOSITION CONTINUITY BETWE TERMINALS Off Pork 65 763 56 63 5841 Low 6143 763 56 58 High 61 763 56 50 Wosher On 763...

Page 674: ...er to Wiper Switch Circuit Breaker Test MOTOR PARK SWITCH TEST Stop the wiper system with the ignition switch so that the wiper blades are not in park position Con nect jumper wires as shown in Fig 12...

Page 675: ...the hard shell con nector With the pump pedal in the normal released position the test light should be out then by depressing the pump pedal the light should turn on If the light turns on the low spe...

Page 676: ...ON ONLY WASHER SWITCH TERMIHAL MONTEGO ANDCOUGAR CONNECT TO POSITIVE TERMINAL OF BATTERY NG 12 Wiper Motor Park Switch Test Connections F R W INSTRUMENT PANEL SWITCH FIG 13 Windshield TURN WIPER AND W...

Page 677: ...nnector from the pump and remove the pump 4 Connect the two hoses and one multiple connector to the pump Po sition the pump assembly to the dash panel and install the four retaining screws 5 Position...

Page 678: ...drive 8 lnstall the heater control as sembly 9 lnstall the arm and blade as sembly RIGHT SlDE 1 Disconnect the battery ground cable from the battery 2 Remove the wiper arm and blade assembly 3 Remove...

Page 679: ...he wiper switch plug from the switch 2 Position the switch assembly 3 Remove the two screws retain 5 MAJOR REPAIRS AND CLEANING AND INSPECTION WIPER MOTOR DISASSEMBLY 1 Remove the gear cover retain in...

Page 680: ...sh springs and brushes in the holders and wrap wire around them to hold them in the fully retracted position Push the in sulated brush connector onto the switch terminal 6 Place the switch contact to...

Page 681: ...anel for the Falcon Fairlane and Montego is mollnted oh the dash panel above the h adlight dimmer switch On the Mustang and Cougar the fuse panel is mounted above the accelerator pedal Eig 1 shows the...

Page 682: ...ltage regulator and washer pump Position the ground wire at the regulator and install the retain ing screw 7 Push the block connector into place in the dash Connect the plugs to the wiper motor and th...

Page 683: ...18 Part I 3 Remove the eight screws re taining the cluster to the instrument panel Position the cluster out and disconnect the speedometer cable Also disconnect the multiple plug to the luster multipl...

Page 684: ...ash tray bulb 1I Remove the ground screw on the lower edge of the instrument panel Disconnect the glove compartment light connector the right courtesy light connector right courtesy light switch the...

Page 685: ...h and the radio feed 5 Connect the feeds to the turn signal flasher unit and steering column connector 6 Connect the connectors to the wiper washer switch headlight switch and the 14405 wiring assembl...

Page 686: ...d Power Seats a 30 Amp Fuse in Fuse Panel o 30 Amp Fuse in Bracket Attached t o Fuse Panel Location I n Headlight Switch I n Headlight Switch Transmission Select or Light Console Parking Brake Warning...

Page 687: ......

Page 688: ...ilating Heating And Accessories DEFROSTER NOZZLE FOR FAIRLANE AND FALCON SECTION AA FIG I Heater Assembly Montego Falcon and Fairlane RIGHT DEFROSTER NOZZLE HEATER CONTROL ASSY A S FIG 2 Heater Assemb...

Page 689: ...in the blower motor circuit controls the low and medium blower speeds The nomenclature for the Fairlane heater controls is located on the lower right side of the instrument DEFROSTER OUTLETS TEMPERATU...

Page 690: ...5 Heater System Mustang Cougar defroster registers The TEMP lever operates the blend sir valve in the heater blower housing The blend air door controls the amount of air flow through the heater core...

Page 691: ...M Bowden cable operated vents and air inlets are adjusted so that the vents are tightly closed when the control knobs are all the way in Loosen the Bowden cable retaining screw at the vent control arm...

Page 692: ...cable at the heater case by aligning the crank arm Fig I with the locating dart directly below the crank arm on the case With the crank arm in this position the heat defrost door is in a horizontal p...

Page 693: ...ct the hoses at the intake manifold and at the water pump 8 Position the hose in the clamp on the choke housing and tighten the screws 9 Fill the cooling system connect the battery ground cable and ch...

Page 694: ...e temperature and defroster cables and install the clip retaining the heater to the defroster nozzle 7 Install the right air duct and install the control cable to the in strument panel 8 Install the g...

Page 695: ...o obtain full off position with inch overtravel to insure a positive shut off 5 Connect the battery ground cable HEATER TEMPERATURE CONTROL CABLE AND OR DEFROSTER CONTROL CABLE FAIRLANE 1 Disconnect t...

Page 696: ...hose clamp over the hose and connekt it to theheater 7 Install the glove box Connect the desfroster hose to the heater Connect the heater hose to the intake manifold or water pump Figs 8 or 9 and fill...

Page 697: ...d Cougar 16 25 Functional Control Lever Does Not Operate A C Doors Properly in Heat Position Mustang and Cougar 16 26 Section Page Functional Control Lever Does Not Operate A C Doors Properly in Defro...

Page 698: ...e leading to two openings in the instrument panel is attached directly in the plenum chamber with a clip The A C registers located in the 1814 C lower instrument panel are located one to the far left...

Page 699: ...for air deflection and can be closed by rotating the lever below each register 90 degrees Warm air is discharged through openings in the heater plenum over the tunnel to both right and left front floo...

Page 700: ...16 14 GROUP 16 Ventilating Heating And Accessories FIG 5 Heater and Air Conditioner Air low Mustang and Cougar...

Page 701: ...arge cold air to the cen ter of the left front floor area A de flector on the tube can be positioned manually for driver comfort The two outboard registers can be closed by a push pull knob and lever...

Page 702: ...temperature The restricting effect of the expan sion valve at the evaporator causes a low pressure on the low pressure side of the system of 12 to 50 psi depend ing on the surrounding air tempera tur...

Page 703: ...rigerant 12 is readily absorbed by most types of oil t i s therefore recommended that a bbttle of sterile mineral oil and a quantity of weak boric acid solution be kept nearby when servicing the air c...

Page 704: ...Air Temp OF 43 48 55 63 45 51 59 67 47 54 62 72 49 57 66 77 51 60 70 82 53 63 73 88 55 65 77 58 68 81 Verify the complaint Discuss the A C system with the owner to pin point the specific complaint an...

Page 705: ...ll Check Clean air passages in condenser if required If ambient temperatures are ex cessively high cool the condenser during checking operation Eliminate iestrictions to condenser air flow If system p...

Page 706: ...o the water valve On all except Ford models the water valve should be closed at zero vacuum Check to make sure the valve is closed to water flow If the valve is not closed with the proper vac uum appl...

Page 707: ...eplaced Visually check the clutch brush set for wear or broken brushes Check for foreign material on the commutator ring IF NOT OK Ground one test lamp probe Move the other probe to the L M and H term...

Page 708: ...ise dis appears Verify the complaint Apply the parking brake Position the transmis sion lever in the park position Start the engine and operate it at 1500 RPM Operate the blower at high speed Move the...

Page 709: ...nd plenum chamber con tact surfaces with Lubriplate Lubri cate door pivot points If door was not obstructed or binding replace the applicable door motor Check the doors and control system for proper o...

Page 710: ...r con tact surfaces with Lubriplate Lubri cate door pivot points If door was not obstructed or binding replace the applicable door motor Check the doors and control system for proper operation TEMPERA...

Page 711: ...oor motor and the reheat door motor If vacuum is present check for improper crossed or leaking hose connections at the T connector if so equipped and at the control assembly Vacuum should be present a...

Page 712: ...recircul ating door motor check the door operation by hand for a bind ing or obstructed condition If vacuum is present at the A C heat door motor A C defrost door motor and the reheat door motor chec...

Page 713: ...ful in removing small traces of refrig erant vapor USE O F SIGHT GLASS Clean the sight glass before check ing for a proper charge of refrigerant Then observe the sight glass for LOW PRESSURE GAUCE HlG...

Page 714: ...re caused by an overcharge of refrigerant condenser air passages clogged a restriction between the condenser inlet and the receiver or high surrounding air temperatures Check the condenser fins for di...

Page 715: ...an is empty no frost showing close the valve remove the empty can attach a new one and open the valve again Allow only the specified amount of refrigerant to be pumped into the system Part 16 5 The fr...

Page 716: ...back to the compressor draw out the ex cess oil until the minimum quantity is indicated Replace the oil filler plug evacuate and connect the compressor 7 8 MIN 1 3 16 MAX I back into the system Opera...

Page 717: ...hten the adjusting nuts 0 4 Install the heater air condi tioner in the vehicle 5 Adjust the temperature cable turnbuckle with the temperature con trol in the minimum heat position Allow approximately...

Page 718: ...Heating And Accessories I WATER VALVES DRYER ASSY 8 CYLINDER 6 CYLINDER FIG 19 Air Conditioner Installation Engine Compartment Falcon Fairlane and Montego FIG 20 Heater Air Conditioner Installation F...

Page 719: ...r air duct support bracket to the defroster nozzle and remove the center air duct Fig 22 22 Remove two defroster nozzle attaching screws and remove the de froster nozzle Fig 21 23 Remove four nuts ret...

Page 720: ...heater air condi tioner assembly and place it on a bench 2 Remove 21 screws and 6 clips and seperate the evaporator housing 3 Slip the heater core out of the plenum 4 Slip the new core with seal into...

Page 721: ...switch to the evaporator case and install the two attaching screws 3 Connect the wires to the ther mostatic switch 4 Install the glove box liner and check the operation of the ther mostatic switch EX...

Page 722: ...able to the control assembly Fig 3 2 Position the control assembly to the instrument panel and install the attaching screws 3 Position the wiring harness to the control assembly and install the two cl...

Page 723: ...tank hose and connect the compressor to condenser hose 9 Install the hood latch and sup port and install both grille upper supports 10 Install the clip holding the hoses together at the radiator sup...

Page 724: ...shipping plugs first Tighten the service valve nuts to specification Part 16 5 Do not over tighten The new ROTO LOK service valves can be rotated slightly on their seat without breaking the high pres...

Page 725: ...tightened to a torque of 20 24 ft lb 10 Inspect the top of the cylinder head service valve ports to be sure that they are free of nicks and im perfections 11 Replace the service valve port Teflon wash...

Page 726: ...the carbon ring Then install the cap screws Tighten the cap screws evenly while turning the crankshaft Be sure that the clear ance between the crankshafl and the hole in the seal cover plate is even a...

Page 727: ...ontrol ON OFF switch is pulled out to the on position elec trical power is supplied to the turn signal lever set speed switch and the speed control regulator assembly Within the regulator assembly ele...

Page 728: ...ered test good electrical contact iight between the connector termin als There should be continuity be tween the center terminalof the con nector and the violet wire terminal There should be no contin...

Page 729: ...d test light to the two switch terminals 3 Depress the brake pedal The switch should show continuity If it does not it is defective 3 REMOVAL AND INSTALLATION ON OFF SWITCH REMOVAL 1 Loosen the knob s...

Page 730: ...Connect the ground wire and connector plug to the relay SERVO ASSEMBLY BELLOWS REMOVAL FIG 2 Turn Signal Switch Lever Installation 1 Disconnect the vacuum hose from the servo Fig 4 Plug the vac uum ho...

Page 731: ...s and or secure connections as required I Trouble ON OFF SWITCH WILL NOT OPERATE SWITCH WORKS BUT SYSTEM WILL NOT OPERATE PossibleCause Verify the complaint 1 Fuse blown 2 Defective wiring 3 Defective...

Page 732: ...es bellows or kinked vacuum hoses Verify the complaint 1 Upper speedometer cable be tween speed control regulator and speedometer defective 2 Defective speedometer head Verify the complaint 1 Defectiv...

Page 733: ...ntrol and five station selecting push but tons The push buttons which are located below the radio dial can be pre set to any stations desiied Refer to Section 3 for the push button ad justment procedu...

Page 734: ...oors on Mustang and Cougar Models and in the side cowl panels on other models Balance between the two speakers is controlled by the ring knob located behind the manual tuning control Fig 3 If optional...

Page 735: ...5P 18805 A is designed for in the car use to rapid ly diagnose radio malfunctions to de termine if the problem is in the radio antenna or the speaker The radio tester can save considerable time in ser...

Page 736: ...lead for defects Repair or replace speaker as required if a strong signal tone is heard from tester or if the speaker rattles Re pair or replace radio as required if a strong signal tone is not heard...

Page 737: ...ridge door open and clean the playback head with a cotton swab slightly moistened with alcohol also swab the surface of the capstan shaft with alcohol while ro tating the flywheel with fingers See not...

Page 738: ...speaker power and cable antenna wires to the radio chassis 2 Remove the rear support bracket 2 Position the radio to the in attaching nut strument panel and install the two 3 Remove four screws that...

Page 739: ...he in strument panel pad and install the two tetaining nuts 2 Position the instrument panel pad on the instrument panel and con nect the radio speaker and clock wires 3 Position the pad in place and i...

Page 740: ...on the left rear trim panel Remove the trim panel to replace the speaker FRONT SPEAKER MUSTANG AND COUGAR I Disconnect the battery ground cable 2 Remove the radio from the in strument panel and positi...

Page 741: ...tang and Cougar F A I R L A N E F A L C O N K 2175 A FIG 7 Radio Suppression Choke Installation CONDENSER TAPE 6 C Y L I N D E R E N G I N E V I E W S H O W I N G FUSE PANEL AND I N S T A L L A T I O...

Page 742: ...tween Fan Pulley and Air Conditioner Compressor New 140 Used 9 110 Compressor Clutch Run Out 1 32 Inch Maximum o Use Texaco Capella E or equivalent Belt Operated for a Minimum of 10 Minutes is consid...

Page 743: ......

Page 744: ...FIG I Montego and Falcon Underbody Dimensions I...

Page 745: ...ks in the bent part Never sealer from the surfaces to be ce tional frame and The heat the area more than a dull red merited For best results apply a application heat and the use medium coat of cement...

Page 746: ...EPUAL DIMENSIONS UNDER 100 HAVE A TOLERANCE OF M EXCEPT AS SHOWN DMENSIONS OVER 100 HAVE A TOLERANCE OF 12 UPPER SUSPENSION FRONT MOUNTING HOLE t REAR SPRING REAR SPRING REARHANGERHOLE L S R V V L n...

Page 747: ...screws located on such assemblies as the doors hood and deck lid does not eliminate the rat tles the trouble is probably caused by misalignment If this is the case follow the adjustment and alignment...

Page 748: ...ised slowly REAR FRAME CONTACT AREA FLOOR JACKCONTACTAREA M1112 6 and the position of the adapters checked FORK LIFT TWIN POST HOIST To assure safe hoisting the front p b t adapters must be positioned...

Page 749: ...time and labor Inspection should also reveal any area of the vehicle which might have a soft enamel finish because of previous repairs In such cases the strong sol vents in the repair paints would ten...

Page 750: ...I L i I L T GROUP 17 o d o o r s And windo ws R A N n O M R I I C T F R S I PITS AND POP UPS I RUNS AND SAGS I 3 i...

Page 751: ...bination of sand ing polishing and buffing OVERSPRAY Overspray is the term applied to the appearance of small particles of con trasting color on painted or bright metal surfaces If it is excessive on...

Page 752: ...ll develop spots that are nearly black etc In the more seriously affected areas it is recommended that all vehicles be washed and inspected on arrival Ve hicles that are kept in outside storage should...

Page 753: ...beyond the polished area to blend it into the original finish If the defect is one which protrudes above the surface sag chunk of dirt etc it may be necessary to level it off before polishing This can...

Page 754: ...ainers of paint which have recent ly been packaged If the material is cold or if it has been in storage for a considerable period the agitation time required will be longer If a rocker or shaker type...

Page 755: ...remely fast drying they are designed to flow out and dry to a full gloss This should match the gloss of the original finish without the necessity for polishing However due to adverse weather condition...

Page 756: ...h heat these dry ing times and temperature should con form to those specified by the sup plier 9 Polish touch up and buff the repair spot as described under panel repair with acrylic lacquer Interior...

Page 757: ...material sprayed will have a different color than if brushed dipped or flow coated Drying is necessary since a wet film will have a different color than one which has been allowed to dry Polish the pa...

Page 758: ...ckward Peel the carrier paper self adhesive side from the end of the transfer tape to the center of the transfer tape and cut the carrier paper off 6 Allow the stripe transfer tape to fold back ir to...

Page 759: ...Air Driven Sander 3 Polishing Discs 4 Hand Rubbing Compound 5 Body Washing Detergent Comp 6 Silicone Wax Remover 7 Paint Remover 8 Acid Metal Conditioners For Steel For Zinc Galvanize 9 Primer Surface...

Page 760: ...17 18 GROUP 17 Body Doors And Windows...

Page 761: ...ns refer to the position of the hood when it is fully lowered The elongated bolt slots in the hinge at the hood provide the side to side adjustment The enlarged holes in the hinge at the fender apron...

Page 762: ...e latch up or doyn and from side to side as re quired for proper alignment with the hood latch hook 2 Tighten the hood latch attach ing bolts and check the operation and alignment of the latch Be sure...

Page 763: ...ch end of the grille to attach it to the headlight housings Fig 5 2 Install the two grille to grille support attaching screws 3 Install the two screws attaching the grille lower edge to the radiator s...

Page 764: ...17 22 GROUP 1 7 Body Doors And Windows FIG 6 Radiator Grille Installation Fairlane FIG 7 Mustang Grille and Related Parts...

Page 765: ...ven grille to stone deflector attaching screws 2 Install two screws attaching each end of the grille to the grille panel 3 Install the hood bumper on each side of the hood opening at the grille Fig 7...

Page 766: ...er 6 Remove two hinge support to radiator support attaching screws from under the left front fender 7 Remove two stone deflector to hinge support attaching screws Fig 8 8 Lower the vehicle and remove...

Page 767: ...MONTEGO REMOVAL I Remove two screws attaching I lnstall the anti rattlers license plate bracket and license plate on the bumper 2 Position the bumper to the ve hicle with spacers between the bumper an...

Page 768: ...17 26 GROUP 17 Body Doors And Windows SPACER 17A924 N 1674 A FIG 7 I Fairlane Front Bumper Installation I VIEW A N i3ebn FIG 72 Mustang Front Bumper lnstallation...

Page 769: ...BUMPER COUGAR REMOVAL I Raise the vehicle and remove two screws retaining each bumper guard to the bumper arm and frame and remove the bumper guards 2 Disconnect the parking light wires and remove the...

Page 770: ...crew and washer assemblies re taining the license plate support brack et to the impact bar Fig 15 and remove the license plate support bracket assembly from the impact bar 7 Remove the rubber license...

Page 771: ...lation Models 54 65 and 76 3 Remove the four bumper to I NSrALLATION mounting bracket retaining bolts and remove the brackets Fig 17 1 Position the license plate light 4 Remove the two license plate a...

Page 772: ...e two bolts and nuts attaching each mounting bracket to the bumper and remove the brack ets from the bumper 4 Remove the anti squeak pads from each end of the bumper INSTALLATION 1 Install the anti sq...

Page 773: ...er used whether a re spective door quarter or luggage compartment trim panel must first be removed to provide access Figs 20 through 4 I FIG 18 Cougar Rear Bumper Installation CLIP 371141 532 WE TYPIC...

Page 774: ...y Doors And Windows M O D E L S 548 62B C 7 1 8 N1 4 7 5 C FIG 20 Falcon Exterior Front Mouldings M O D E L S 628 C M O D E L 5 4 8 M O D E L S 54A 62A O N L Y N1368 E FIG 27 Falcon Exterior Side Moul...

Page 775: ...mpers And Exterior Mouldings 17 33 N1370 E FIG 22 Falcon Exterior Side Mouldings Model 71 M O D E L S 5 4 8 628 C SHOWN M O D E L S S4A 62A T Y P I C A L M O D E L 7 1 A 8 N 1 3 7 2 E FIG 23 Falcon Ex...

Page 776: ...17 34 GROUP 17 Body Doors And Windows N147b C FIG 24 Fairlane Exterior Front Mouldings FIG 25 Fairlane Exterior Side Mouldings Models 5 4 2 L65C...

Page 777: ...17 3 Front End Bumpers And Exterior Mouldings 17 35 MODEL 630 N1477 C FIG 26 Fairlane Exterior Side Mouldings Models 63D 65D 8 76D MODEL 710 R P 0 MODEL 71D FIG 27 Fairlane Exterior Side Mouldings Mod...

Page 778: ...s And Windows MODELS 65 A B E SHOWN MODELS 63 8 E 76 B E TYPICAL MODELS 54A 8 N1382 E FIG 28 Fairlane Exterior Side Mouldings Models 54A 8 B 638 8 E 65A B 8 E 76B 8 E FIG 29 Fairlane Exterior Side and...

Page 779: ...PART 17 3 Front End Bumpers And Exterior Mouldings 17 37 FIG 30 Fairlane Exterior Rear Mouldings...

Page 780: ...Doors And Windows M O D E L 54C D 6 M O D E L 63A C H J 65F GH J M O D E L 7 1 8 N 1 3 7 4 E FIG 31 Montego Exterior Front side Mouldings M O D E L S65A 8 FIG 32 Montego Exterior Side Mouldings Models...

Page 781: ...W N M O D E L S 6 3 A G H J T Y P I C A L FIG 33 Montego Exterior Side Mouldings Models 63A C H 8 J 65F G H 8 J 71C M O D E L S 6 5 C D ES H O W N M O D E L 76BD T Y P I C A L M O D E L S 1 4 G D N 1...

Page 782: ...ws STD PROD M O D E L S 54GB65GBE F GH J 76BD R P O M O D E L S S 4 B 6 5 B M O D E L S S 4 A w B NlJ17 E FIG 35 Montego Exterior Rear Mouldings Except Models 63 and 71 FIG 36 Montego Exterior Rear Mo...

Page 783: ...PART 17 3 Front End Bumpers And Exterior Mouldings 17 4 1 FIG 37 Mustang Exterior Front Mouldings N1416 C FIG 38 Mustang Exterior Side Mouldings...

Page 784: ...17 42 GROUP 17 Body Doors And Windows MODELS 45 76 MODEL 63 FIG 39 Mustang Exterior Rear Mouldings FIG 40 Cougar Front and Side Exterior Mouldings...

Page 785: ...PART 17 3 Front End Bumpers And Exterior Mouldings 17 43 NG 41 Cougar Rear Exterior Mouldings...

Page 786: ...s Fairlane and Montego Models 63 65 66 and 76 17 57 Front Door Window Glass Mustang and Cougar 17 58 Section Page Front Door Window Regulator Manual Windows Montego Falcon Fairlane Models 54 and 71 17...

Page 787: ...ct a voltmeter from a ground to the red wire terminal of the power window relay If no volt age is available repair or replace the 20 ampere fuse the ignition switch or the wire from the ignition switc...

Page 788: ...own against the stop on the glass channel Then tighten the two stop attaching screws DOOR GLASS TILT 1 Loosen the front and rear run retainer attaching screws Item N and S Fig 2 2 With the glass up po...

Page 789: ...Window Mechanisms 17 47 APPLY AN EVEN COATING OF POLYETHYLENE GREASE C4AZ 19584 A TO ALL WINDOW REGULATOR ROLLERS SHAFTS AND THE ENTIRE LENGTH OF ROLLER GUIDES AS ILLUS RATED BY THE WADED AREAS FIG I...

Page 790: ...ems F and G Fig 5 6 Position the vent window and division bar run rearward toward the door glass Then tilt the vent win dow fore and aft as necessary to ob tain a parallel relationship to the FIG 2 Fr...

Page 791: ...PART 17 4 Windshield Window Glass And Window Mechanisms 1749 FIG 3 Front Door Window Mechanism Models 54 and 71...

Page 792: ...17150 GROUP 17 Body Doors And Windows FIG 4 Door Window Mechanism Model 62 FIG 5 Door Window Glass Adjustment Mustang and Cougar...

Page 793: ...er the window half way down Position the rear run retainer and division bar for proper alignment with the door window frame Then tighten screw and washer assemblies U and R Fig 8 securely 7 Install th...

Page 794: ...backward and up or down at screws A Fig I I to obtain a 0 28 inch parallel dimen sion between the front edge of the quarter window and the rear edge of the door window View AA Fig I I After adjustment...

Page 795: ...inner Hold the glass and disengage the cover panel attaching screws panel up and off the tailgate regulator arm brackets from the 2 Remove the two glass opening 5 Remove the water shield from glass c...

Page 796: ...qsnq 8u ds lnu aql aAomax 8 a1 pue unJ l u o jaql aAomax S f S d lnuq3ol pue M J S u lsnrpe Jam01 Jeq uo s pm o p u luaA aql aAomax p wmop dem aql Ile ssq8 aql Jam01 pue dols Jam01 ssel8 a q aAomax C...

Page 797: ...lator to the door in ner panel Support the glass and channel assembly and lay the regulator in the bottom of the door 8 Remove the front run and retain er from the vent window division bar 9 Remove th...

Page 798: ...in the glass runs 6 lnstall the vent window division bar lower adjusting screw and nut 7 lnstall the rubber bumper in the lower stop and adjust the door window glass mechanism Section 2 8 lnstall the...

Page 799: ...remove the front and rear guide 5 Remove two screws attaching the glass channel bracket to the glass channel Fig 14 6 Remove the nut retaining the window regulator arm to the glass channel at the piv...

Page 800: ...install the four attaching screws 4 Install the watershield and trim panel on the door FRONT DOOR WINDOW REGULATOR AND OR MOTOR MONTEGO AND FAIRLANE MODELS 5 4 AND 71 REMOVAL 1 Remove the trim panel a...

Page 801: ...r panel and install the retaining nut 5 Position the glass channel bracket to the window regulator arm and the glass channel Install the two glass channel bracket attaching screws 6 Connect the motor...

Page 802: ...AND MONTEGO MODELS 63 65 66 AND 76 1 Remove the trim panel and watershield from the door 2 Remove two screws attaching the guide to the glass channel Fig 14 3 Disengage the guide from the run and rem...

Page 803: ...3 Install the belt weatherstrip in the door 4 Position the front and rear roller carriers to the glass channel and install the two attaching screws Fig 15 5 Position the glass channel bracket to the g...

Page 804: ...r run out of the retainer and away from the division bar 7 Remove the glass run retainer and division bar from the door 8 Pull the stationary glass and weatheistrip from the door 9 Remove the weathers...

Page 805: ...glass channel and install the three attaching screws 7 Connect the motor wires at the connector 8 Remove the window support and check the operation of the window mechanism 9 Install the watershield an...

Page 806: ...arter glass and channel assembly from the vehicle INSTALLATION REMOVAL 1 Remove the rear seat cushion and back 2 Remove the trim panel and po sition the water shield away from the access hole 3 Remove...

Page 807: ...l 5 Remove the roller from the window regulator arm 5 lnstall the upper stop and up per rear stop on the glass channel INSTALLATION Fig 17 6 Install the two rear guide up 1 Install the roller on the w...

Page 808: ...2 and tighten the guide assembly attaching screws 5 Install the quarter trim panel and the rear seat back and seat cushion QUARTER WINDOW REAR GUIDE MUSTANG AND COUGAR REMOVAL I Remove the quarter tr...

Page 809: ...glass channel Fig 17 12 Install the lock pillar seal 13 Adjust the quarter windowmech anism as outlined in Section 2 Install the watershield and quarter trim panel Group 18 1 Remove the quarter trim p...

Page 810: ...Doors And Windows WELD STUD PRIMER RETAINER 19562 424 13 VlEW A BUTYL TAPE 19562 1 4 INCH MINIMUM SPACER 03200 SIDE MOULDING I I I I VIEW H VIEW 0 FIG 19 Windshield and Moulding Installation Montego...

Page 811: ...t mould ing retainer attaching screws and re move the mouldings and retainers View D Fig 19 6 Remove the outside top mould ing with the tool shown in Fig 20 7 Remove the windshield interior upper garn...

Page 812: ...ndshield open ing View D Fig 22 11 Clean the body flanges of all butyl tape and perform sheet metal or paint repairs if necessary INSTALLATION REMOVAL 1 Lower the top and remove the windshield pillar...

Page 813: ...PART 17 4 Windshield Window Glass And Window Mechanisms 17 71 VIEW N VIEW F FIG 22 Windshield and Moulding Installation Montego and Fairlane Model 76...

Page 814: ...osition the windshield and weatherstrip assembly in the wind shield opening and with a helper applying pressure from the outside use the draw cord to pull the lip of the weatherstrip over the window o...

Page 815: ...sition the left and right front upper body pillar weatherstrip retainers Fig 24 and install the retaining screws 12 Install the front upper body pillar weatherstrips by pressing them securely into the...

Page 816: ...When the temperatures are below MEASURED FROM EDGE OF G L A S S K R 2 MINUTES EPOXY CATALYST SECTIONAL nm u MIRROR A S S E M B L Y R1171 A 67 degrees F the mirror and arm should not be mounted to the...

Page 817: ...ass and clean it thoroughly 4 Apply primer furnished in the butyl tape replacement kit C6AZ 19562 B to the glass opening flange Fig 27 5 Apply primer around the entire perimeter of the inside and edge...

Page 818: ...te moulding retention Repair or replace the retainers as necessary 2 Clean old sealer from the weatherstrip if the weatherstrip is to be re used 3 Apply sealer in the glass open ing groove of the weat...

Page 819: ...ning flange 9 Install the back window out side mouldings Figs 29 and 30 TAILGATE WINDOW GLASS REMOVAL 1 Open and temporarily support the tailgate 2 Remove the tailgate cover pan el retaining screws an...

Page 820: ...g bolts and remove the regu lator with the motor attached 3 Install the tallgate cover panel to the tailgate INSTALLATION 1 D o not remove the electric TAILGATE POWER WINDOW regulator drive assembly f...

Page 821: ...taining pin insert the key and rotate the cylinder until the retaining pin drops and then remove the lock cylinder INSTALLATION I To install the lock cylinder in sert the key in the lock cylinder and...

Page 822: ...WITCH FIG 33 Tailgate Power Window Switch Installation REMOVAL 1 Rem6ve the interior trim panel and access cover from the tailgate 2 Remove the glass and channel assembly from the tailgate 3 Remove th...

Page 823: ...d Cougar 17 97 Luggage Compartment Latch Fairlane Montego and Mustang 17 97 Luggage Compartment Lock Cylinder Fairlane Montego and Mustang 17 97 Luggage Compartment Lock Cylinder Falcon and Cougar 17...

Page 824: ...g rod Section 2 to obtain the speci fied dimension at the door outside handle FRONT DOOR LOCKS WHEN THE INSIDE LOCK PUSH BUTTON IS IN THE UNLOCKED UP POSITION Inspect the latch assembly to de termine...

Page 825: ...ARGINS MUST BE 2 SUBTRACT 02 FRO DIMENSIONS FOR EACH WINDOW MOULDING SECTION I1 DIMENSION WINDOW MOULDING IS USED 4 FENDER TO ROCKER PANEL MARGIN MUST BE CON SISTENT WITH FENDER TO DOOR MARGIN N 164 F...

Page 826: ...17 84 GROUP 17 Body Doors And Windows N 1650 A FIG 5 Body Clearance Dimensions Fairlane...

Page 827: ...06 3 ADD O2 TO DIMENSION X OF SECTION 9 WHEN O9 PERMISSABLE WITH FIBERGLASS HOOD ONLY WINDOW MOULDING IS USED 2 SUBTRACT 02 FRfY4 MARGIN DIMENSIONS FOR 4 FENDER TO ROCKER PANEL MARGIN MUST BE EACH WIN...

Page 828: ...ON A A MODEL 63 ONLY NOTE 1 MARGINSMUST BE PARALLEL WITHIN 06 2 SUBTRACT 02 FROM MARGIN OIMENSIONS FOR EACH WINDOW MOULDING 3 FENDER TO ROCKER PANEL MARGIN MUST BE CON SISTENT WITH FENDER TO DOOR MARG...

Page 829: ...LLEL WITHIN 06 2 SUBTRACT 02 FROM MARGIN DIMENSIONS FOR EACH WINDOW MOULDING 3 FENDER TO ROCKER PANEL MARGIN MUST BE CONSISTENT WITH FENDER TO DOOR MARGIN DIMENSIONS 0 p 7 1 qi 7 t 06 06 m FLUSH t 06...

Page 830: ...t with the cam when the latch is in the safety and open positions FRONT DOOR LATCH ACTUATING ROD ADJUSTMENT 1 Remove the door trim panel and watershield 2 Disconnect the latch actuating rod from the l...

Page 831: ...e the trim panel loosen the hinge to tailgate bolts and shift the tail gate as required DUAL ACTION TAILGATE ADJUSTMENTS While full adjustments are pro vided for the dual action tailgate no unique met...

Page 832: ...nding panels Care should be taken not to distort or mar the lug gage compartment door or sur rounding body panels LUGGAGE COMPARTMENT DOOR LATCH ADJUSTMENT The striker plate can be adjusted laterally...

Page 833: ...t not be more than one slot DOOR EMERGENCY OPENING PROCEDURE NG 17 Luggage Compartment Door Alignment Falcon Fairlane and Montego Typical If a door latch system is inoper ative and the door cannot be...

Page 834: ...17 92 GROUP 17 Body Doors And Windows FIG 19 Torsion Bar Adjustment Falcon Fairlane and Montego Typical I e d l WELDING ROD OR EQUIVALENT FIG 20 Latch Actuating Tool...

Page 835: ...FAIRLANE AND MONTEGO MODELS 63 65 66 AND 76 1 Remove five screws attaching the weatherstrip to the rear edge of the door at the belt line 2 Remove one screw attaching the weatherstrip to the front edg...

Page 836: ...lass runs or hardware When a door is replaced make any needed minor repairs to the new shell drill holes necessary for mouldings paint the door and transfer all usable parts Cement the weatherstrip pr...

Page 837: ...AD 22448 9 LOCK CONTROL KNOB 21850 9 LATCH ASSEMBLY 21812 3 3MMET 21999 I 1 1 RE OTE CONTROL LINK 21940 OUTSIDE HANDLE 26600 1 PAD 22448 9 REMOTE CONTROL LINK 26414 TCH ASSEMBLY 26412 3 FIG 22 Door Ha...

Page 838: ...nder is replaced both door lock cylinders and the ig nition lock cylinder should be re placed in a set This will avoid carrying an extra key which will fit only one lock 1 Remove the trim panel and po...

Page 839: ...ing bolts 2 Remove the protective cover and install the torsion bar reversing the procedure in step 3 above The farther rearward the anchor end is twisted the greater the tension 3 Remove the prop and...

Page 840: ...tension into the sleeve and cover making sure the extension is inserted into the slot of the latch Fig 24 SINGLE ACTION TAILGATE HINGE RIGHT SIDE REMOVAL 1 Open the tailgate and mark the hinge locati...

Page 841: ...PART 17 5 Doors And Tailgate 17 99 FIG 26 Tailgate Latch Mechanism Single Action...

Page 842: ...he giite and install the regulator arms to the regulator channel Close latch pawl to engage the switch and lower the window into the tailgate 9 Install the tailgate access panel watershield and trim p...

Page 843: ...Tailgate 17 101 RACKET 430A66 LOWER HINGE UPPER TO LOWER LATCH ACTUATING LlNK 431A24 43012 UPPER LATCH RELEASE LlNK 431D54 UPP ER HINGE LOCK RELEASE CONTROL 43170 R 1114 D I FIG 27 Tailgate Latch Mec...

Page 844: ...serting a small steel rod into the two holes in the switch assembly and spreading the spring clips outward Then slide the switch assembly off the latch han dle Fig 33 Part 16 4 4 Remove two nuts retai...

Page 845: ......

Page 846: ...ARNISH MOULDING SPACER Xz2WATERSHIELD 237A04 5 I RETAI ING CLIPS TRIM PANEL ASS Y 23942 375555SlOO WATERSHIELD 237A04 5 TRIM PANEL RETAINER 137 52 1 NG CLIPS 375553 5100 RETAINING C L I S 375529 52 TR...

Page 847: ...anel If necessary carefully loosen the door so equipped 7 If the door has power windows watershield 6 With a putty knife pry the disconnect the switch lead wires from FIG 3 Typical Door Trim Water Shi...

Page 848: ...OR TRlM PANEL REMOVAL 1 Remove the retaining screws from the window regulator handle and the inside door handle and re move the handles from their shafts Fig 5 2 Remove the two retaining screws from t...

Page 849: ...PART 18 1 Interior Trim And Roof Outside Cover 18 5 FIG MODEL 63 FIG 7 Quarter Trim Panel Falcon Fairlane Montego MODEL 62 R 1378 A...

Page 850: ...stalla tion procedure will cover all models 1 Remove the window regulator handle and the arm rest retaining screws and remove the handles from their shafts 2 Remove any screws retaining the trim panel...

Page 851: ...ion along the door edge of the trim panel 6 Position and install the upper trim panel cap and retaining screw if so equipped 7 lnstall the rear seat back and rear seat cushion QUARTER TRlM PANELS MODE...

Page 852: ...ard and install the rear 6 Position the rear seat back 7 Position the rear floor section seat back and seat cushion assembly and hinges and install the and install the retaining screws FIG 70 Rear Sea...

Page 853: ...trim panel back window flange and around the rear seat cushion 7 Remove the coat hooks and the mating headlining edge Tuck the 17 Steam between the headlining dome light lens assemblies headlining und...

Page 854: ...BROWN 52104 HEADLINING ASSEMBLY A B C D E F ADHESIVE C2AZ 19C525 A FIG 73 Headlining Installation Typical Station Wagon FIG 74 Headlining Installation Fairlane Montego Model 63 4 Remove 4 screws and...

Page 855: ...inside rear view mirror and sun visors 20 lnstall the right and left quar ter trim upper front panels Fig 1 I 21 Install the quarter trim upper front mouldings and front caps 22 lnstall the back windo...

Page 856: ...eading retainer at lining material under the windshield ter windd Pull the headlining down the A pillar ViewDD header weatherstrip to remove wrinkles and cement it in 22 Install the rear view mirror 1...

Page 857: ...d 3 Install the pad retaining screws remove the moulding 4 Position the glove compartment 2 Position the pad assembly to 4 Remove the seven screws which and install the glove compartment re the instru...

Page 858: ...r lighter Remove the receptacle as sembly from the instrument panel 5 Thru the receptacle opening remove the nut and washer retaining the inboard edge of the instrument cluster to the instrument panel...

Page 859: ...ur screws retain ing the heater control assembly to the instrument panel and position the assembly out of the panel 3 Thru the heater control open ing remove the nut retaining the lower left end of th...

Page 860: ...and install the retainer screws 12 Connect the battery PAD TOP INSTRUMENT M ULDING PANEL 04522 3 PAD SUPPORT 04282 045C72 FIG 21 Instrument Panel Pad Installation Mustang 4 CONSOLE CONSOLE MUSTANG AN...

Page 861: ...S 044E70 I UPPER PAD AND RETAINER ASS Y 045E06 SHIFT LEVER O P M l N PAD AND RETAINER ASS Y PAD AND RETAINER UPPER PAD AND RETAINER ASS Y 044E70 ASS Y 045E06 I FRONT FINISH PANEL 045844 I MUSTANG MODE...

Page 862: ...ctor to the console lamp wiring and connect the radio wiring 2 Position the radio and console assembly and install the six retain ing screws 3 Position the radio to its rear support bracket and instal...

Page 863: ...Black VR 1724 S White VR 1525 S Blue VR 1903 S Gold VR 1915 S Parchment VR 1631 S Brown VR 2045 S Dulling Agent VR 95F17 S Class V drop ship The above colors are packaged in quantities of 6 When order...

Page 864: ...be applied to scuffs or abrasions in most areas of the vinyl top Minor Surface Cuts i Connect the soldering iun and set the transformer heat range to No 7 position approximately 225 degrees F Clean t...

Page 865: ...ve as shown in Fig 33 It is not necessary to use cement if the cut is over a padded area Allow the adhesive to air dry for several minutes then carefully lay the material into the damaged area so that...

Page 866: ...es The following is a typical re pair of loose material at the blind quar ter area and generally applies to other areas such as around the backlite opening Partially or completely remove FIG 36 Expell...

Page 867: ...rovided this is done im mediately and the adhesive is not al lowed to age on the vinyl roof There fore it is imperative that the clean up is performed as soon as possible Fresh sealer smears can be re...

Page 868: ...particularly glassedges 13 Drill 5 32 inch holes approxi mately 5 inches apart in the top and sides of the rear window opening re cess Then install drive nails to retain the top at the back window Ap...

Page 869: ...make a clean circular cut around the moulding retainer weld studs 1I Apply adhesive CSAZ 19C 525 A to the windshield opening and the underside of the roof cover Make angle cuts as necessary at the cor...

Page 870: ...NAL SECTIONAL SECTIONAL 375461 VIEW BB VIEW AA VIEW FF R 1361 8 FIG 46 Outside Roof Cover installation cougar retainer from the drip rail trough windshield and back window openings not necessary to re...

Page 871: ...s approxi mately 5 inches apart across the top of the windshield opening recess with an awl Then install drive nails to re tain the top at the recess Apply sealer over the drive nail heads Cover the g...

Page 872: ...elts 18 41 Removal and Installation 18 41 5 Front Seat Headrest 18 45 Description and Operation 18 45 Guide Rod Adjustment and Replacement 18 45 Mounting Bracket and Check Assembly Replacement 18 45 1...

Page 873: ...back assem bly on the seat On vehicles with the split seat back install the hairpin clip at the seat center bracket and the seat cushion stud and install the pivot co vers 6 On a vehicle with a solid...

Page 874: ...e the rear seat cushion from the vehicle by lifting on the front of theseat and pulling it forward 2 Remove the cushion cover hog rings and remove the cushion cover from the seat frame 3 lnspect the p...

Page 875: ...EW AA COVER ASSEMBLY FIG 4 Front Seat Cover Installation Mustang Cougar A HOG RlNG 4 REQ D B HOG RING 4 REQ D C HOG RlNG 18 REQ D D HOG RlNG 16 REQ D E HOG RlNG 7 REQ D COVER ASSEMBLY 63804 FIG 5 Typi...

Page 876: ...18 32 GROUP 18 Trim Seats And Convertible Top FIG 6 Typical Front Seat Back Cover Installation 4 Door FIG 7 Typical Front Seat Back Cover Installation 2 Door...

Page 877: ...taining the seat back cover to the frame and remove the rear seat back cover 3 Transfer the listing wires to the new cover 4 Position the new cover on the pad and seat frame and secure it in place wit...

Page 878: ...AT TRACK The seat track assembly is easily replaced if the seat assembly is re moved from the vehicle 1 Remove 4 floor pan plug but tons to gain access to the seat track retaining nuts Mustang and Cou...

Page 879: ...hog rings as shown in Fig 13 9 Secure the rear edge of the co ver assembly to the bottom of the spring assembly with hog rings 10 Install the two scuff plates on the cushion 11 Install the seat back s...

Page 880: ...D EACH BOCSTER C HOG RlNG 6 REP D EACH BOLSTER D HOG RING 15 RFn n E HOG RING 7 REP D F HOG RlNG 5 REQ O ALONG READ G ADHESIVE CZAZ IPC525 A SCUFF PLATE 61643 ANTI RATTLER 63115 COVER ASSEMBLY 62WO FI...

Page 881: ...LY 64700 1 A HOG RlNG 19 REQ D SPRING ASSEMBLY B HOG RING 3 REQ D 64700 1 C HOG RlNG 5 REP D D HOG RING I7 REQ D E HOG RING 5 REQ D F HOG RING I2 REQ D G HOG RING 5 REP D K ADHESIVE C2AZ 19C525 A A HO...

Page 882: ...y a 20 ampere circuit breaker which is mounted on the starting motor relay in the engine compartment WUR WAY POWER SEAT DIAGNOSIS GUIDE Refer to Wiring Diagram Manual Form 7795P 68 for locations of wi...

Page 883: ...ight obstruct track movement 1 Test the relays as stated in Step 5 under Motor Will Not Operate Re place relay if found defective IF OK 2 Disconnect the switch wiring multiple connector Under the seat...

Page 884: ...wir ing loom at the quick disconnect and remove the seat assembly from the vehicle Fie 16 u 2 Remove the four bolts retaining the cushion assembly to the seat track and remove the assembly 3 Disengag...

Page 885: ...sembly taining nuts 4 Check the operation of the seat 4 SEAT BELTS SEAT BELT INSTALLATI O N belt retaining bolts must be torqued vehicle and must not be interchanged as shown in the figures between ve...

Page 886: ...GROUP 1 8 Trim Seats And Convertible Top BENCH SEAT SECTIONAL VIEW CC SECTIONAL VIEW AA MODEL 76 ONLY STATION WAGON f VIEW EE EXPLODED EXPLODED FIG 17 Seat Belt Installation Falcon Fairlane Montego...

Page 887: ...MBLY 611A72 WA SHER 382581 5100 BOLT 382516S100 WASHER 354959 5 WASHER 356420 52 FIG 18 Front Seat Belt Installation Mustang and Cougar VIEW CC MODELS 65 76 TORQUE RETAINING BOLTS TO 25 30 FT LEIS VIE...

Page 888: ...18 44 GROUP 18 Trim Seats And Convertible Top R STRAP I If FIG 20 Shoulder Strap Installation Falcon Fairlane Montego VIEW BB NG 21 Shoulder Strap Installation Mustang and Cougar...

Page 889: ...ck the rod off until the notches on the rod face the centerline of the seat 5 Loosen the locknut on the right guide rod and adjust the right rod so that the notches on both rods face each other and ar...

Page 890: ...OR BENCH SEATS HEADREST ASSEMBLY 611 GUIDE ROD SLEEVE 610A16 SLEEVE 610A16 MOUNTING BRACKET ASSEMBLY 610810 MOUNTING BOLT ASSEMBLY 610804 SECTIONAL VIEW AA 00 VIEW CC VIEW DD 2 DOOR AND 4 DOOR BENCH S...

Page 891: ...a scrub brush Be sure to rinse the top thoroughly with clean water during and after washing Do not use a cleaning material that is not recommended for vinyl material because damage to the top may resu...

Page 892: ...1 2 INCH V I E W C VIEW E FIG I Montego Fairlane Top Adjustments...

Page 893: ...replaced HYDRAULIC TESTS Faulty hydraulic system operation can be caused by lack of fluid leaks air in the system obstructibns or kinks in the hoses or faulty oper LIGHT REPAIRS be adjusted and secur...

Page 894: ...ted loosen the eccentric nut View B Fig 4 and rotate the eccentric pin to obtain a 318 inch parallel dimension between the front door glass and the front and center side rails 2 Hold the eccentric pin...

Page 895: ...he specified clearance for the top material to door glass frame is 118 inch Hold the eccentric and tighten the lock nut HOLD DOWN SIDE CLAMPS MANUAL TOP The hold down side clamp assem blies located on...

Page 896: ...the valve body 7 Install a new seal on the center bolt and install the reservoir cover on the valve body using the line pre viously scribed as a guide 8 Place the assembly in a hori zontal position f...

Page 897: ...stall the counterbalance rod retaining pin and washers 3 Install the quarter trim panel 4 Install the rear seat back and seat cushion BACK CURTAIN MONTEGO FAIRLANE 1 Unfasten the clamps that hold the...

Page 898: ...sition the new back curtain to the tacking strip Cut out the bolt hole locations on the back curtain 9 Position the back curtain as sembly into the vehicle and tack the webbing and quarter assembly to...

Page 899: ...and left case assembly and the roof bow then remove the staples retain ing the right and left case assembly tothe rear roof bow 6 Mark the location of the zipper center at the rear roof bow with tail...

Page 900: ...and back curtain 2 Staple them to the new top and back curtain in the same location as they were on the old top 3 Center the dot on the back cur tain with the V mark center on the rear bow and staple...

Page 901: ...PART 18 3 Convertible Top 18 57...

Page 902: ...FRONT END OF GAUGE USING THIS TEMPLATE DEVELOP REAR END OF GAUGE USING THIS TEMPLATE FABRICATE GAUGE FROM A P I OF PLYWOOD 3J 3 AW X 4 7 8 X I 2 DEVELOP CENTER PORTION OF GAUGE I N 2 R E W I R E D ACC...

Page 903: ...he new top assembly back curtain window as sembly and or compartment trim as sembly proceed asfollows a Locate the center punch mark on the belt center tacking strip re tainer Fig 13 View A A Trans po...

Page 904: ...center between the bond seams of the top center deck at the No 4 bow on the underside of the material Install a 6 inch piece of mask ngtape on the top material inner surface at the centerline of the...

Page 905: ...oggle clamps and lower the top 2 Remove the screws attaching the weatherstrip retainer to the No 1 bow and remove the retainer Fig 17 3 Remove the adjusting screws at the outboard ends of the No I bow...

Page 906: ...ng tee nuts and separate the retainer from the side rail This is not necessary on the rear side rail Fig 17 3 To remove the weatherstrip from rear side rail slide the weatherstrip out of the retainer...

Page 907: ...nder s I X I X I X I 1 1 x 1 m cfl X I Toggle Clamp Adjustment I I 1 I I II I x a cfl Air in Hydraulic System Insufficient Hydraulic Fluid Top Lowered when Wet Causing Fabric to shrink I Balance Link...

Page 908: ......

Page 909: ...TCH CLUTCH 18487ASSY HEATER RESISTOR BOX 18578 ASSY HEATER BLOWER SWITCH C5AB 144894 CONTROL SWITCH 2 9 7 12 TO IGNITION SWITCH TO POWER SOURCE 30 AMP FUSE FOR A C ONLY 14 AMP FUSE FOR HTR ONLY FIG I...

Page 910: ...A C CONTROL SWlTC 2 6 9 BLUE 2 7 0 BLACK YELLOW STRIPE 2 9 7 BLACK GREEN STklPE 3 4 8 GREEN 9 1 3 YELLOW SPLICE GROUND DETAIL ITEM REFERENCE SHOWN ON PRODUCT DRAWING ALL DRAWING IN PARENTHESIS INDICAT...

Page 911: ...BLACK 401 194 RED 397 RED BLACK STRIPE A L L LETTERS CIRCLED AS SHOWN INDICATE CONNECTORS 398 YELLOW BLACK STRIPE 400 BLUE UNLESS OTHERWISE SPECIFIED ALL CONNECTORS ARE BLACK IRE FUNCTION NDT APPLICAB...

Page 912: ...GES A L L LETTERS CIRCLED AS SHOWN INDICATE CONNECTORS Y WIRE FUNCTION NOT APPLICABLE TO THIS CIRCUIT IGNITION SWITCH W I R I N G C O L O R C O D E 5 7 6LACK 401 194 RED 3 9 7 RED 6UCK STRIPE 3 9 8 YE...

Page 913: ...CATE CONNECTORS UNLESS OTHERWISE SPECIFIED A L L CONNECTORS ARE BLACK 1 0 C 8 7 7 ASSY I 640 20 0 OAB 14499 B FUEL TANK STA WAG O N L Y 6 U Ib 6 a O b TO IGNITION SWITCH TO PRlNTED a n a m CONN 16 W E...

Page 914: ...COLOR CODE 3 2 A 3 2 RED BLUE STRIDE 3 6 7 GREEN WHITE STRIPE NOTE 3 7 BLACK YELLOW 4 5 0 GREEN DETAIL ITEM REFERENCE SHOWN ON 3 8 5 7 BLACK 5 2 0 VIOLET PRODUCT DRAWING 162 GREEN RED STRIPE 6 2 7 A 6...

Page 915: ...19 8 GROUP 19 Schematics...

Page 916: ...GAUGE W I R I N G C O L O R C O D E 1 2 2 YELLOW 1 2 3 RED 1 7 5 BLACK SPLICE a GROUND FIG 8 Convertible Top Mustang NOTE DETAIL ITEM REFERENCE SHOWN ON PRODUCT DRA ING A L L NUMBERS IN PARENTHESIS I...

Page 917: ...CH OFF W I R I N G C O L O R C O D E 2 5 7 YELLOW 2 6 0 VIOLET 261 ORANGE BLACK STRIPE GROUND 18C394 ASSY DEFOGGER MOTOR 0 NOTE DETAIL ITEM REFERENCE SHOWN ON PRODUCT DRAWING ALL NUMBERS IN PARENTHESI...

Page 918: ...W I R I N G C O L O R C O D E 2 5 7 21 YELLOW 186 BROWN 2 6 0 RED BLACK STKlPE 260A VIOLET 2 9 7 BLACK GREEN STRIPE SPLICE A GROUND NOTE DETAIL ITEM REFERENCE SHOWN ON PRODUCT DRAWING ALL NUMBERS IN P...

Page 919: ...STARTING 1 3 A 1 3 RED MOTOR RELAY 5 3 7 A L L 1 4 WRU 145 BLACK BATTERY TERMI NAL 2 5 BLACK4RANGE STRWE 140A 1 4 0 BLACK RED STRIPE 2 9 6 RED 2 9 7 BLACK GREEN STRIPE 9 8 4 A 9 8 4 BROWN SPUCE GROUN...

Page 920: ...GROUP 19 Schematics 19 13...

Page 921: ...19 14 GROUP 19 Schematics USE PANEL FIG 12 Exterior Lights Turn Signals and Horns Fairlane...

Page 922: ...LAMP ASSY 15536 SIGNAL LAMP REAR LICENSE LAMP STOPLAMP SWITCH L H TURN SIGNAL LAMP 57 140 LEFT HAND BACK UP LIGHTING SWITCH 578 14B 1 LEFT HAND REAR STOP 6 TURN SIGNAL LAMP BACK UP LAMP SWITCH 140 STD...

Page 923: ...4 BROWN 37A 37 l l A 11 BLACK YELLOW STRIPE 482A 4 8 2 B L U E Y E L L W STRIPE 34 12C 1 2 8 12A 1 2 GREEN BLACK STRIPE 13A 1 3 RED BLACK STRIPE SPLICE 5 7 14D 14C 148 14A 1 4 BLACK 1 5 RED YELLOW ST...

Page 924: ...A THRU J BLUE RED 5 4 A THRU E GREEN YELLOW STRIDE 5 3 A THRU E BLACK BLUE STRIDE BLANK OR SPLICE 1 GROUND UNLESS OTHERWISE SPECIFIED ALL CONNECTORS ARE BLACK DETAIL ITEM REFERENCE SHOWN ON PRODUCT D...

Page 925: ...19 18 GROUP 19 Schematics FUSE PANEL FIG 14 Exterior Lights Turn Signals and Horns Falcon...

Page 926: ...GROUP 19 Schematics 19 19 FIG 74 Exterior Lights Turn Signals and Horns Falcon Continued...

Page 927: ...2 1 GREEN WHITE STRIPE 2 5 ORANGE BLUE STRIPE 29 ORANGE YELLOW STRIPE 2 9 7 30 GREEN ORANGE STRIPE 40 GREEN RED STRIPE 44 BLACK YELLOW STRIPE 1 3 7 GREEN BLACK STRIPE 1 4 0 RED BLACK STRIPE 2 9 6 BLAC...

Page 928: ...RIPE YELLOW BLUE YELLOW STRIPE VIOLET RESISTANCE WlRE SPLICE GROUND HORN SWITCH R H HORN RELAY ASSY TE WlRE FUNCTION NOT APPLICABLE TO THIS CIRCUIT A L L NUMBERS IN PARENTHESIS INDICATES WlRE GAGES A...

Page 929: ...19 22 GROUP 1 9 Schematics FIG 16 Exterior Lights Turn Signals and Horns Montego FUSE DANEL...

Page 930: ...ICENSE LAMl LEFT HAND BACK UP LAMP ASSY EFTHAND REAR STOP 6 TURN SIGNAL LAM M K U P LAM SWITCH STANDARD TRANS NOTE HEADLAMl DIMMER SWITCH UNLESS OTHERWISE SPECIFIED ALLCONNECTORSARE BLACK ALL LETTER5...

Page 931: ...N RED STRIPE 37 37A 11 1 1 A BLACK YELLOW STRIPE 39 12 12A 12 12C GREEN BLACK STRIPE 13 1 3 A RED BLACK STRIPE 57 THRU 5 7 E 14 14A 146 14C 1 4 0 BLACK 1 5 RED YELLOW STRIPE 460 157 2 1 YELLOW 25 BLAC...

Page 932: ...TRIPE BROWN BLUE YELLOW STRIPE SPLICE GROUND HORN SWITCH I TURN SIGNAL 1 14290 ASSY I 1 1 7200 ASSY L H HORN 4 8 2 1 4 2 9 0 ASSY NOTE WlRE FUNCTION NOT APPLICABLE TO THIS CIRCUIT I LIGHTING SWITCH NO...

Page 933: ...YELLOW STRIPE 12A 1 2 3 4 GREEN BLACK STRIPE 13A 1 3 RED BLACK STRIPE 14C THRU 14 BLACK 15 RED YELLOW STRIPE 2 5 BLACK ORANGE STRIPE 3 2 RED BLUE STRIPE 3 7 BLACK YELLOW STRIPE 4 4 BLUE 2 9 6 RED 297A...

Page 934: ...REAR STOP TURN SIGNAL LAMP A 1 4 0 A b R H BACK UP LAMP l47CB m lg 1 4 8 LICENSE PLATE ILLUMINATION LAMP L H BACK UP LAMP 114 1 21 40 L H REAR STOP 1 TURN SIGNAL LAMP BLUE 1 4 4 0 1 ASSY L I NOTE A L...

Page 935: ...OIILY TO IGNITION SWITCH TO POWER SOURCE HEATER MOTOR B L c i m W NOTE ALL LETTERS CIRCLED AS SHOWN INDICATE CONNECTORS UNLESS OTHERWISE SPECIFIED ALL CONNECTORS ARE BLACK WIRING COLOR CODE 257 YELLO...

Page 936: ...RING COLOR 913 152 21 2 7 0 3 7 HEATER SWITCH 26 8 2 6 9 A LL LETTERS CIRCLED SHOWN 0 INDICATES CONNECTORS 1 WIRE FUNCTION NOT APPLICABLE TO CIRCUIT CODE YELLOW BLACK YELLOW STRIPE BROWN RED BLUE SPLI...

Page 937: ...19 30 GROUP 19 Schematics FIG 27 ignition Starting and Charging Cougar...

Page 938: ...PE 4 8 2 BLUE YELLOW STRIPE 6 4 0 RED YELLOW STRlPE TO TRANS SWITCH 643 YELLW BLACK STRIPE 904 GREEN RED ST RIPE 9 7 7 VIOLET 26A BLACK RED STRIPE 31 WHITE RED 140 16A PINK RESISTANCE SPLICE GROUND 29...

Page 939: ...UP 19 Schematics 14300 ASSY STARTING MOTOR RELAY BATTERY TEMP SENDING OIL PRESSURE SENDING UNlT 642 FOR FAIRLANE ONLY OIL PRESSURE SENDING UNlT FIG 22 Ignition Starting and Charging Fairlane Falcon an...

Page 940: ...GROUP 19 Schematics 19 33 FIG 22 Ignition Starting and Charging Fairlane Falcon and Montego Continued...

Page 941: ...1 WHITE RED STRIPE e 3 2 3 2 RED BLUE STRIPE 3 5 WHITE 3 7 BLACK YELL OW ST IPE 5 7 3 8 BLACK 3 9 RED WHITE STRIPE 2 6 2 BROWN 6 4 0 A 640E 640D 6 4 0 RED YELLOW STRIPE 6 4 2 WHITE GREEN STRIPE 6 4 3...

Page 942: ...UE GREEN STRIPE SPLICE I GROUND 32 I 1 4 0 1 TO REAR 1 4 2 9 0 ASSY TO PRNDL LAMP TO BATTERY TERMINAL OF STARTING MOTOR RELAY IGNITION SWITCH FUSE PANEL DETAIL ITEM REFERENCE SHOWN ON PRODUCT DRAWING...

Page 943: ...19 36 GROUP 19 Schematics FIG 24 Ignition Starting and Charging Mustang...

Page 944: ...CK YELLOW STRIPE 39 RED WHITE STRIPE w140A I 4 0 BLACK RED STRIPE 9 8 4 2 6 2 BROWN 482 BLUE YELLOW STRIPE 640 RED YELLOW STRIPE 9 0 4 GREEN RED STRIPE SRLICE GROUND NEITPRAL SWrrCH FOR A W A T I C TR...

Page 945: ...STRIPE 30 A B C BLACKGREEN STRIPE 31 WHITE RED STRIPE 3 4 GREEN BLACK STRIPE 3 9 RED WHITE STRIPE 4 9 WHITE BLUE STRIPE 5 0 GREEN WHITE STRIPE 5 7 BLACK 640 A B RED YELLW STRIPE 1 9 B CLUSTER ILL LAMP...

Page 946: ...UE STRIPE 5 0 GREEN WHITE STRIPE 5 7 BLACK A B 6 0 BLACK WHITE STRIPE 6 4 0 REO YELLOW STRIPE 6 5 4 VIOLET 6 5 5 YELLOW 9 7 7 RE0 SPLICE GROUND CLUSTER ILL LAMP NOTE bNLESS OTHEWISE SPECIFIED ALLCONNE...

Page 947: ...19 40 GROUP 19 Schematics...

Page 948: ...GROUP 19 Schematics 19 41...

Page 949: ...19 42 GROUP 19 Schematics...

Page 950: ...GROUP 19 Schematics 19 43...

Page 951: ...DOOR 2 5 BLACK ORANGE STRIPE COURTESY LAMP 3 7 8 37A 3 7 BLACK YELLOW STRIPE SWITCH NOTE 5 3 THRU 53H BLACK BLUE STRIPE 54 THRU 54E GREEN YELLOW STRIPE ALL LETTERS CIRCLED 57A 5 7 BLACK 4 4 1 VIOLET...

Page 952: ...R E D STRIPE A L L CONNECTORS ARE BLACK 2 5 BLACK ORANGE STRIDE A L L LETTERS CIRCLED AS 3 7 A 3 7 BLACK Y E L L O W STRIPE SHOWN INDICATE CONNECTORS 5 3 E 5 3 D 53C 5 3 0 5 3 A 5 3 BLACK BLUE STRIPE...

Page 953: ...O L O R C O D E 1 9 A THRU 1 9 F 1 9 BLUE RED STRIPE ALL LETTERS CIRCLED ASSHOWN 2 1 YELLOW INDICATE CONNECTORS 25 BLACK ORANGE STRIPE 3 7 A 3 7 BLACK YELLOW STRIPE WIRE FUNCTION NOT APPLICABLE TO 5 3...

Page 954: ...IP MODEL 76 LIGHTING SWl TCH 14401 ASSY NOTE UNLESS OTHERWISE SPECIFIED W I R I N G C O L O R C O D E ALLCONNECTORS AREBLACK 19 THRU 19G BLUE RED STRIPE A L L LETTERS CIRCLED AS SHOWN 21 YELLOW INDICA...

Page 955: ...O D E 2 5 BLACK4RANCE STRIPE 3 7 BLACK YELLOW STRIPE 5 3 THRU 5 3 E BLACK BLUE STRIPE 5 4 THRU 5 4 E GREEN YELLOW STRIPE 5 7 A 5 7 3 8 A BLACK SPUCE OR BLANK TERMINAL GROUND NOTE UNLESS OTHERWISE SPEC...

Page 956: ...HOUT POWER WINDOWS NOTE W I R E FUNCTION NOT APPLICABLE TO D E T A I L 6 I T E M REFERENCE SHOWN THIS CIRCUIT ON PRODUCT DRAWING A A L L LETTERS CIRCLED AS SHOWN INDICATE CONNECTORS 1 4 6 7 8 ASSY USE...

Page 957: ...19 50 GROUP 19 Schematics MASTER WINDOW REGULATOR CONTROL ASSY 14505 14631 ASSY 226 I WINDOW MOTOR 14553 K 1727 C I FIG 37 Power Windows Fairlane and Montego...

Page 958: ...S SHOWN INDICATE CONNECTORS UNLESS OTHERWISE SPECIFIED ALLCONNECTORS ARE BLACK R R WINDOW SWlTCH ASSY 14046 I I LR WINDOW SWITCh ASSY 14048 o 771 LO U WINDOW MOTOR 14553 W I R I N G C O L O R C O D E...

Page 959: ...19 52 GROUP 19 Schematics FUSE PAWL POWER SOURCE CLUSTER FEED TO BATTERY SUPPLY JUNCTION HARNESS RADIO RECEIVER AM AM FM FIG 38 Radio and Stereo Tape A M and AM FM Cougar L I LIGHTING SWITCH...

Page 960: ...CONNECTORS WIRE FUNCTION NOT APPLICABLE TO THIS CIRCUIT W I R I N G C O L O R C O D E BLUE RED STRIPE BLACK ORANGE STRIPE BLACK YELLOW BLACK STRIPE BLACK RED STRIPE RED BLACK GREEN STRIPE BLUE RED ST...

Page 961: ...tics CLUSTER FEED STARTING MOTOR RELAY 14300 ASSY POWER SOURCE 2 5 TOBATTERYSUPPLY JUNCTION IN WIRING HARNES IGNITION SWITCH I I LIGHTING SWITCH RADIO RECEIVER CAM AM FM FIG 39 Radio and Stereo Tape A...

Page 962: ...K ORANGE STRIPE INDICATE WIRE GAUGE 5 7 A 4 7 BLACK 137 YELLOW BLACK STRIPE A L L LETTERS CIRCLED AS SHOWN INDICATECONNECTORS 2 9 6 RED 3 0 2 9 7 A 2 9 7 BLACK GREEN STRIPE 4 9 0 BLUE RED STIRPE WIRE...

Page 963: ...ICABLE TO THIS CIRCUIT REAR SPEAKER WITH AM 8 AM FM RADIO RECEIVER FOR MERCURY INTERMEDIATE ONLY 2 9 6 RED 137 YELLOW 8LACK STRIPE 1 9 THRU 19C BLUE RED STRIPE 1 4 0 BLACK RED STRIDE 297A 2 9 7 RLACK...

Page 964: ...BLACK SPLICE f GROUND ART OF 9 A B 4 0 ASSY C7AB 14489 0 C7AB 1 4 4 8 9 F 9 D 7 5 2 A S S Y C 5 A B 1 4 4 8 9 4 1 4 4 0 1 ASSY C5AB 14489 C 1 3 4 8 0 ASSY NDTE DETAIL 6 I T E M REFERENCE SHOW ON PRODL...

Page 965: ...BLUE 5 7 THRU 5 7 C BLACK 3 8 5 WHITE RED STRIPE 4 3 6 A 4 3 6 YELLOW 4 3 7 YELLOW RE0 STRIPE 4 3 8 A 4 3 8 YELLOW BLACK STRIPE 4 9 4 4 4 0 WHITE 4 4 1 A 4 4 1 VIOLET 4 4 4 GREEN BLACK STRIPE 4 4 6 O...

Page 966: ...GROUP 19 Schematics 19 59...

Page 967: ...REDIWHITE STRIPE SPLICE GROUND 1 4 2 8 9 ASSY NOTE DETAIL ITEM REFERENCE SHOWN ON PRODUCT DRAWING A L L NUMBERS IN PARENTHESIS INDICATE WIRE GAUGE ALL LETTERS CIRCLED AS SHOWN INDICATE CONNECTORS UNL...

Page 968: ...SAF CONV WARNING INDICATOR SWITCH ASSY C6AB 10 B924 C NOTE DETAIL ITEM REFERENCE SHOWN ON PRODUCT DRAWING A L L NUMBERS IN PARENTHESIS INDICATES WlRE GAGES A L L LETTERS CIRCLED AS SHOWN INDICATES CO...

Page 969: ...TCH SWITCH 6 1 4 4 8 9 375 DOOR CI RELAY 20 I IGNITION SWITCH 0SED POSITION W I R I N G C O L O R C O D E 3 2 RED BLUE STRIPE 5 3 BUCK BLUE STRIPE 5 4 GREEN YELLOW STRIPE 8 7 GREEN ORANGE STRIPE STEER...

Page 970: ...ETTERS CIRCLED AS SHOWN INDICATE CONNECTORS UNLESS OTHERWISE SPECIFIED ALLCONNECTORS ARE BLACK WIRE FUNCTION NOT TO THIS GlRCUlT APPLICABLE W I R I N G C O L O R C O D E 28 BLACK 56 BLUE 58 WHITE 63 R...

Page 971: ...INDICATE CONNECTORS WlRE FUNCTION NOT APPLICABLE TO THIS CIRCUIT J INTERMITTENTWIPER WASHER SW I 7 20 AMP FUSE 1 POWER SOURCE DASH PANEL OPERATION FUNCTION CONTACTS CLOSED INTERMITTENT I l2 PARK P LOW...

Page 972: ...RED 2 9 7 A BLACK GREEN STRIPE 2 8 A 2 8 6 1 5 A BLACK 7 6 3 ORANGE 984 BROWN IGNITION SWITCH WASHERflIPER COORDINATION SWITCH NOTE UNLESS OTHERWISE SPECIFIED ALLCONNECTORSAREBLACK A A L L LETTERS CIR...

Page 973: ......

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