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Ford FAIRLANE ZF Series, Repair Manual

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Ford FAIRLANE ZF Series Repair Manual Download Page 493

Summary of Contents for FAIRLANE ZF Series

Page 1: ..._ _ __ _ __ _ XA ZF REPAIR MANUAL...

Page 2: ...e CAMPBELLFIELO VICTORIA Incorporated in Victoria Copyright Ford Motor Company of Australia Limited Reproduction In whole or In part prohibited without written approval Registered In Australia for tra...

Page 3: ...n this manual were in effect at the time the manual was approved for printing The Ford Motor Company of Australia Limited reserves the right to discontinue models at any time or change specifications...

Page 4: ...FALCON FAIRLANE w P oROUP 1 PAGE PART 1 1 Vehicle Identification XA ZF Series 1 2 PART 1 2 Accessories 1 4...

Page 5: ...A 7 20 THIS PLATE IS AFFIXED WITH THE APPROVAL OF THE AUSTRALIAN MOTOR VEHICLE CERTIFICATION BOARD Q Q Location Left hand Upper Firewall Panel Interpretation Prefix Manufacturers use only Serial No Ma...

Page 6: ...wo letters indicate tu tone the first signifying the upper colour and the second the lower colour Code Colour A Medium Yellow B Onyx Black c Beige D Yellow z Wild Violet Met G Turquoise M Blue I Jewel...

Page 7: ...18492 C XA 18492 D XA 18493 B XA 19000A Less Aerial XA 18805 A Radio Kit Delu x e Manual Less Aerial XA 18805 B Radio Kit Super Fringe Deluxe XA 18805 C Push Button Less Aerial Radio Kit Super Fringe...

Page 8: ...9030 C XA 9030 B Item Part No WHEEL DISCS and COVERS Deluxe Except wj Radial Ply Tyres XW 18303A w Radial Ply Tyres XW 18303B Full Wheel Cover XA ARD2DA 1130BA Full Wheel Cover ZF ARD20A 1130AA Lock R...

Page 9: ...REFERENCE TO SERVICE INFORMATION AND NOTES Date Letter No Page Brief Detail...

Page 10: ...FALCON FAIRLANE w P GROUP 2 PAGE PART 2 1 General Broke Service 2 2 PART 2 2 Brake System 2 9 PART 2 3 Specifications 2 25...

Page 11: ...akes shut off the engine and ex haust all vacuum from the booster system before performing this tesL Depress the brake pedal and hold it in the applied position Ifthe pedal gradually falls away under...

Page 12: ...est line first on the individual system being serviced During the complete bleeding operation DO NOT allow the reservoir to run dry Keep the master cylinder reservoirs filled with Motorcraft brake flu...

Page 13: ...and tyre and the shoe and lining assemblies as outlined on Page 2 22 2 On all models make thickness measurements with a micrometer across the thinnest section ofthe shoe and lining If the assembly ha...

Page 14: ...should be replaced 9 On floating caliper type disc brakes the caliper assembly must be removed from the spindle prior to removal of the shoe and lining assemblies 10 On floating caliper type disc bra...

Page 15: ...iper not properly aligned on rotor Stuck or seized piston one caliper Broken or missing shoe hold down spring or clip Worn or cut insulators or broken stabilizers Worn out lining Damaged insulator or...

Page 16: ...E DRAGS Brake line restricted Drum out of round Faulty retracting spring Faulty brake cylinder Loose carrier plate Dirty brake fluid Air in hydraulic system Insufficient shoe to carrier plate Distorte...

Page 17: ...or improperly adjusted Lining glazed or worn brake shoe Oil or grease on lining Dirt on drum lining surface Faulty brake cylinder Insufficient shoe to carrier plate lubrication BRAKES DO NOT APPLY Lea...

Page 18: ...valve is fitted on the suspension tower immediately below the master cylinder Fig 4 The original differential pressure valve which is integral with the master cylinder is retained to ensure the integ...

Page 19: ...lots on the outboard legs of the caliper housing The outer brake shoe and lining assembly is also held in a fixed position by brake shoe hold down pins which extend through the brake shoe and caliper...

Page 20: ...r shoe and iining assembly against the rotor The resultant reaction forces the caliper housing and outboard shoe and lining assembly inward against the rotor Braking torque is tran l ferred from the o...

Page 21: ...r spring is hooked to the primary brake shoe and to the lever The automatic adjuster oper ates only when the brakes are applied while the vehicle is moving rearward and only when the secondary shoe is...

Page 22: ...re used in the rear brake The anchor pin on all brakes are fixed and are non adjustable SECONDARY SHOE PARKING BRAKE CABlE AND fRONT IRAKE Taxi lEAR IRAIII fRONT Of C A l FIG 15 Self Adjusting Brake 2...

Page 23: ...e when ad justing the brake shoes If the shoes are adjusted when the drums are hot and expanded the shoes may drag when the drums are cool and con tracted 1 After the shoes have been in stalled or the...

Page 24: ...l and tire frotn the drum l Remove the grease cap from the hub Remove the cotter pin nut lock adjusting nut and flat washer from the spindle Remove the outer bearing cone and roller assembly 3 Pull th...

Page 25: ...ng Dis connect the parking brake cable from the parking brake lever 5 After removing the rear brdke secondary shoe disassemble the park ing brake lever from the shoe by re moving the retaining clip an...

Page 26: ...y of the guide should lie flat against the web Replace the guide if it shows damage d Check the pivot hook on the lever The hook surfaces should be square with the body of the lever for proper pivotin...

Page 27: ...Bleed the brakes as outlined on Page 2 3 FRONT WHEEL HUB AND ROTOR ASSEMBLY DISC BRAKES REMOVAL l Remove the wheel and tyre from the hub Be careful to avoid damage or interference with the bleeder sc...

Page 28: ...s which hold the caliper anchor plate to the steering spindle remove the two bolts and lift the caliper and anchor plate assembly from the spindle INSTALLATION 1 Position caliper correctly over disc a...

Page 29: ...the hairpin retainer from the brake pedal pin and then remove the booster push rod and the nylon spacer and bushing off the brake pedal pin Fig 23 2 Open the hood and remove the master cylinder from...

Page 30: ...rface with a cloth soaked in clean denatured alcohol If one drum is turned down the oppo site drum on the same axle should also be cut down to the same size ROTOR REFINISHING The finished braking surf...

Page 31: ...e cylinder bore Be sure the seal does not become twisted and that it is seated fully in the groove GROUP 2 BRAKES PISTON RETRACTING TOOL GIRLING D Weld Nut on tame side of Brake Shoe as Tangs Drill 33...

Page 32: ...sembly on a clean bench area with the open end of cylinder up 2 Dip new piston seal in clean disc brake fluid and install in cy linder groove Position seal at one area in the groove and gently work ar...

Page 33: ...signs of etching pitting scoring or rust Honing of the master cylinder is not recommended If it is necessary to hone the ma ter cyl inder bore to repair damage do not exceed allowable hone specificati...

Page 34: ...FT LBS Parking Brake Control Assembly Mounting prior to bleeding the system and replaced on completion ofthe bleeding operation Failure to observe this precaution will cause the switch to be damaged...

Page 35: ...REFERENCE TO SERVICE INFORMAnON AND NOTES Date Letter No Pal Brief Detail...

Page 36: ...RT 3 3 PART PART 3 5 PART 3 6 PART 3 7 Suspension Steering Wheels and lyres General Service Suspension Power Steering Steering Column and Linkage Steering Gear _yvheels and lyres Specifications GROUP...

Page 37: ...ll the way to the right stop and to the left stop several times to distribute the dye solution throughout the hydraulic system Do not hold the wheel against each wheel stop for more than 3 to S second...

Page 38: ...against the stop for more than S seconds FRONT WHEEL ALIGNMENT CHECKS Do not attempt to check and ad just front wheel alignment without first making a preliminary inspection of the front end parts Ch...

Page 39: ...Rear Alignment Spacer Installation Take the two tubes identified Bl and the two remaining supports B3 assemble together with the pins located in the holes marked LIN COLN for the Country Ride sus pen...

Page 40: ...front wheels in the straight ahead posi tion Run the engine so that the power steering will be in the centre neutral position if so equipped Measure the dis tance between the extreme front and also be...

Page 41: ...X X X X X 13 Air in Power Steerin System X X X X 14 Obstruction in Power Steering Lines X X X 15 Loose or Weak Shock Absorber X X X X X X 16 Loose or Worn Suspension Arm Bushings X X X X 17 Binding F...

Page 42: ...ail Fig 8 To adjust the camber loosen the ec centric bolt nut and spread the re taining body bracket sufficiently to allow unrestricted lateral movement ofthe arm assembly in relation to the body brac...

Page 43: ...ing rod sleeves to specification The sleeve position should be as shown in Fig 12 when the clamp bolts are tightened STEERING GEAR FLUID CHECKING PROCEDURE MANUAL 1 nter the steering wheel l Remove th...

Page 44: ...7 As soon as all of the fluid has been poured in tum off the ignition key and attach the coil wire I Remove the plug from the res ervoir return pipe and attach the re turn hose to the reservoir 9 Che...

Page 45: ...3 As the wheel is being moved in and out observe the lower end of the spindle and the lower arm FIG 13 Measurln1 Upper Ball Joint Radial Play Durln1 the forqolaa cbeck tbe upper ball joint wiD be unlo...

Page 46: ...na The swivelina action of the ball joints allow the wheel and spindle as semblies to move up and down with chanaes in road surface The swivel ina ball joints also permit the spindles and wheels to be...

Page 47: ...heck for cracks in the metal at the holes and replace the arm if it is cracked 8 Attach the new ball joint to the upper arm Use only the bolts nuts and washers supplied in the kit Do not rivet the new...

Page 48: ...al and install the cotter pin grease cap and hub cap or wheel cover 16 Lower the car and install the shock absorber and upper mounting bracket 17 Check caster camber and toe in and adjust as necessary...

Page 49: ...el and tyre SJI A SJI A ORB FIG 20 Spring Compressor Installed Upper View Typical 4 Install the spring compressor using Tool 53lO A and compress the spring Fig 20 21 5 Remove the cotter pin from the u...

Page 50: ...in ina nut Torque the nut to specifica tion 6 Torque the lower ball joint stud nut to specification and install the cotter pin 3 15 7 Install the wheel tyre and hub and drum on the spindle and adjust...

Page 51: ...Tum the tool with a wrench un til the tool places the studs under ten sion and with a hammer tap the spindle near the studs to loosen them in the spindle Do not loosen the studs In the spindle with to...

Page 52: ...ers from the shock absorber studs 3 17 Installation 1 Place the inner washer and bushing on each shock absorber stud 2 Expand the shock absorber and position it to the spring clip plate and to the mou...

Page 53: ...3 18 GROUP 3 SUSPENSION STEERING WHEELS lYRES Utility and Van FIG 26 Rear Spring Shock Absorber Typical...

Page 54: ...the sprina is in the approximate curb load position and then torque the front hanger stud lockout to specifi cation 10 Remove the safety stands and c wer the car REAR SUSPENSION RADIUS ROD Removal 1...

Page 55: ...traight ahead position is substantially less direct than in turns to such an extent that whereas four turns of the steering wheel would be required if the on centre ratio were used constantly from loc...

Page 56: ...UT SHAFT 3 21 LOCKING SPRING Fig 30 WORM FOLLOWER Steering Gear Manual Section ADJUSTER ACCESS PLUG FOR WORM FOLLOWER ADJUSTER SCREW TOP COVER WORM ADJUSTING SCREW LOCKNUT a Fig 31 Steering Gear relat...

Page 57: ...e 32 shows the power section of the gear and it will be seen that the sector shaft again in section has three teeth formed in it engag ing in the combined rack piston This rack piston has a spherical...

Page 58: ...UMP STEERING ON RIGHT TURN PUMP OUTPUT D RETURN TO PUMP STEERING GEAR Fig 34 Oil Flow Gear on Right Turn PUMP STEERING ON LEFT TURN PUMP OUTPUT RETURN TO PUMP STEERING GEAR Fig 35 Oil Flow Gear on Lef...

Page 59: ...hin the crescent shaped void As this sealed chamber moves throup the crescent shaped void its volume cbanaes resultina in a pump ina action As the rotor rotates 90 Fig 36 the slipper slides outward in...

Page 60: ...proper belt tension The reservoir will be deformed when pried on or pressed against and a leak will result 3 Recheck the belt tension When the tension has been correctly ad justed torque the bolts and...

Page 61: ...e oil pressure hose from the pump a MAJOR REPAIR OPERATIONS POWER STEERING PUMP PULLEY REMOVAL Other tban puDey removal and res ervoir or seal replacement the pump should not be disassembled but re pl...

Page 62: ...d copper gasket from the pump INSTALLATION 1 Install a new gasket on the out let fitting a new copper gasket on the support stud and a new reservoir 0 ring seal on the pump housing plate Fig 41 The ol...

Page 63: ...S 1 2 3A 5 6 7 89JOJ I AND 18 ASSEMBLY 34 COMPRISES 22 23 2 4 35 36 AND 65 G 11 f 43 4 4 45 6 2 11 f b 2 E 2 4 65 47 48 ASSEMBLY 6 _J JldV 19 ASSEMBLY AOTATEO THROUOH IICt FOR CLARITY 38 ASSEMBlY 34 w...

Page 64: ...Sector Shaft 30 Cover Piston 31 Seal Piston 32 Piston Rack 33 Piston Rack Assy 34 Housing Assy Steering Gear 35 Housing 36 Bearing Sector Shaft 37 Seal Sector Shaft 38 Ring Seal Back up 39 Clip Retai...

Page 65: ...he gear this must be removed with a puller working against the end of the torsion bar 9 Using the Tool No XA 3745A unscrew the piston cover en suring that the spanner is held ftrmly against the cover...

Page 66: ...and fitting of the pin in the trimming operation during manufacture equa lising the steering efforts in dght and left turns A Sleeve 1 Remove the sleeve complete with its teflon seals rubber seal and...

Page 67: ...nto a fum block of wood ensuring that the sleeve is being held at the instant of impact to drive it fully home against the end of the worm It is important that the pin is fumly held in the drive slot...

Page 68: ...housing to ensure that the centre point of the worm coincides with the on centre position of the gear This position of the worm valve and sleeve assembly in the housing is adjustable by the number of...

Page 69: ...EMBLY 1 Replace the worm bearing race in the housing together with the shims removed ifany or the predetermined number of shims if a new worm valve and sleeve assembly i to be fitted see page 3 33 Use...

Page 70: ...ce existing 10 Wrap one layer of plastic insu lating tape around the valve splines to prevent damage to the valve seal when the worm valve and sleeve assembly is being fitted 11 Position the steering...

Page 71: ...ensure that the circlip is loaded close to the groove in the housing otherwise it will fatigue in service The rounding of one side of the backing ring is a legacy of the blank ing operation during it...

Page 72: ...follower adjusting screw accessible through the hole in the top cover Turn the adjusting screw a turn at a time until an increase in torque reading is noted when oscillating the input shaft 5 either s...

Page 73: ...s been collapsed a complete new column must be installed with new brackets The steering gear shift ignition lock is situated to the right of the steering column The main body of the lock is bolted to...

Page 74: ...nnector f U N F NUT r 11 e I WELDED TO PLATE r the bearingand flange from the shaft NUT 8 Remove the bearing and insu lator from the flange INSTALLATION 1 Install flange bolts square head in flange if...

Page 75: ...he transmission control rod s from the lever s at the lower end of the column 5 Remove the two nuts steering shaft flange to flexible coupling 6 Remove the nuts and bolts that secure the column retain...

Page 76: ...mn NOTE To remove shift tube upper bearing ignition lock must be re moved first Bearing can then be removed from lower end of column INSTALLATION 1 Assemble upper shift tube bearing in the column with...

Page 77: ...3 42 GROUP 3 SUSPENSION STEERING WHEELS lYRES FIG 63 Steering Linkage Fairlane Falcon...

Page 78: ...rod ends from the centre link Fig 64 4 Remove the cotter pin and nut attaching the idler arm to the centre link Disconnect the idler arm from the centre link 5 Remove the cotter pin and nut attaching...

Page 79: ...emoval procedures see Page 346 REMOVAL 1 Remove pitman arm securing nut from sector shaft 2 Undo the four bolts securing the sector shaft cover and remove cover drain oil 3 Install steering gear assem...

Page 80: ...ade in the following order to avoid mage or gear failure 1 Disconnect the Pitman arm from the steering Pitman to idler arm rod 2 Loosen the nut which locks the sector adjusting screw Fig 67 and turn t...

Page 81: ...remove the sector shaft with the cover Remove the cover from the shaft by turning the screw clockwise Keep the shim with the screw 3 Loosen the worm bearing ad juster nut and remove the adjuster assem...

Page 82: ...amp the housing in a vise with the sector shaft axis horizontal and position the steering shaft lower bear ing in its cup 12 Position the steering shaft and ball nut assemblies in the housing 13 Posit...

Page 83: ...ousing by the bearing retainer plate which is bolted to the housing flange The inner end of each axle shaft is splined to the differential in the rear axle ADJUSTING NUT HUI IIOLT WHEEL ASSEMBLY FIG 7...

Page 84: ...here 1 Remove the valve cap and core and deftate the tyre completely 1 With a bead loosening tool break loose the tyr side walls from the wheel Fig 69 3 Potidon the oater llde of the wbeel downward a...

Page 85: ...be cleaned inspected and repacked If the bearing cups or the cone and roller assemblies are wom or damaged they should be replaced DRUM BRAKES 1 Raise the car until the wheel and tire clear the ftoor...

Page 86: ...ged remove them with a drift 9 Thoroughly clean the inner and outer bearing cones and rollers with solvent and dry them thoroughly Do not spin the bearings with com pressed air Inspect the cone and ro...

Page 87: ...heel bearing grease 1 Raise the car until the wheel and tyre clears the floor Pry off the hub cap or wheel cover and remove the wheel and tyre assembly from the hub and disc 2 Remove lock wires and 2...

Page 88: ...Ball Joint to Spindle Upper and lower 11 Strut to lower Arm 12 lower Arm to Underbody 13 Stabilizer Bar Mountin Bracket to Underbody 14 Strut to Underbody 15 Stabilizer Bar to Lower Arll D Torque nut...

Page 89: ...J 54 GROUP 1 SUSPENSION STEERING WHEELS TYRES FIG 80 Front Suspension Torque Limits FIG 81 Rear Suspension Torque Limits...

Page 90: ...onnectin1 Rod End to Spindle Arin 30 40 3 Idler Ann Mountln1 BriCkel to Underbody 28 35 4 Pitman Ann to Steerln1 Ann to ldler Ann ROd or to Valve and link Assembly 35 47 5 Steerin1 sclndle Ann Connect...

Page 91: ...to Stop 5 Worm Bearing Preload in lbs 3 8 Total Preload Worm Bearing plus Sector Mesh in lbs 10 16 Lube Capacity oz Lube Type ESW MIC87 A STIDINO GEAR TOIQUI LIMITS Sector shaft cover bolts 30 ft lbs...

Page 92: ...ximum load for passenger vehicles is all seating positions occupied plus 200 lb load in the luggage compartment when applied to sedan or 300 lb when applicable to station wagon Maximum load for commer...

Page 93: ...PO RPO NA RPO RPO RPO RPO RPO RPO NA RPO RPO RPO RPO RPO RPO NA RPO NA RPO NA NA NA NA NA RPO RPO RPO RPO RPO NA RPO RPO RPO RPO RPO RPO NA RPO RPO RPO RPO RPO RPO NA NA RPO RPO RPO RPO RPO NA NA RPO...

Page 94: ...FALCON FAIRLANE w P REAR AXLE PART 4 1 Rear Axles PART 4 2 Rear Axle Overhaul PART 4 3 Specifications GROUP 4 PAGE 4 2 4 14 4 28...

Page 95: ...ring the cone or inner race the tapered rollers which roll freely between the cup and cone and the cage which serves as a retainer to maintain the proper spacing bet ween the tapered rollers grouped...

Page 96: ...e Assembly with Tapered Roller Unit Type Axle Shaft Bearings Typical DIFFERENTIAL DIFFERENTIAL COVER DIFFERENTIAL BOLTS BOLTS THRUST WASHER PINION PINION THRUST WASHER THRUST BLOCK FIG 3 Integral Carr...

Page 97: ...g assemblies rear wheel bearings are pressed onto the outer ends of the axle shafts and set in the outer ends of the axle housing These bearing support the semi floating axle shafts at the outer ends...

Page 98: ...wever excessive noise often indicates the beginning of other troubles in the axle A road test can help determine whether the noise is being caused by trouble in the rear axle or m other parts of the c...

Page 99: ...nting Each type is deter wns in the differential case will be and ftoat noise differs with speed most pronounced on turns A con and if the noise is very rough and tinuous whine under a light load irre...

Page 100: ...sible gear combinations FIG 8 Unacceptable Non Hunting Pattern Centre Heel Centre ACCEPTABLE PATTERN FIG 9 Acceptable Non Hunting Gear Set Coast Pattern PART 4 1 REAR AXLES DRIVE SIDE BACKLASH CORRECT...

Page 101: ...justment Since each gear set rolls a characteristic pattern the patterns in Fig 11 should be con sidered as typical only and should be used as a guide rather than a rigid standard The drive pattern is...

Page 102: ...ft with the tool shown in Fig 16 6 Inspect the machined surface of the axle shaft and the axle hous ing for rough spots or other irreg ularities which would affect the FIG 15 Removing Rear Wheel Beari...

Page 103: ...can be easily removed by drilling a hole in the outside diameter of the collar to a depth approxi mately three quarter the thick ness of the collar Do not drill all the way through the collar as the...

Page 104: ...ter edge of the new seal with oil resistant sealer and install the seal using the tool shown in Fig 23 II Align the pinion flang spline mark with the pinion shaft spline mark and install the flange wi...

Page 105: ...en pre load If this is done a new pinion bearing spacer must be installed In addition the U joint flange must never be hammered on or pneumatic tools used 17 Remove the oil seal replacer tool from the...

Page 106: ...ssion output shaft 4 Connect the drive shaft to the axle U joint flange aligning the scribe marks made on the drive shaft end yoke and the axle U joint flange during the removal procedure Fig 28 Insta...

Page 107: ...above the housing with mech nics wire The hydrau lic brake lines and the parking brake cables ar still attached to the brake carrier plates 8 Support the rear axle hous ine on a jack and then remove t...

Page 108: ...patterns on the drive gear in dicate incorrect adjustment Noise caused by incorrect adjustment can often be corrected by re adjusting the gears Typical patterns and the recessary corrections ar expla...

Page 109: ...tion Gear scoring is the result of excessive shock loading or the use of an incorrect lubricant Scored gears cannot be reused Examine the teeth and thrust sur faces of the difl erential gears Wear on...

Page 110: ...ar i e a washer this amount thinner must be used A negative e g 002 mark ing means that a washer this size thicker must be used A zero mark ing indicates that the washer sel ected with the gauge is th...

Page 111: ...nd play i e 258 012 2 3 Tentatively select spacers which will increase the total spacer thickness 004 i e increase the spacer on each side 002 e g each spacer becomes 266 4 Fit the carrier spreader ad...

Page 112: ...ng backlash moves the drive gear away from the pin ion a Drive pattern moves slightly higher and toward the heel b Coast pattern moves higher and toward the heel 3 Thicker shim with the back lash cons...

Page 113: ...springs and place the second thrust block over the springs 7 Place the remaining side gear on the thrust block 8 Install a shim if originally fitted on the side gear and place the cone on top 9 Insta...

Page 114: ...e cover facing down lift off the case Remove the pre load spring plate and four pre load springs 9 From the cover remove the side gear four clutch plate ear guides clutch hub friction and steel clutch...

Page 115: ...drift drive in the long pinion shaft from the outside of the case aligning the lock pin holes in the shaft with the holes in the case The centre block should be posi tioned so the long shaft is driven...

Page 116: ...correct amount of shim s to subtract from the 0 050 shim originally installed In order to correctly select the proper shim s the shim tem plate tool and the chart must be used 15 Mter the proper shim...

Page 117: ...ng with new clutch plates is 100 to 250 lb ft With re used clutch plates the minimum torque required is 40 lb ft The torque may fluctuate 10 40 lb ft REMOVAL AND DISASSEMBLY OF DRIVE PINION AND BEARIN...

Page 118: ...concave side up PINION BEARING CUPS Do not remove the p1mon bearing cups from the retainer unless the cups are worn or dam aged The flange and pilot of the retainer are machined during manu facture by...

Page 119: ...ghten the pinion shaft nut a little at a time until the proper preload is established Do not overtighten the nut If exces sive preload is obtained as a result of overtightening replace the collap sibl...

Page 120: ...ear ings were excessively worn Use the new bearings for assembly If the runout is still excessive the case is defective and should be replaced DRIVE PINION AND RING GEAR SET When replacing a ring gear...

Page 121: ...red to turn axle shaft and side gear with one wheel on ground Rotating torque required during bench check after assembly original or new cones and housing DIIVI PINION ADJUSnNG SHIM THICKNISS CHANGII...

Page 122: ...lutch plates new clutch plates 100 250 lbs ft If pinion bearing preload exceeds specification before this torque is obtained install a new spacer tRotating torque may fluctuate up to 40 lbs ft TORQUE...

Page 123: ...9 272 7 6 3 50 1 4 Diff Pinion 199 270 7 75 2 75 4 Diff Pinion D2DW BA 9 00 3 00 4 Diff Pinion D2DW CA 9 00 1 Integral Carrier Limited Slip 2 Removable Carrier Traction Lock AXLE APPLICATION BY VEHICL...

Page 124: ...FALCON FAIRLANE w P DRIVE LINE AND CLUTCH PART 5 1 Drive Line PART 5 2 General Clutch Service PART 5 3 Clutch PART 5 4 Specifications GROUP 5 PAGE 5 2 5 8 5 12 5 21...

Page 125: ...he seal Undercoating or other foreign material on shaft Universal joint U bolts loose Universal joints worn or lack of lubricant Drive shaft mis aligned drive line angle Pinion flange runout Pinion ru...

Page 126: ...during the fore going procedures tap the ears of the driveshaft sharply to relieve the bind Do not install the drive shaft unless the universal joints are free of bind 5 If the rubber seal installed...

Page 127: ...sion can be eliminated as the source of the prob lem Repeat the above procedure but shift the transmission to neutral and shut off the engine Again if the vibration is unchanged it can be assumed that...

Page 128: ...VE LINE 5 5 AVERAGE OF READINGS Indicator Flange Bearing Driveshaft Universal Cup Runout Cross Shaft Runout 1 3 5 2 5 3 3 4 4 Average 4 4 FIG 6 Checking Driveshaft Universal Cross Shaft Runout the cro...

Page 129: ...cups FIG 7 Runout Chart 6 Rotate the flange slightly until the dial gauge indicates the highest point of the cap Zero the dial gauge FIG 8 Universal U bolts reworked assembly in the manner described...

Page 130: ...t for initial location of clamps 3 Install two Jubilee Type hose clamps on the propeller shaft as shown in Fig lO Position each clamp with heads 180 from crayon mark ing Tighten clan1ps 4 Run the car...

Page 131: ...edal assist spring with lubri plate bushes 302 C I D engine only 4 Lubricate bushes with MIC75A CLUTCH NOISY WHEN PEDAL 1 Release bearing failure 1 Replace bearing FREE TRAVEL IS TAKEN OUT ENGINE RUNN...

Page 132: ...park plugs to alleviate compression i While for cing the flywheel for ward rotate the crankshaft through one revolution and note MAXIMUM NEGATIVE BORE RUN OUT 0 0151NCH Cl017 C FIG 1 Flywheel Housing...

Page 133: ...The bearing is pre lubricated and should not be deaned with solvent Inspect the bearing retainer for damaged or loose spring clips and rivets Inspect the release bearing hub bore for burrs which may...

Page 134: ...surface Force each individual finger down then release it quickly If the finger does not return quick ly a binding condition is indicated and the pressure plate should be replaced The pressure plate...

Page 135: ...porate a spring dampened hub and the linings are cushion mounted to ensure a smooth take up of the drive The clutch disc hub is free to slide along the splines of the main drive gear shaft the forward...

Page 136: ...lease bearing is moved to ward the clutch moving the fingers of the diaphragm spring The release bearing is retained to the clutch release lever fork by means of two clips This method of clutch operat...

Page 137: ...king plug to prevent dirt enter ing the line 3 Withdraw the master cylinder after removing the two nuts and spring washers securing the master cylinder to the bulkhead INSTALLATION l Refit the master...

Page 138: ...he knife edge pivot Fig 10 3 Remove the release lever toward the centre of the flywheel housing FIG 11 lnstallation Sketch Clutch Operating Mechanism 5 15 INSTALLATION 1 Lubricate the knife edge pivot...

Page 139: ...5 16 GROUP 5 DRIVE LINE AND CLUTCH FIG 12 lnstallation 6 Cyl Clutch FIG 13 lnstallation 302 CID V8 Clutch FIG 14 lnstallation 351 Twin Disc Clutch...

Page 140: ...h a film of moly type grease Do not lubricate the clutch disc hub 4 Make certain that the fly wheel housing and the cylinder block mounting surfaces are clean Position the flywheel housing on the cyli...

Page 141: ...cylindrical adaptors Replace the guide pins with the grade 8 mounting bolts one at a time Tighten the pressure plate to fly wheel bolts finger tight Fig 19 Ensure the centre drive plate centralizing...

Page 142: ...flange 3 Fit the spring retainer in the rear end of the return spring com press the spring and locate the valve stem in the key hole slot in the end of the spring retainer 4 Insert the front of the pi...

Page 143: ...5 20 GROUP 5 DRIVE LINE AND CLUTCH I FIG 25 Clutch Operating Cylinder...

Page 144: ...e retaining bolts 7260 Series Universal pinion yoke nuts 1310 Series Universal pinion yoke U bolt nuts Clutch master cylinder mounting nuts Clutch slave cylinder mounting bolts Twin plate clutch press...

Page 145: ...REFERENCE TO SERVICE INFORMATION AND NOTES Date Letter No Pa1e Brief Detail...

Page 146: ...smission Series BW 199333 3 Speed Fully Synchronised Manual Shift Transmission Series BW 199332 and 199331 4 Speed Fully Synchronised Manual Shift Transmission RUG A R and RUG B F Specifications GROUP...

Page 147: ...sis proce dure is compiled as a guide in cor recting problems related to manual transmissions Trouble symptoms DIAGNOSIS GUIDE TRANSMISSIONS To eliminate all possibility of maladjustments or faulty co...

Page 148: ...op check clutch to make sure that it is within specification B Excessive engine idle speed C Binding input shaft pilot bear ing SHIFT LINKAGE 1 Improper crossover 2 Loose nuts at steering column lever...

Page 149: ...and shift rods If the nuts are loose check for bell mouthing of slots 2 Bent transmission shift rods or linkage interference 3 Lack of lubrication of shift linkage trunnions STEERING COLUMNS 1 Improp...

Page 150: ...slots STEERING COLUMN 1 Incorrect adjustment of shift linkage Make certain that when slowly shifting out of low gear the low gear shift lever at the transmis sion is completely out of low gear detent...

Page 151: ...al and throwout bearing rub are sometimes mistaken for main shaft bearing noise Gear lioll over noise will disappear when the clutch is disengaged or when the transmission is engaged in gear Throwout...

Page 152: ...LACEMENT 1 Remove the driveshaft 2 Remove the seal from the ex tension housing with the tool shown in Fig 1 3 Install the new seal in the extension housing with the tool shown in Fig 2 4 Install the d...

Page 153: ...he teeth are chipped broken or worn Replace the counter shaft if it is bent scored or worn 8 Replace the reverse idler gear or sliding gear if the teeth are chipped worn or broken Replace the idler ge...

Page 154: ...ted the shift lever moves the first and reverse sliding gear into mesh with the low gear on the countershaft cluster PART NQ ___________ MODELl I REF NQ I ____ SERIAL NQ _ I LwARNER BORG WARNER r 1 AU...

Page 155: ...e than one gear at a time Detent balls are provided to hold the selected gear in the desired position EJ IN CAR ADJUSTMENTS GEAR SHIFT LINKAGE ADJUSTMENT 1 Place the gear shift lever in the neutral po...

Page 156: ...ut shaft splines with the splines in the clutch disc Move the transmission forward on to the guide pins If the transmission front bearing retainer hangs up on the release bearing hub move the clutch r...

Page 157: ...spe sliding gear into first speed posltlon 16 Move the second and third gear synchronizer outer sleeve rear wards to engage the second speed gear clutch teeth 17 Remove the output shaft as sembly thro...

Page 158: ...tent ball which should now be fitted Interlock sleeves are selective ly fitted for axial movement of 002 to 010 in all gear selection positions refer Fig 21 Do not fit taper pin to second and third ca...

Page 159: ...ig 18 and the 8 Place the cluster assembly in the bottom of the gear case Fig 24 ensuring that the tangs of the thrust washers fit the grooves of the case 9 Assemble the second and third gear speed sy...

Page 160: ...zer sleeve to the rear ofthe case Fig 26 14 Fit the snap ring to the output shaft to retain the second speed gear and synchronizer assembly Measure the end float between the snap ring and the synchron...

Page 161: ...ning ring snap ring Fig 32 and third speed blocker ring to the input shaft Select the snap ring to FIG 30 lnput Shaft Rollers FIG 31 lnstalling Input Shaft Bearing keep the end float to a m1mmum withi...

Page 162: ...fer Fig 21 33 Install a new welch plug into the front face of the case ensuring that it does not protrude above the case face Fig 21 Use sealer on plug 34 Pour lubricant over the entire gear train whi...

Page 163: ...ves Fig 36 in stead of sliding gears The synchro nizers enable quicker shifts elimin ates gear clash and permit easy engagement of low gear at low vehicle speeds The forward speed gears are heli cal c...

Page 164: ...rough the reverse gear and sleeve to the output shaft and out the rear of the transmission Engagement of second and third gears is the same as first except for ratio In third gear the input gear and s...

Page 165: ...rom the front of the output shaft and slide off the second and third speed synchronizer assembly and the second gear with its blocker ring Take note of the synchronizer assembly hub end positions for...

Page 166: ...efer Fig 40 8 Place cluster assembly in the bottom of the gear case ensuring that the tabs of the thrust washers fit the grooves ofthe case Fig 41 9 Assemble first and reverse speed synchro assembly a...

Page 167: ...it tapered retaining pins into case use sealer on pins 19 Pull output shaft rearwards entering the rear bearing into the case until the bearing outer snap ring can be fitted Fit the oil slinger input...

Page 168: ...ct above the case face Fig 45 30 Position the top cover gasket install the top cover tighten the six bolts and lock washers to 8 12lbs ft torque Use sealer on bolt threads FIG 47 lnstalling Output Sha...

Page 169: ...r pan A flexible rubber dust boot Fig 50 is provided to seal the driver s compartment from the ex terior The shift pattern is shown on the top of the gear shift lever knob A safety measure is incorpor...

Page 170: ...h the synchronizer sleeve power is transmitted to the output shaft rotating it in a reverse direction NOTE All HELICAl GEARS IN CONSTANT MESH WITH COUNTERSHAFT GEAR FIG 49 Power Flow SECOND SPEED GEAR...

Page 171: ...e sure that the mounting surface of the transmission and the flywheel housing are free of dirt paint and burrs Install two guide pins in the flywheel housing lower mounting bolt holes Move the trans m...

Page 172: ...om the gear shift lever sup port shaft and withdraw the shaft 11 Clean and inspect all parts for wear or damage particularly the wave washers REASSEMBLY AND INSTALLATION 1 Lubricate all mating parts w...

Page 173: ...ent Transmission gear shift Transmission gear shift lever Transmission gear shift lever inner Transmission gear shift lever long 1 2 wave spring Transmission gear shift lever support Transmission gear...

Page 174: ...the front of the case Then withdraw Tooi T64P nii A COUNTERSHAFT FIG 52 Removing Counter shaft from Case the third and fourth speed shift rail from the front ofthe case Do not lose the interlock pin...

Page 175: ...he shaft 24 Remove the next snap ring and the second speed gear thrust washer from the shaft Slide the second speed gear and the blocking ring off the shaft 25 Remove the next snap ring then slide the...

Page 176: ...the shaft Fig 60B 2 Press the input shaft gear out of the bearing as shown in Fig 61 3 Press a new bearing onto the input shaft with the tool shown in Fig 61 4 Secure the bearing with a snap ring SYNC...

Page 177: ...FT AND BEARING ROLLER BEARINGS rr 1 v I BLOCKING RING FIG 608 Input Shaft Gear Disassembled INPUT SHAFT SEAL 1 Remove the seal from the input shaft bearing retainer as shown in Fig 62 2 Coat the seali...

Page 178: ...11 Install the first and second speed synchronizer onto the front of the output shaft Fig 69 making sure that the shift fork groove is to ward the rear of the shaft The first and reverse synchronizer...

Page 179: ...gs 29 Position the front blocking ring in the third and fourth speed syn chronizer Place the input shaft gear in the transmission case making sure that the output shaft pilot enters the roller bearing...

Page 180: ...to make sure that they operate properly 38 Use a new cover gasket and in stall the cover Coat the cover attach ing screws with sealer and install and tighten them to specifications 39 Coat the third a...

Page 181: ...4 Output Shaft Bearing End Float 0 000 0 004 Interlock Sleeve all Four Gear Positions v ith one cam in neutral and the other in gear there must be 0 002 min to 0 0 I0 max axial movement of the inter l...

Page 182: ...Cam and Shaft 18 23 Shift Fork to Shift Rail 10 18 Filler Plug to Case 10 20 Flush to Detent Set Screw special 0 020 below surface Third and Fourth Shift 10 18 Rail Detent Bolt Transmission to Flywhe...

Page 183: ...REFERENCE TO SERVICE INFORMATION AND NOTES Date Letter No Page Brief Detail...

Page 184: ...AIRLANE w P GROUP AUTOMATIC TRANSMISSION 7 PAGE PART 7 1 Borg Warner Automatic Transmission 7 2 PART 7 2 C4 Automatic Transmission 7 37 PART 7 3 F M X Automatic Transmission 7 82 PART 7 4 Specificatio...

Page 185: ...ATIC D Normal Drive Position Car starts in first gear and automatic ally shifts to second and third gears 2 Second gear Car starts and remains in second gear 1 First gear Car starts and remains in fir...

Page 186: ...raulic needs of the automatic transmission and torque converter EPICYCLIC GEAR TRAIN The gear train consists of two sun gears two sets of pinions mounted on a pinion carrier and a ring gear In forward...

Page 187: ...er and automatic transmission are sup plied by this pump The oil pump consists of an inner externally toothed gear in mesh with an internally toothed gear housed eccentrically to the inner gear The dr...

Page 188: ...irst to second WEIGHT VALVE GOVERNOR SPRING VEHICLE STATIONARY FIG 6 Governor Operation LOW SPEED OPERATION and second to third valves to con trol the change points sensitivity relative to throttle pr...

Page 189: ...rge end of the valve is opposed by reduced throttle pressure opera ting on the small end of the valve and throttle pressure operating on the end of the second to third valve plunger The latter force i...

Page 190: ...vo release Due to absence of governor pressure the shift valves and servo orifice con trol valve do not operate in this selector position Power Flow The rear clutch is applied so that the converter tu...

Page 191: ...ol pressure feed to line 22 and replacing it with governor pres sure from line 2 The transmission is now in normal drive range 3 2 SHIFT AT SPEED When 2 is manually selected from FIG 8 Inhibitor Switc...

Page 192: ...valve The front clutch and the front servo are now applied giving 2nd gear The control pressure in lines 12 and 3 at the range control valve is also exhausted via the manual control valve This allows...

Page 193: ...I_J 11 M __ MODULATOR 1 1 L J l s r r w P R N D 2 L j pel J n n r l r u u r l r MANUAL 7 ___ I 1 r 1 DUMP VALVE I I r r t 1 1 0 1 I I I r 3 I t i 1 1 I 2 r a r L I 1 7 t rx fXI 3 SHIFT 2 SERVO I 0 1 I...

Page 194: ...is water cooled check the fluid lines and fit tings between the transmission and the cooler in the radiator tank for looseness wear or damage If leak age cannot be stopped by tightening a fitting repl...

Page 195: ...ase pressures within the transmission Observe the front oi the flywheel back of the block in as far as possible and inside the converter housing Fig I Run the engine until fluid leakage is evi dent an...

Page 196: ...n verter before making the next test If the engine speed recorded by the tachometer exceeds the maximum limits specified in Table 1 release the accelerator immediately because clutch or band slippage...

Page 197: ...penings the changes may be difficult to detect Confirmation that the trans mission is in third gear mar be obtained by selecting 2 when a third to second change should be felt Test 5 a At 30 m p h in...

Page 198: ...EAII CLUTCH FII ONT lAND II EAII lAND ONE WAY CLUTCH TUII IINE SELECTOR LEVER FRONT REAR FRONT REAR ONE WAY POSITION CLUTCH CLUTCH BAND BAND CLUTCH LOCK UP 1 D DRIVE 1 2 1 orO LOCK UP 2 DRIVE 2 D DRIV...

Page 199: ...AY CLUTCH DRIVE PLATE AND STARTER RING GEAR CLUTCH PISTONS FRONT CLUTCH FRONT OIL PUMP PINION CARRIER CENTRE SUPPORT FRONT BRAKE BAND REAR CLUTCH FRONT PUMP ADAPTOR PINIONS GOVERNOR RING GEAR FORWARD...

Page 200: ...valve sticking m Second to third shift valve plunger sticking n Converter out check valve missing or sticking p Pump check valve missing or sticking D Incorrect engine idling speed E Incorrect front b...

Page 201: ...eutral 1 3 2 c Upward Cban1es 0 No first to second change 1 2 8 9 10 6 7 3 4 s No second to third change 1 8 9 10 6 7 2 3 4 s Above normal change speeds 1 8 9 10 2 7 3 4 s 6 f Below normal change spee...

Page 202: ...4 2 7 8 3 c Downward Chance Quality 1 0 Slip on second to first change 1 Slip on third to second change 1 6 7 8 4 s 3 9 2 1 Harsh second to first change 3 2 1 1 Harsh third to second change 1 s 3 4 2...

Page 203: ...may be attributable to other malfunctions a No drive in D 1 2 or R b Slip and squawk or judder on full throttle starts in D 1 2 or R c Overheating due to high fluid level during sustained high speeds...

Page 204: ...m in relation to the accelerator pedal This method can be used when a new downshift valve cable is being fitted and the transmission sump is removed The method of adjustment is as follows 1 Remove all...

Page 205: ...ent screw see Fig 19 until a fast idling speed is obtained then turn the volume control screw Fig 19 either clockwise or anti clockwise to obtain the maximum vacuum reading Readjust the idling speed a...

Page 206: ...essary add enough fluid to the transmission to raise the level to the F Full mark on the dipstick Do not overfill the transmission OIL COOLER FLUSHING PROCEDURE When a clutch or band failure or other...

Page 207: ...ach ing screws at the front of the console and the four screws in the glovebox and remove the console and gear lever slide assembly 4 Detach the dial indicator light 5 The gear lever slide assembly wh...

Page 208: ...omposidon dutch plates and bands should not be cleaned in a vapor degreaser or with any type of detergent soludon To clean these p811s wipe them oft with a lint free cloth New clutch plates and bands...

Page 209: ...e pipe is not damaged and prise the pipes out 5 Remove the valve bodies as sembly Disconnect the cable from the downshift cam and remove three bolts two longer bolts pass ing through the rear of valve...

Page 210: ...lubricated with automatic trans mission fluid REASSEMBLING THE VALVE BODIES 1 Refit the modulator valve spring valve plunger valve and plug Secure the plug with the dowel Refit the servo orifice cont...

Page 211: ...7 28 GROUP 7 AUTOMATIC TRANSMISSION 1ST 2ND SHIFT VALVE J lND JRD PLUNGER FIG 27 Exploded View of Upper Valve Body and Valves FIG 28 Exploded View of G T A Control Valve and Body UPPER VALVE BODY...

Page 212: ...way that it cannot be refitted incorrectly 5 The front band should be adjusted as previously described 6 Refit the sump Ensure that the lower face of the transmission and the sump flange are perfectly...

Page 213: ...el wasner which has two flats on the internal diameter locating on the rear clutch projection 14 Withdraw the rear clutch and sun gears Fig 33 The needle thrust race and washer are posi tioned on the...

Page 214: ...tes alternating Re move the clutch inner hub which will reveal a further large circlip retaining the diaphragm spring and piston Remove this circlip and spring To remove the piston it is neces ary to...

Page 215: ...ick externally splincd spacer plate Fig 40 Note that the outer splined plates for the rear clutch are dished whereas the front clutch plates are flat These dished plates can be fitted so that the dish...

Page 216: ...ress the straight spring arm and engage with the lug on the servo body GOVERNOR To Dismantle To separate the two parts of the governor body remove the two cheese headed screws together with their spri...

Page 217: ...ps to the out side See Fig 46 Turning the cage whilst presSmg inwards will assist in fitting the one way clutch Then fit the centre support to the assembly so that the centre bou is inside the one way...

Page 218: ...o_t damaged Align the bolt holes usmg the small hole as a register and secure with the five bolts and lockwashers 15 Refit the governor Fig 46 Turn the output shaft until the governor driving ball hol...

Page 219: ...REFERENCE TO SERVICE INFORMATION AND NOTES Date Letter No Pace Brief Detail...

Page 220: ...edometer cable con nection at the transmission Leak age at the oil pan gasket often can be stopped by tightening the attach ing bolts to the proper torque If necessary replace the gasket Check the flu...

Page 221: ...ump seal leaks The following areas of possible leakage should also be checked to determine if engine oil leakage is causing the problem a Leakage at the rocker arm cover valley cover may allow oil to...

Page 222: ...D TO WASHER D1067 A Tire Pressure Gouge FIG 3 Typical Converter Leak Checking Tool 4 Place the converter in a tank of water Observe the weld areas for bubbles If no bubbles are observed it may be assu...

Page 223: ...ansmission If the vacuum reading is lower than 18 inches an engine problem is indicated or there is leakage in the vacuum line Make necessary re pairs to obtain a minimum vacuum reading of 18 inches A...

Page 224: ...at engine idle is too high in all ranges the trouble may be in the diaphragm unit or its connecting vacuum tubes and hoses throttle valve or control rod With the engine idling discon nect the hose fr...

Page 225: ...t shows normal speeds the acceleration is good but the car drags at cruising speeds the difficulty is due to a seized stator assembly If the stator is defective replace the converter INITIAL ENGAGEMEN...

Page 226: ...vos do not operate dis assemble clean and inspect them to locate the source of the trouble If air pressure applied to any clutch passage fails to operate the clutch or operates more than one clutch at...

Page 227: ...Transmission Overheats AOF n Maximum Speed Too Low Poor Acceleration n Transmission Noisy in N F d Transmission Noisy in First Second and Reverse Gear F h d Transmission Noisy in P F d Fluid Leak MNOP...

Page 228: ...tional quarts of transmission fluid 6 Repeat steps 3 through 5 until the transmission fluid flowing out of the cooler return line is clean 7 If there is no fluid flow or the fluid does not flow freely...

Page 229: ...r valves in the governor housing and check them for free movement Each valve should fall of its own weight when dry CLUTCH ASSEMBLY 1 Inspect the composition clutch plates for damage These plates shou...

Page 230: ...ing driven at fo im peller speed This is known as the coupling point When the turbine is rotating at less than o impeller speed the con verter is multiplying torque The fluid leaving the turbine blade...

Page 231: ...shaft from rotating The gear set is in neutral N Neutral Places the gear set in neutral but does not lock the transmission TOWING Important Should it be necessary to tow a vehicle fitted with a C4 tra...

Page 232: ...iston and band the hydraulic pressure is ex hausted from the apply side of the piston The compressed return spring expands to release the piston and the low reverse band POWER FLOW All Gear Rotations...

Page 233: ...r flow through the input shell to the sun gear With the sun gear and the forward clutch hub ring gear driven at the same speed the forward planet assembly that is splined to the output shaft is forced...

Page 234: ...CLUTCH ONE WAY CLUTCH HOLDING REVERSE PLANET CARRIER AGAINST ROTATION INPUT SHAFT INPUT SHAFT 2 RANGE OR D RANGE 2 7 51 l OUTPUT SHAFT l OUTPUT SHAFT D RANGE LOW D RANGE HIGH FORWARD CLUTCH REVERSE HI...

Page 235: ...he l 2 shift valve The 1 R passage supplies fluid through a ball shuttle valve to the line coasting boost valve 2 3 shift valve downshift valve and through the downshift valve to and through the throt...

Page 236: ...ATIC TRANSMISSION DRAIN BACK CONVERTER PRESSURE REUEF VALVE X EXHAUST FIG 20 Hydraulic Control System C4 Automatic 250 VI and 351 2V 250 2V and 302 2V are the same but incorporate a ball in the thrott...

Page 237: ...inward allowing governor pressure to exhaust and close the passage between line pres sure and governor pressure When governor pressure is reduced the secondary valve will again move outward closing th...

Page 238: ...sure on 250 2V and 302 now re places regulated downshift pressure and is directed to the 2 3 and 1 2 shift valves In D Range Because there is no control line pressure feed to the downshift valve in th...

Page 239: ...e D2 valve and to the reverse and low band via the low servo modulator valve The transmission will remain in low or first gear until another mode of operation is selected 2 Range In 2 range 2 oil pres...

Page 240: ...s section of the manual THROTTLE ADJUSTMENTS 1 Apply the parking brake and place the selector lever at N 2 Run the engine at normal idle speed If the engine is cold run the engine at fast idle speed a...

Page 241: ...light S The gear lever slide assembly which incorporates the dial may be detached from the console by remov ing the four attaching screws 6 Remove the selector housing and lever assembly attaching bo...

Page 242: ...nto the gauge pin holes of the switch The gauge pin has to be inserted to a full U inch into the three holes ofthe switch Fig 25 3 Torque the two switch attach ing bolts to specification Remove the ga...

Page 243: ...g 29 10 Hold the detent spring roller in the centre of the manual detent lever and install the detent spring to lower valve body bolt Tighten the bolt to specifications 11 Tighten all the control valv...

Page 244: ...the bolts to speci fication 10 Adjust the reverse band 11 Lower the car and check the transmission fluid level EXTENSION HOUSING BUSHING AND REAR SEAL REPLACEMENT 1 Disconnect the drive shaft from the...

Page 245: ...ansmission and secure the transmission to the jack with a safety chain FIG 35 Converter Drain Plug Location FIG 36 Transmission Mounted on Jack 15 Remove the four crossmem ber and mounting pad attachi...

Page 246: ...vacuum unit gasket and control rod 3 From the vacuum unit hole in the case remove the primary throttle valve Fig 38 4 Remove the two extension housing to case attaching bolts and mount the transmissi...

Page 247: ...r housing up FIG 44 Removing or Installing Input Shaft D 1867 8 FIG 45 Removing Front Pump P INTERMEDIA BAND CLEARANCE HOLE IN CASE D 1389 A FIG 46 Removing or Installing Intermediate Band 2 Remove th...

Page 248: ...embled REVERSE PLANET CARRIER REVERSE RING GEAR AND HUB THRUST WASHER NO 7 LOW AND REVERSE DRUM FIG 51 Lower Part of Gear Train Disassembled e I 19 LOW R D1396 A FIG 53 Removing or Installing Low Reve...

Page 249: ...r distributor sleeve are re moved 21 Remove the transmission from the holding fixture Position the transmission on the bench in a vertical position with the extension housing up Remove the four exten...

Page 250: ...case Lubricate the piston seal with clean transmission fluid and install the servo piston Fig 58 5 Place a new cover seal on the cover and install the servo cover Install the four cover attaching bolt...

Page 251: ...Case Thread service kits may be purchased from local suppliers To repair a damaged thread the following procedures should be carefully followed 1 Drill out the damaged threads using the same drill siz...

Page 252: ...ing pin and remove the inter mediate accumulator retainer valve and spring from the body 13 Press the main oil pressure booster valve inward and remove the retaining pin Remove the main oil pressure b...

Page 253: ...1 2 3 BACK OUT VALVE tt THROTTLE MODULATOR i u mM m VALVE INTERMEDIATE 3 SERVO ACCUMULATOR 3 ALVE l io tlt s3 LE i REGULATOR VALVE LJ 5s tD 1 EG I RETAINER PIN g 3f i RETAINER it_ _ V SLEEVE H MAINOI...

Page 254: ...rt in the pump housing and install the five attaching bolts Torque the bolts to specifications 6 Install the four seal rings on the stator support Two large rings are assembled first in the ring groov...

Page 255: ...iner 9 When new composition clutch plates are used soak the plates in transmission oil for fifteen minutes before the plates are assembled Install the clutch plates alternately by starting first with...

Page 256: ...to the clutch hub Install the steel ring on the piston Install the disc spring and retaining snap ring Fig 79 8 Install the lower pressure plate with the flat side up and radius side downward Install...

Page 257: ...al snap ring on the sun gear Fig 83 REVERSE RING GEAR AND HUB 1 emove the hub retaining snap rmg from the reverse ring gear 2 Remove the hub from the reverse ring gear Fig 85 3 Install the hub in the...

Page 258: ...2 Install a new transmission case bushing with the tool shown in Fig 88 Front Pump Stator Support 1 Remove the front and rear stator support bushings if they are worn or damaged Use the cape chisel Fi...

Page 259: ...d press a new bushing into the drum with the handle and tool shown in Fig 93 Forward Clutch Hub 1 Press the bushing from the clutch hub as shown in Fig 94 2 Install a new bushing into the clutch hub a...

Page 260: ...TO OUTPU fSHAFT 01549 A FIG 101 Governor and Reverse Ring Gear and Hub Snap Ring ldentificatton and the parking pawl retaining pin has to be inserted in the alignment hole in the distributor sleeve 7...

Page 261: ...SE PLANET CARRIER 11 FORWARD CLUTCH AND 19 THRU r WASHER NO 7 CYLINDER 20 SNAP RING FIG 102 Transmission Sub Assemblies 21 REVERSE RING GEAR AND HUB 22 tow AND REVERSE BAND 23 BAND STRUTS 24 THRUST WA...

Page 262: ...Fig 106 23 Using the end play check reading that was obtained during the transmission disassembly to determine which No 2 steel backed thrust washer is required proceed as follows a Position the stat...

Page 263: ...utch Units THRUST WASHER NO 3 FIG 107 Number 3 Thrust Washer Location THRUST WASHER NO 7 j REVERSE PLANET CARRIER THRUST WASHER NO 6 D1444 A FIG 105 Number 6 and 7 Thrust Washer Location FORWARD CLUTC...

Page 264: ...ing fixture to place the transmission in a hori zontal position Check the trans mission end play as shown in Fig 42 If the end play is not within specification either the wrong selec tive thrust washe...

Page 265: ...et Check the fluid filler tube con nection at the transmission If leakage is found here install a new 0 ring Check the fluid lines and fittings between the transmission and the cooler in the radiator...

Page 266: ...present in or at the bottom of the converter housing 2 Oil galley plug leaks will allow oil to flow down the rear face of the block to the bottom of the converter housing 3 Leakage by the crankshaft s...

Page 267: ...ge adjustment proce dures STEEL PLATE o a X 1 DRILL TO SUIT SPACER 82Q 9438 A PLUG RUBBER PLUG 1Y2 DIA X 2 LONG Y2 HOLE THRU APPROXIMATELY 40 DUROMETER STANDARD BOLT Y2 13 X 4 1 2 LONG SQUARE CHAIN 10...

Page 268: ...r Leakage Control Pressure is Low at Engine Idle Test No 1 If control pressure at engine idle is low in all selector lever positions trouble other than the diaphragm unit is indicated When control pre...

Page 269: ...essure is still extremely erratic the trouble is in the transmis sion hydraulic regulating circuits Clean and inspect the control valve body VACUUM DIAPHRAGM ADJUSTMENT The vacuum diaphragm fitted to...

Page 270: ...the converter SHIFT POINT CHECKS Check the mimimum throttle up shifts in D The transmission should start in first gear shift to second and then shift to third within the shift points specified in the...

Page 271: ...s installed in the vehicle TESTING TOOL INSTALLATION 1 Install a plug in the filler tube hole in the case or fluid pan and pour about four quarts of clean transmission fluid into the transmission thro...

Page 272: ...on oil cooler 1 After installing a new or re built automatic transmission and converter assembly in the vehicle do not connect the cooler return line to the transmission Place the trans mission select...

Page 273: ...ce holding tool in one of the four holes provided in the stator Fig 13 3 Insert the tool in the converter pump drive hub As the tool enters the converter the pins will engage the stator clutch inner r...

Page 274: ...F M X AUTOMATIC TRANSMISSION 7 91 Split Fib Bushing END PLAY CHECK Torque Wrench Tooi T58L 7902 Bor 7946 A Tooi T63P 7902 A STATOR CLUTCH CHECK 01934 A FIG 13 Typical Converter Checking Tool FMX Tran...

Page 275: ...ct the sun gear shaft splines for burrs and wear 10 Check the fit of the seal rings in the grooves of the shaft The rings should enter the grooves freely with out bind 11 Check the fit of the seal rin...

Page 276: ...rd the unit Check the splines on the turbine shaft for wear and replace the shaft if the splines are excessively worn Inspect the bushing in the turbine shaft for scores FRONT PUMP AND STATOR SUPPORT...

Page 277: ...n Transmission Noisy in N F ad Transmission Noisy in First Second Third or Reverse Gear F habd Transmission Noisy in P F d Fluid Leak MNOPQSTUX jmp Probably Trouble Sources A Fluid Level S Extension H...

Page 278: ...a stator All these parts are enclosed and operate in a fluid filled housing When the engine is running the fluid in the torque converter flows from the impeller to the turbine and back to the impelle...

Page 279: ...en plates are connected to the rear clutch drum and secondary sun gear When the rear clutch is applied in the reverse and third gear ratios the secondary sun gear is driven The pis ton is returned to...

Page 280: ...SION FORWARD CLUTCH FIG 24 Hydraulic Control System COOLER RETURN OIL CHECK VALVE X EXHAUST LOW REVERSE SERVO 7 97 CHECK BALL USED IN PHD MODEL TRANSMISSIONS ONLY LOW SERVO MODULATOR VALVE CONVERTER C...

Page 281: ...secondary sun gear turns free in the reverse direction and has no effect on the gear train Power Flow First Gear D In first gear at the D selector lever position the pinion carrier is held against rot...

Page 282: ...ig 30 The secondary pinions drive the internal gear in the reverse direction The pri mary sun gear and the primary pinions rotate freely and have no effect on the gear train REAR BAND REAR CLUTCH RELE...

Page 283: ...ottle valve is controlled by a spnng loaded vacuum diaphragm unit mounted on the rear of the transmis sion case Fig 24 The vacuum diaphragm is actuated by the engine intake manifold vacuum working aga...

Page 284: ...g the servo apply force as follows To make a complete servo applica tion apply pressure must stroke the servo piston against the force of the release spring and at the same time force out the fluid in...

Page 285: ...llowing direct and reverse clutch apply pressure to exhaust at the manual valve without further obstruction 1 2 SHIIT VALVE SHUTTLE BALL CHECK VALVE Fluid is directed from the D and 1 R P passages of...

Page 286: ...lever in D position l Raise the vehicle and loosen the manual lever shift rod retaining nut Fig 31 Move the transmission manual lever to the D position fourth detent position from the back of the tran...

Page 287: ...21 Raise the vehicle Install the transmission manual lever rod to the selector lever With the transmission in neutral and the selector lever against the neutral stop tighten the selector lever to manu...

Page 288: ...the gas ket When removing the extension housing and or governor hold the output shaft and rear support from moving rearward to prevent the needle bearing and race from dropping out of location 12 Remo...

Page 289: ...push rod in the bore of the vacuum diaphragm unit Using the diaphragm unit as a guide insert the push rod into the threaded opening of the case Torque the dia phragm unit to specification Connect the...

Page 290: ...rol valve body Check the clearance between the manual valve and the manual lever actuating pin as given above in Oil Pan and Control Valve Body Replace ment 10 Adjust the rear band 11 Install the flui...

Page 291: ...m the starter and remove the start er 5 Remove the nuts that attach each muffler inlet pipe to the exhaust manifolds Separate the pipes from the manifolds and allow them to hang 6 Disconnect the oil c...

Page 292: ...n pressure oil tube by gently prying up the end that connects to the main control valve as sembly first Then remove the other end of the tube from the pressure re gulator Be sure to remove the tube in...

Page 293: ...ther tilt the band to the rear and remove the rear band from the case II Remove the two center support outer bolts one each side from the transmission case 12 Exert enoug h pressure on the end of the...

Page 294: ...ver the output shaft hub Then press the bushing on the output shaft hub as shown in Fig 46 PRIMARY SUN GEAR SHAFT I Position the primary sun gear shaft in the clutch bench fixture 2 Check the fit of t...

Page 295: ...eated in the groove 17 Check the free pack clearance between the pressure plate and the snap ring with a feeler gauge The clearance should be 0 030 0 055 inch If the clearance is not within specifi ca...

Page 296: ...ing wall Pry the loose ends of the bushing up with an awl and re move the bushing 9 Slip a new bushing over the end of the installation tool and position the tool and bushing to the bushing hole Then...

Page 297: ...hing screws Check the pump gears for free rotation REAR SUPPORT BUSHING REPLACEMENT I Remove the three pressure tubes from the support housing Tool T64L 7003 A2 Hondic D 2050 A FIG 62 Installing Rear...

Page 298: ...PLUG SIDE PLATE THROTTLE REDUCING VALVE r CDMPENSATDR E _ _ Qj _ DDWNSHIFTVALVE 0 MANUAL __ 0 VALVE THROTTLE BOOST SHORT VALVE AND SLEEVE 1 SPRING RETAINER 2 1 SCHEDULING cw VALVE THROTTLE BOOST VALV...

Page 299: ...cumulator valve and 1 2 shift accumu lator lockout valve FIG 65 Check Valve Locations 18 Remove the through bolts and screws Then separate the bodies Re move the separator plates from the valve bodie...

Page 300: ...ve the shaft press on the end opposite the serra tions Inspect the adjusting screw threads and the threads in the lever 6 Check the servo spring and servo band strut for distortion BODY PIN _ _ 0 SHAF...

Page 301: ...er to fly out of the case 5 Remove the manual lever shaft nut and remove the detent lever Re move the outer manual lever and shaft from the transmission case 6 Tap the toggle lever sharply toward the...

Page 302: ...he race Fig 71 The service center supports are not chamfered The following as sembly procedures cover both types of center supports Installation Center Support With Chamfered Edge I Install the center...

Page 303: ...times 9 After all of the rollers have been started into the cam race rotate the carrier counterclockwise while pushing it forward Again straighten any roll ers which still may be in a cocked po sition...

Page 304: ...PRESSURE REGULATOR BOD 1 Install the pressure regulator body and attaching bolts and torqu the bolts to specifications 1 Install the control and converter valve guides and springs Install the spring r...

Page 305: ...OINTS 3 23 1 Diff ratio Manual Shift Throttle M P H Manual Shift Throttle M P H D 1 2 K D 31 39 D 1 2 Zero 8 10 D 2 3 K D 53 61 D 2 3 Zero 10 13 D 3 2 K D 44 54 D 3 1 Zero 4 8 D 3 1 K D 19 29 1 2 1 Ze...

Page 306: ...shaft 10 15 Pressure point use sealer 4 5 bearbox droin pluQ IU 14 Oil tube collector to lower body 20 30 in lb Governor line plate to lower body 20 30 in lb _1 _ower body end plote to lower body 20 3...

Page 307: ...Thrust WIShers Available Turbine and Stator End Play Check 0 040 inch maximum lnttrmtdialt Band Adjustment Adjust tcrtw to 10 ft lbs torque tnd back off 1 turns low Rtvtrst Band Adjustment Adjust tcr...

Page 308: ...or 3 1 36 38 STALL SPEED LIMITS Engine Model Engine Speed rpm 250 1V 250 2V 302 2V 351 2V CLUTCH PLAnS AtYirst Hi h Clutch Transmission Modtl Sttel Composition PlattS Platts PEE AC PEF C Converter siz...

Page 309: ...LIMITS Capacity Imp 91 4 QIS Enaine Model Entine Splld rpm Type M2C33F 351 ClD 4V 1650 1850 FMX TRANSMISSION WITH 351 4V ENGINE AXLE RATIO 2 75 1 Throttle Range Shift 1 Closed 0 1 2 10 16 Above D 2 3...

Page 310: ...0 061 063 By Thickness 0 074 076 0 067 069 0 081 083 CONTROL VALVE SPRING ICENT FICATION Free Sprin Wire Sprin Total Len th Dia O D Dia Le111th at Lbs Load Sprin Col or Coils Inches Inches Inches Loa...

Page 311: ...r to Shaft 17 20 Guide Plate to Case Filler Tube to Engine 20 25 Intermediate Servo Cover to Case Filler Tube to Pan Regulafor to Case 17 22 Transmission to Engine 40 50 Planetary Support to Trans Cas...

Page 312: ...FALCON FAIRLANE w P ENGINE GROUP 8 PAGE PART 8 1 General Engine Service 8 2 PART 8 2 200 250 C I D Six Cylinder Engines 8 22 PART 8 3 302 C I D 351 C I D Engines 8 44 PART 8 4 Specifications 8 67...

Page 313: ...ion Damper and Sleeve Crankshaft Flywheel Manual Shift Transmission Flywheel Automatic Transmission Connecting Rods Pistons Pins and Rings Main and Connecting Rod Bearings Cylinder Block Oil Pan Oil P...

Page 314: ...RK PLUGS Check the spark plugs If the spark plugs are not at fault check the following items MANUAL CHOKE Check the choke linkage for bind ing or damage Make certain the choke plate closes when the ch...

Page 315: ...ak Perform a manifold vacuum or compression test to determine which mechanical component of the engine is at fault MISSES ERRATICALLY AT ALL SPEEDS EXHAUST SYSTEM Exhaust system restricted IGNITION SY...

Page 316: ...low float sett ing Power valve or passages clogged or damaged Fvel pump pressure incorrect Power valve piston stuck In the up position 6 cylinder and 302 V8 Automatic choke malfunctioning or improperl...

Page 317: ...nt volta t tive ENGINE temperatures ot regulator defec Cylinder head bolts not properly tm qued Incorrect valve clearance Low oil level or im on ect viscos ity oil used COOLING SYSTEM Insufficient coo...

Page 318: ...r malfunc tion If these conditions are found to be presept the lifter should be disassembled and cleaned in solvent to remove all traces of deposits Air bubbles in the lubricating oil 8 7 Intake manif...

Page 319: ...o perform a dynamic compression check follow the procedures in Part 9 1 Section 1 under Ignition System Tests Compression Gauge Check 1 Be sure the crankcase oil is at the proper level DISCONNECT AL T...

Page 320: ...will cause the plunger to force oil back into the TABLE 1 Manifold Vacuum Gauge Readings Gauge Reading Engine Condition 18 inches or over All engines Normal Except where otherwise specified Low and st...

Page 321: ...idle condi tion remains when the good regulator valve is installed the crankcase venti lation regulator valve is not at fault Check the crankcase ventilation sys tem for restriction at the intake mani...

Page 322: ...must be re placed CAMSHAFT END PLAY Push the camshaft toward the rear of the engine Install a dial indicator so that the indicator point is on the camshaft sprocket retaining screw Fig 10 Zero the di...

Page 323: ...8 ENGINE 1 Disconnect the brown red lead I terminal and the red and blue lead S terminal at the starter relay Install an auxiliary starter switch between the battery and S terminals of the Starter re...

Page 324: ...tact the approximate centre of the valve face It is good practice to de termine where the valve seat contacts the face To do this coat the seat with Prussian blue then set the valve in place Rotate th...

Page 325: ...0 040 FIG 19 Piston Ring Gap If the new rings are to be installed in a used cylinder that has not been refinished remove the cylinder wall glaze Be sure to clean the cylinder bore thoroughly followin...

Page 326: ...ould make it unfit for further service Replace all studs that are stripped or otherwise dam aged Remove all fiilngs and foreign matter that may have entered the manifold as a result of repaln EXHAUST...

Page 327: ...ition and the end of the stem for grooves FIG 22 Typical Cylinder Head Flatness or scores Check the valve head for signs of burning erosion warpage and cracking Defects such as minor pits grooves etc...

Page 328: ...ON Clean the camshaft in solvent and wipe it dry Inspect the camshaft lobes for scoring and signs of ab normal wear Lobe wear character istics may result in pitting in the general area of the lobe toe...

Page 329: ...f the pin bore is not within specifications Replace defective connecting rod nuts and bolts If the connecting rod has been removed from the piston it should be checked for bend or twist before assembl...

Page 330: ...face following the procedure and specifi cations recommended for the cylin der head The cylinder block can be machined to bring the cylinder head gasket surface within the fiat ness specifications but...

Page 331: ...ve spring ten GROUP 8 ENGINE sion If the spring tension is not with in specifications and or the spring is defective replace the spring Check the relief valve piston for scores and free operation in t...

Page 332: ...REFERENCE TO SERVICE INFORMAnON AND NOTES Date Letter No Pa1e Brief Detail...

Page 333: ...OLDS Exhaust gases provide the heat necessary to assist in vaporizing the incoming fuel mixture CYLINDER HEAD Sectior Camshaft Rear Bearing Bore Plug Replacement Hydraulic Valve Lifter Main and Connec...

Page 334: ...aulic ram which forces the valve in the cylinder head to open During this period a slight leakage of oil past the plunger occurs calibrated leak down rate As the high point of the camshaft lobe rotate...

Page 335: ...engine through the oil filler cap located on the front of the valve rocker arm cover The filler cap contains a filter FIG 4 Hydraulic Valve lifter Operation ing element which filters the incom ing air...

Page 336: ...ock the coolant is A directed upward into the cylinder head where it cools the combustion chambers valves and valve seats on its return to the front of the engine At this point the coolant tl ows into...

Page 337: ...racket and remove the insulator Installation 1 Position the insulator to the en gine front support insulator bracket and install the retaining bolt and nut Torque to specifications 2 Carefully lower t...

Page 338: ...procedures INSTALLATION 1 Clean the mating surfaces of the exhaust manifold and cylinder head Inspect manifold to muffler inlet pipe sealing ring l Apply graphite grease to the mating surface of the e...

Page 339: ...2V engines the inlet and exhaust manifolds must be re moved before the cylinder head can be removed INSTALLATION Note On 250 2V engines the cyl inder head is replaced first followed by the exhaust ma...

Page 340: ...g retainer with dividers Fig 18 6 Check the dividers against a scale If the assembled height is greater than specifications install the necessary 0 030 inch thick spacer s between the cylinder head sp...

Page 341: ...ic transmission disconnect the transmission oil cooler lines from the radiator 2 Remove the radiator Remove the drive belt fan and pulley Using tool6306 AG Remove the crankshaft damper 3 Remove the cy...

Page 342: ...coil and remove it from the retaining clip on the cylinder head 8 Disconnect the engine temper ature sending unit wire from the sending unit Disconnect the flexible fuel line from the fuel tank line...

Page 343: ...flywheel and engine rear cover plate 3 Drill a t inch hole in the cam shaft rear bearing bore plug and use a suitable tool to remove the plug Fig 28 FIG 28 Camshaft Rear Bearing Bore Plug Removal 4 Cl...

Page 344: ...on the locking tang side of the block and partially install the bearing so that the tool can be inserted in the oil hole in the crankshaft With the tool posi tioned in the oil hole in the crank shaft...

Page 345: ...l the connecting rod assem bly down firmly on the crankshaft journal 7 Place a piece of Plastigage on the lower bearing surface the full width of the cap and about 1 4 inch off center 8 Install the ca...

Page 346: ...have been in stalled check the connecting rod side clearance on each crankshaft journal Fig 34 r INSERT ERED PILOT PISTON PIN Tool T68P 6 J35 A Cup Detail J FIG 35 Removing Piston Pin 9 Prime the oil...

Page 347: ...housing and transmission following the pro cedure in Group 7 It is not neces sary to adjust the transmission when it bas been removed only for fly wheel removal CLUTCH PILOT BEARING REPLACEMENT Inspec...

Page 348: ...ody 2 Position the intermediate drive shaft into the distributor socket 3 Position a new gasket on the pump housing Insert the intermed iate drive shaft nto the oil pump Install the pump and shaft as...

Page 349: ...ew gasket over the studs of the ex haust manifold l Carefully lower the engine into the engine compartment 3 Make sure the studs on the ex haust manifold are aligned with the boles in the muffler inle...

Page 350: ...necting rod from which the cap is being removed is down Remove the connecting rod cap Push the connecting rod and piston assembly up in the cylinder Repeat for the remaining caps 7 Remove the main bea...

Page 351: ...for scratches burrs nicks or dirt If the thrust faces are not PRY CAP BACKWARD FIG 47 Typical Thrust Bearing Alignment defective or dirty they probably were not aligned properly Install the thrust bea...

Page 352: ...seal surfaces of all parts and assemblies refer to Page 8 19 ASSEMBLY Install the replacement cylinder block assembly on a work stand Transfer all parts removed from the old cylinder assembly to the n...

Page 353: ...the bearing cap bolts to specifications 10 Install the thrust bearing cap by following steps 12 through 15 under Crankshaft Installation 11 Check the crankshaft end play by following steps 17 through...

Page 354: ...ter resistant sealer Install but do not tighten two bolts at opposite ends of the head to hold the head and gasket in position Remove the guides then install the remaining bolts 47 The cylinder head b...

Page 355: ...shaft Rear Bearing Bore Plug Valve Lifter Valve Lifter Disassembly Crankshaft Rear Oil Seal Replacement Main Bearings Connecting Rod Bearings Pistons and Connecting Rods Flywheel Clutch Pilot Bushing...

Page 356: ...ear Supports Refer to page 8 15 for cleaning and inspection procedures Refer to page 8 2 for test procedures ENGINE FRONT SUPPORTS The front supports are located on each side of the cylinder block Fig...

Page 357: ...ion and the valve will be held open To determine whether a shorter or a longer push rod is necessary make the following check 1 Disconnect the brown lead I terminal and the red and blue lead S termina...

Page 358: ...e engine wire loom and position it out of the way 3 Disconnect the spark plug wires from the spark plugs by grasping twisting and pulling the moulded cap only Remove the wires from the harness bracket...

Page 359: ...d exhaust manifold is FIG 9 Typical VB engine crankcase ventilation system components being removed remove the oil filter 3 Disconnect the muffler inlet pipe at the exhaust manifold 4 Remove the exhau...

Page 360: ...en to 60 ft lbs and finally to specifications When cylinder head bolts have been tightened following this procedure it is not necessary to retorque the bolts after extended operation However the bolts...

Page 361: ...stem seals and retainers may be replaced without removing the cylinder head provided damage to the valve or valve seat has not occurred REMOVAL 1 Disconnect the automatic choke heat chamber air inlet...

Page 362: ...and remove the drive belt 7 Remove the water pump pulley 8 Remove alternator bracket from water pump and position it out of the way 9 If equipped with power steering remove the power steering pump bra...

Page 363: ...nt cover and water pump assembly 15 Disconnect the fuel pump outlet line from the fuel pump Remove the fuel pump attaching bolt and nut and lay the pump to one side with the flexible fuel line still a...

Page 364: ...ey can be installed in their original positions 6 Using a magnet remove the valve lifters and place them in a rack so that they can be installed in their original bores Fig 26 If the valve lifters are...

Page 365: ...l attaching bolts with oil resistant sealer Position the engine rear cover plate on the cylinder block dowels Position the flywheel on the crankshaft flange Install and torque the attaching bolts in s...

Page 366: ...alve or the valve tensioning finger 3 Remove the plunger assembly the check valve and the check valve retainer and plunger spring Carefully remove the plunger spring the check valve retainer and the c...

Page 367: ...to the rear main bearing cap at the rear of the top mating surface Fig 30 Do not apply sealer to the area forward of the oil slinger groove Lubricate the journal with engine oil and install the rear m...

Page 368: ...bore If a connecting rod is ever transposed from one block or cylinder to another new bearings should be fitted and the connecting rod should be numbered to correspond with the new cylinder number 3...

Page 369: ...will distort the bearing and cause a failure Install the bearing inserts in the connecting rod and cap with tangs fitting in the slots provided FLYWHEEL REMOVAL 1 On a vehicle with a manual shift tran...

Page 370: ...e over the oil pan gasket 5 Position the oil pan rear seal on the rear main bearing cap Fig 40 Be sure the tabs on the seal are over the oil pan gasket 6 Position the oil pan against the block and ins...

Page 371: ...oosen and remove the power steering pump drive belt 9 Remove the water pump pulley 10 On vehicles with power steering remove the power steering pump brackets and position the pump out of the way in an...

Page 372: ...Remove the spark plugs to allow easy rotation of the crankshaft 2 Disconnect the fuel pump outlet line at the pump Remove the fuel pump from the cylinder block Remove the alternator and mounting brac...

Page 373: ...resistant sealer to the rear main bearing cap at the rear of the top mating surface Fig 32 Do nGt apply sealer to the area forward of the oil slinger groove 12 Apply heavy engine oil MS to the journa...

Page 374: ...the top of the cylinders 2 Remove the camshaft rear bearing bore plug Remove the camshaft bearings Fig 45 DETAIL 1 2 or J EXPANDING COLLET EXPANDING MANDREL DETAIL 5 PULLER SCREW DETAIL 4 PULLING PLA...

Page 375: ...in deflection does not exceed 0 5 inches Remove the camshaft sprocket cap screw washer and two piece fuel pump eccentric Slide both sprockets and the timing chain forward and remove them as an assembl...

Page 376: ...into the oil pump 30 Prime the oil pump by filling either the inlet or outlet port with engine oil Rotate the pump shaft to distribute the oil within the pump body 31 Position a new gasket on the pump...

Page 377: ...ature GROUP 8 ENGINE FIG 47 Water Pump By PIJS Orfice Plug sending unit with electrical conductive sealer Install the oil pressure and temperature sending units in the block 54 Install the ignition co...

Page 378: ...2 164 123 204 166 124 206 168 126 208 170 127 210 172 129 212 Quick Reference Compression Pressure Limit Chart 8 61 GENERAL ENGINE Continued 200 LC 250 LC BORE AND STROKE 200 Six 250 SIX 302 V 8 2 V 3...

Page 379: ...r 0 006 inch overall DIAMETER Standard 0 3433 D 3443 0 070 0 090 0 060 0 080 Intake 30 Exhaust 45 Intake and Exhaust 45 VALVE SEAT RUNOUT Maximum All Engines 0 0015 COMBUSTION CHAMBER VOLUME CC 200 an...

Page 380: ...200 and 250 Intake and Exhaust 0 2455 Wear Limit 0 240 CAMSHAFT AND TIMING CHAIN Continued 302 351 2 V Intake 351 4 V 302 351 2 V Exhaust 351 4 V CAMSHAFT END PLAY 0 235 0 247 0 235 0 262 200 and 250...

Page 381: ...o Crankshaft Side Clearance 200 and 250 0 0035 0 01 05 Wear Limit 0 014 CONNECTING ROD Continued 302 and 351 CONNECTING ROD 0 01 0 0 020 Wear Limit 0 023 Twist Maximum Total Difference 200 and 250 0 0...

Page 382: ...ll MAIN BEARING BORE DIAMETER 200 and 250 2 4012 2 4020 302 2 9417 2 94 9 351 OIL PUMP Rotor Type RELIEF VALVE SPRING TENSION Lbs Specified Length in inches 200 and 250 9 0 10 1 1 078 302 351 23 6 24...

Page 383: ...TO VIBRATION DAMPER UBS BOLTS 25 35 PLACE BOLTS 35 45 CONNECTING ROD NUTS 200 250 and 302 19 24 302 351 40 45 TORQUE LIMITs Ft Lbs ALL MODELS Cont VALVE ROCKER ARM COVER All Engines VALVE ROCKER SHAFT...

Page 384: ...IRLANE w P IGNITION SYSTEM GROUP 9 PAGE PART 9 1 General Ignition System Service 9 2 PART 9 2 Dual Advance Distributor Bosch 9 14 PART 9 3 Dual Advance Distributor Motorcraft 9 18 PART 9 4 Specificati...

Page 385: ...351 302 250 200 distributors is 12100 To procure replacement parts it is necessary to know the complete part number In addition Bosch distributors can be identified by their diaphragm colour coding as...

Page 386: ...e engine by using an auxiliary starter switch between the starter relay battery and S terminals If the spark is good the trouble lies in the secondary circuit If there is no spark or a weak spark the...

Page 387: ...itch on 5 If the voltmeter reading is 0 1 volt or Jess the primary circuit from coil to ground is satisfactory 6 If the voltmeter reading is greater than 0 1 volt test the voltage drop between each of...

Page 388: ...tester 2 Turn the test control knob to the set position 3 Adjust the set control knob un til the needle on the dwell meter lines up with the set line 4 Start the engine and let it idle 5 Turn the test...

Page 389: ...ons BREAKER PLATE WEAR A worn breaker plate on the dual advance distributors will cause the breaker point dwell to change as engine speed and load condition are varied On the dual advance distributor...

Page 390: ...curately aligned and strike squarely in order to realize the full advantages provided by this design and assure normal breaker point life Any misalignment of the breaker point surfaces will cause prem...

Page 391: ...l the gauge at a right angle 90 to the movable arm until the breaker points just start to open Fig 12 If the tension is not within specifications adjust the spring tension on the pivot type points or...

Page 392: ...n in side the cap may become separated or the weather seal may be damaged 200 AND 250 C I D SIX CYLINDER ENGINES The ignition wire installation is shown in Fig 16 FIG 16 6 Cylinder Engine Ignition Wir...

Page 393: ...prolong the use of the abrasive blast as it will erode the Insulator and electrodes Clean the electrode surfaces with a small file Fig 21 Dress the elec trodes to obtain flat parallel surfaces on bot...

Page 394: ...EMS OR WORN OR LOOSE BEARINGS CAN BE CLEANED IF ENGINE IS NOT REPAIRED USE A HOTTER PLUG IDENTIFIED BY LIGHT TAN OR GRAY DE POSITS ON THE FIRING TIP CAN tlE CLEANED IDENTIFIED BY A WHITE UR LIGHT GRAY...

Page 395: ...or with a soft bristle brush and mild cleaning solvent or mineral spirits Dry the rotor with compressed air Inspect the rotor for cracks or burning Replace the rotor if it is defective DISTRIBUTOR VAC...

Page 396: ...adiator cap is installed 8 Cover the radiator sufficiently to induce a high temperature condition 9 Continue to run the engine until the red high temperature light comes on or the temperature indicate...

Page 397: ...e to the carburettor throttle bore When the throttle plate opens the distributor vacuum passage is exposed to manifold vacuum which causes the diaphragm to move against the tension of the spring This...

Page 398: ...rimary terminal flat pin connector 4 Remove screw and washers 2 and lift out the contact set 5 Remove screw and washer as semblies 22 and lift out the con denser and primary terminal block 6 Remove sp...

Page 399: ...entrifugal Advance Weights 12 Fibre Washer Weights to Driving Plate 13 Distributor Shaft Driving Plate Assy 14 Spacer Shim 15 Distributor Cap 16 Carbon Brush and Spring 17 Rotor 18 Spring Clip Cap to...

Page 400: ...te unit must be replaced Reassembly To assemble distributor reverse disassembly procedure Important Cleanliness is essential oil and grease must be kept away from the electrical contact surfaces and i...

Page 401: ...ATE CONTROL SLOT has a spring loaded diaphragm which is connected to the breaker plate The spring loaded side of the diaphragm is airtight and is con nected through a vacuum line to the carburettor th...

Page 402: ...inside of the distributor pull the primary wire through the opening in the distribu tor 4 Remove the spring clip the flat washer and the spring washer secur ing the breaker plate to the sub plate 5 R...

Page 403: ...A 5 Install the cam assembly Be sure that the marked spring bracket on the cam assembly is near the marked spring bracket on the stop plate If a new cam is being installed make sure that the cam is i...

Page 404: ...sconnect the primary and the condenser wires from the breaker point assembly 3 Remove the breaker point as sembly and condenser retaining screws Lift the breaker point assem FIG 5 Gear Pin Removal or...

Page 405: ...pin Install the distributor cap clamps 6 Check the shaft end play with a feeler gauge placed between the collar and the base ofthe distributor If the end play is not within specifi cations replace th...

Page 406: ...t replacing the other Refer to Fig 6 for the correct location of the parts 1 Follow steps 1 2 3 and 4 under Bench Assembly Original Shaft and Gear 2 Attach the distributor shaft sup porting tool to th...

Page 407: ...nd fuel economy the initial ignition timing may be advanced 30 over the normal setting No further improvement will be achieved by advancing beyond this point DISTRIBUTOR DIMENSIONS Shaft end play inch...

Page 408: ...17 15 9 11 Maximum advance 17 11 ARD10E 12100 D 250 C I D 2V H C GREEN DOT CENTRIFUGAL VACUUM Distributor r p m Advance 0 in Hg Advance 0 500 0 600 0 2 800 4 6 5 0 1000 5 7 8 0 2 75 1500 7 5 9 5 12 4...

Page 409: ...REFERENCE TO SERVICE INFORMATION AND NOTES Date Letter No Pace Brief Detail...

Page 410: ...10 3 Stromberg WW Series Carburettor PART 10 4 Ford Motorcraft Model 2100 Carburettor PART 10 5 Motorcraft Model 4300 Carburettor PART 10 6 Fuel Pump and Fuel Filter PART 10 7 Air Cleaner PART 10 8 F...

Page 411: ...ge code Always refer to the Master Parts Catalogue for parts usage and inter changeability before replacing a car burettor or a component part for a carburettor D DIAGNOSIS AND TESTING DIAGNOSIS FUEL...

Page 412: ...ARBURETOR HARD STARnNG Cracked carburettor body Defective main body and for fuel bowl gasket High fuel level or ftoat setting Fuel inlet needle not seating prop erly or worn needle and or seat Imprope...

Page 413: ...g bolts or defective gasket Air leak at the throttle shaft caused by a worn throttle shaft Accelerating pump diaphragm de fective Incorrect accelerating pump stroke adjUstment A RICH MIXTURE ON ACCELE...

Page 414: ...removed If the pump volume meets specifications with the filter removed replace the filter If the pump vol ume is still below specifications repeat the capacity test using an auxiliary fuel supply If...

Page 415: ...ss will occur in both part throttle and power application of the carburettor The power by pass jet or sealing gasket must be replaced if found defective Power Valve Test A power valve must not be re G...

Page 416: ...on adjust the kickdown cable Refer to Group 7 for the procedure 6 Lubricate all pivot points with engine oil ACCELERATOR PEDAL IDLE HEIGHT ADJUSTMENT V 8 Engines Refer to Figs 5 and 6 for a view of th...

Page 417: ...the accelerator pedal for the specified idle height and adjust lf necessary Refer to Throttle Llnk ap adjustment In this section for the proper procedure 7 Lubricate the accelerator pedal hinge with...

Page 418: ...IP 9825 Fig 3 200 250 1V 250 2V Manual 6 cylinder B Warner Trans VJf W W w AU i OMATIC TRANSMISSION KID CABLE ADJUSTMENT ADJUST ROD ASSY 97401 TO OBTAIN FULL THROTTLE WHEN SHAFT ASSY 97251 TOUCHES THE...

Page 419: ...O BE SUCH THAT THE TRANSMISSION DOWNSHIFT LEVER C ROTATES COUNTER CLOCKWISE AND CONTACTS THE INTERNAL STOP WITH THE PEDAL DE PRESSED TO W O T TRANS DOWNSHIFT LEVER ROTATED AND HELD AGAINST INTERNAL KI...

Page 420: ...Y ASSEMBLED THIS DISTANCE IS TO BE SUCH THAT THE I TRANSMISSION DOWNSHIFT LEVER C ROTATES COUNTER CLOCKWISE AND CONTACTS THE INTERNAL STOP WITH THE PEDAL DEPRESSED TO W O T TRANS DOWNSHIFT LEVER ROTAT...

Page 421: ...Y LOCATED REF PANEL DASH REF VIEW COLOUR CODE 351 2V BLUE 351 4V ORANGE KICK DOWN CONTROL ADJUSTMENT WITH TRANS ROD 7A186 INSTALLED HOLD CARBURETTOR THROTTLE LEVER IN W O T POSITION AGAINST STOP 2 HOL...

Page 422: ...rs inspect the idle tubes in each nozzle bar 8886m bly If they are plugged bent or broken replace the booster venturi and nozzle bar 8886mbly FUEL PUMP On all fuel pumps except Carter permanently seal...

Page 423: ...hrough the carburettor on its way to enter the cylinders a re duced pressure is created at the fuel discharge outlets The fuel bowl is vented to atmos phere at closed throttle and to car burettor air...

Page 424: ...s engine R P M and air ftow through the carburettor The greater air ftow through the venturi causes a pressure drop in the venturi great enough to bring the main metering system into operation as the...

Page 425: ...demand or wide open throttle operation the carburet tor must deliver a richer fuel ail mix ture than supplied during the opera tion of the main fuel system at cruise or part throttle operation When th...

Page 426: ...orm in the ftoat chamber when a hot engine Is stopped Idling or operating at very low speeds By venting the ftoat chamber to atmos phere by means of a vent control valve engine performance Is Im prove...

Page 427: ...the black service limiter cap on the head of the idle mixture adjusting screw 11 Replace the air cleaner and check the idle speed to ensure that the mixture screw was not accidently rotated while fitt...

Page 428: ...nstall a new gasket on the carburettor main body Make sure the gasket is not damaged and that no foreign material has adhered to the gasket 7_ Insert the pump rod into its guide hole In the main body...

Page 429: ...pagel r67 2 Loosen the choke outer cable clamp screw and the inner cable tocking screw Remove the cable 3 Hold the carburettor fuel line umon and undo and remove the fuel line 4 Remove the spring cli...

Page 430: ...ODY 1 Do not remove the idle mixture adjusting screw and spring unless absol utely necessary 2 Remove the throttle lever re taining nut and lockwasher and re move throttle lever assembly 3 If It Is ne...

Page 431: ...sition over the pump and press in the split spring retaining bush flush with the surface of the main body 10 Place a new gasket on the malil body then fit the pump rod and spring clip 11 Locate choke...

Page 432: ...common Float System Accelerating System and Power System Each barrel is equipped with a main and an auxiliary Venturi Choke Tube The carburettors employ an automatic choke control situated in the thro...

Page 433: ...ent is to permit the escape uf fuel vapours formed in the float chamber under high temperature operating conditions Additionally the throttle body has two small vents one in each barrel to permit the...

Page 434: ...for the development of maximum engine power This additional fuel is provided by the action of a vacuum piston located in the air horn which automatically controls the opening of the power by pass jet...

Page 435: ...d the fast idle mechanism Fig 9 which operates in conjunction with the automatic choke control to provide the correct fast idle speeds to prevent stalling during the engine warm up period An integral...

Page 436: ...he end of the fast idle stop screw The throttle opening is now controlled entirely by the slow idle adjustment screw which is set to provide the normal specified slow idle speed CHOKE MODULATION SPRIN...

Page 437: ...screw on second step of cam as illustrated From the point of initial contact with second step of cam adjust to obtain correct fast idle R P M With fast idle stop screw on second step of cam as illust...

Page 438: ...18 Hold choke valve closed by applying light upward pressure on thermostat lever pick up ear in direction shown by arrow The dimension TL measured from centre of upper right cover screw hole to therm...

Page 439: ...10 30 GROUP 10 FUEL SYSTEM 30 FIG 20 Parts Illustrated are typical In appearance and may not look exactly like the part required...

Page 440: ...ORN Fig 20 Remove vacuum power piston 19 using a block of wood and small open end wrench as a pry 4 Set the ignition timing to specification 5 Attach an accurate tachometer to the engine 6 Run the eng...

Page 441: ...linder Pump outlet check ball 23 drops into channel under pump nozzle screw 20 Assemble float fulcrum pin 62 in float lever and install float in float chamber Place ends of fulcrum pin spring 63 again...

Page 442: ...osition when assembling to avoid possibility of the vacuum piston stem 19 becoming wedged between the power by pass jet 24 and the main body and to ensure the upper ends of the idle tubes 26 engage in...

Page 443: ...V used on the 351 C engine has a unique two piece fast idle lever and the crankcase emission hose connec tion is incorporated in the main body OPERATION FUEL INLET SYSTEM ACCELERATING PUMP ASSEMBLY V1...

Page 444: ...depressed This permits unload ing of a flooded engine The automatic choke is equipped with a bimetal thermostatic spring and a vacuum piston Fig 4 The bimetal thermostatic spring mecha nism winds up...

Page 445: ...rd the closed position providing a richer mixture to help prevent stalling GROUP 10 FUEL SYSTEM THERMOSTATIC SPRING PISTON AND LEVER ASSEMBLY B2599 A The linkage between the choke le ver and the throt...

Page 446: ...Fig 6 supplies fuel until the other systems can once again provide the proper mixture When the throttle is closed the diaphragm return spring forces the diaphragm toward the cover drawing fuel into t...

Page 447: ...e fuel air ratio must be increased for added power The added fuel re quired during this period is supplied by the power fuel system Fig 8 The power fuel system is con trolled by the intake manifold va...

Page 448: ...is in the full open position 5 Turn the headlights on high beam to place the alternator under a load condition in order to properly adjust to the specified engine idle speed 6 The final idle speed ad...

Page 449: ...the anti stall dashpot Jock nut 2 Hold the throttle in the closed position and depress the plunger with a screwdriver blade Measure the clearance between the throttle lever and the plunger tip Turn t...

Page 450: ...e the cam is at the kickdown position while checking or adjusting the fast idle cam clearance Check for the specified clearance between the lower edge of the choke plate and the air horn wall To adjus...

Page 451: ...ze the fuel level Check the fuel level after each adjustment until the specified level is achieved 6 Install a new air horn gasket the air horn assembly carburettor identifica tion tag and the retaini...

Page 452: ...the cause of complaint the carburettor should be carefully removed from the engine without removing the fuel from the bowls The contents of the bowls may then be examined for contamination as the carb...

Page 453: ...the air horn was not previously removed remove the choke control rod retainer Remove the choke housing assembly gasket and fast idle cam and rod from the fast idle cam lever 4 Remove the choke lever r...

Page 454: ...1 2 turns for a preliminary idle fuel mixture adjustment Do not install the idle mixture limiters at this time Install the power valve cover and new gasket The power valve cover must be installed with...

Page 455: ...SYSTEM 4 Insert the end of the choke plate rod into the automatic choke lever Install the air horn retaining screws and the carburetor identification tag Tighten the retaining screws Install the choke...

Page 456: ...ET 9B550 VALVE NUT 33923 S RETAINER 375894 S ACCELERATING PU OVER TRAVEL LEV SCREW THROTTLE SHAFT AND LEVER ASSEMBLY 9581 SPRING 9578 CHOKE LEVER 9A753 ADJUSTING SCREW 372307 S ER 9F571 FAST IDLE CAM...

Page 457: ...l bowl is vented by an internal balance vent The hot idle compensator shown in some illustrations is not fitted when this carburetor is fitted to the Cleveland engine The main primary fuel system has...

Page 458: ...2 Model 4300 4 V Carburetor Typical Left Front 3 4 View LEVER SECONDARY AIR VALVE DASH PDT FUEL INLET FIG 3 Mode 4300 4 V Carburetor Top View Typical CHOKE FAST IDLE CAM ADJUSTING SCREW CHOKE HCXJSING...

Page 459: ...are required as in high engine speeds and heavy load con ditions the fuel level and float height drop thereby opening the auxiliary valve Fig 5 in addition to the main or primary fuel inlet valve The...

Page 460: ...n and com pensates for the tendency of the air to become less dense at high speeds The bleed also doubles as an anti siphoning vent at low speeds And it discourages percolation when a hot engine is sh...

Page 461: ...loaded and tends to push the rod down The stem of the power valve is also spring loaded tending to hold the power valve up or closed Manifold vacuum is sensed on top of the piston through passages in...

Page 462: ...anifold vacuum below them Increased air flow then causes fuel to be discharged into the booster venturis from the secondary main discharge tubes The amount that the air valves open and therefore the a...

Page 463: ...ain the desired engine performance characteristics Refer to the Specifications when evercarburettor adjustments are made IDLE SPEED AND FUEL MIXTURE All carburettors are equipped with idle fuel mixtur...

Page 464: ...g If it is not possible to adjust the idle speed with the air cleaner installed remove it make the adjustment then replace the air cleaner and check again for the specified rpm Manual transmission veh...

Page 465: ...cleaner assembly heater hose and mounting bracket if so equipped from the carburettor 2 Loosen the thermostatic spring housing clamp retaining screws Set the spring housing to the specified index mar...

Page 466: ...CHOKE SHAFT SCREW LEFT HAND THREAD INCH WIRE GAUGE APPLY LIGHT PRESSURE TO CHOKE LEVER FIG 23 Choke Plate Pull Down and Fast V1235 A Idle Cam Adjustment fast idle speed lever forward to increase or b...

Page 467: ...ottle dashpot piston into their chambers as the air horn is gently lowered into position 4 Install the longest of the air horn v 1152 4 FIG 26 Auxiliary Supplemental Valve Setting retaining screws in...

Page 468: ...the choke clear air tube to the air horn 4 Adjust the engine idle speed the idle fuel mixture anti stall dashpot if so equipped and the accelerating pump stroke if required Install the air cleaner Pag...

Page 469: ...primary bores with the ground flat edge of the plates facing up and towards the idle tnixture needles Install the plate retaining screws snug but not tight 3 Rotate the throttle shaft to the closed po...

Page 470: ...VALVE ASSEMBLY 9564 PRIMARY THROTTLE SHAFT AND LEVER ASSEMBLY 9581 SECONDARY THROTTLE SECOI ARY THROTTLE SHAFT AND LEVER 9A592 I SECONDARY THROTTLE RETURN SPRING 9B504 THROTTLE BODY AND CHOKE HOUSING...

Page 471: ...on 10 Insert key end of air valve dampener rod into keyed hole in the air valve lever Slide other end of rod into eye on the air valve pl tte Position the air valve dampener lever on the air horn and...

Page 472: ...Fuel Pump Assembly AC Type are mounted on the left side of the cylinder front cover An AC type fuel pump Fig 1 is used on the 200 and 250 Six en gines A Carter Permanently Sealed Fuel pump is used on...

Page 473: ...female union on the carburetor and unscrew the flared union fllter to carburetor Discard the filter 4 Place the new filter in position and tighten the flared union filter to carburetor 5 Tighten the f...

Page 474: ...sition the fuel pump dia phragm and spring assembly into the pump body 7 Hold the diaphragm as lembly in the pump body position the pump body so that the mounting flange faces up Apply slightly more p...

Page 475: ...Clean and inspect the fuel pump component parts Refer to Cleaning and Inspection Pagelo 13 for the proper procedure Replace all worn or damaged parts ASSEMBLY The fuel pump assembly is shown in Fig 2...

Page 476: ...l REMOVAL 1 Remove the wing nut retaining the air cleaner assembly to the car burettor 2 Remove the air cleaner ass mbly from the carburettor To prevent dirt from entering the carburet tor the filter...

Page 477: ...itch in water heated to 105 110 degrees F Only slight movement of the bi metal is necessary to unseat the bleed valve VACUUM OFF VACUUM ON FIG 2 Duct and Valve Assembly HOT AND COLD TYPE VACUUM OPERAT...

Page 478: ...r pipe 4 Install and tighten the filler pipe retaining screws 5 Tighten the hose clamp and install the siphoned fuel back in the fuel tank FILLER PIPE STATION WAGON The station wagon has an upper fill...

Page 479: ...screws _ 2 Refit the rubber hose to the fuel tank inlet and tighten the clamps 3 If the fuel gauge sending unit was removed make sure all the old gasket material has been removed from the unit mountin...

Page 480: ...sending unit 4 If the fuel gauge sending unit is to be removed turn the unit re taining ring cmmterclockwise and remove the sending unit retaining ring anq gasket 5 Remove the spare tyre from the lug...

Page 481: ...1 5 32 1 9 32 Main discharge jet 28 25 28 25 High speed bleeder No 70 No 70 Main metering jet 058 067 Power bypass jet No 55 2 X No 54 Pump discharg e jet No 67 No 67 Idle discharge hole No 55 No 55 I...

Page 482: ...link position Lower hole Accelerator Pump Shot 1 0 Strokes cc 14 18 AUTOMATIC CHOKE SETTINGS Thermostat Cover Index Mean Thermostat Lever 1 094 Modulator 03 Vacuum Kick 160 Cam Index 160 Wide open Th...

Page 483: ...Power Valve Timing ln Hg l 8 5 7 5 Power Valve Identification Plain Green Air Distribution Plate Yes Yes Spark Port 0 050 0 05X 0 085 PUMP SYSTEM Rod Position Overtravel Lever No 4 No 3 Pump Lever B l...

Page 484: ...0 031 0 035 Secondary 0 024 0 024 Anti Syphon Bleed Primary Secondary 0 022 0 022 Power Valve Jet 0 059 0 059 Power Valve Timing ln Hg 7 5 8 5 6 7 Air Valve Spring Color Yellow Yellow Soark Port 0 06...

Page 485: ...ic Pressure Psi 500 Engine rpm 8 Cyl 4 6 6 Cyl 3 5 5 0 Minimum Fuel Pump Volume Flow 500 Engine rpm All 6 Cyl 8 Cyl 1 pint in 36 seconds 1 pint in 24 seconds Minimum Intake Static Vacuum Inches of Mer...

Page 486: ...FALCON FAIRLANE w P COOLING SYSTEM GROUP 11 PAGE PART 11 1 General Cooling System Service 11 2 PART 11 2 Water Pump and Fan Drive Clutch 11 5 PART 11 3 Radiator 11 10 PART 11 4 Specifications 11 11...

Page 487: ...l leakage due to a defective cylinder head gasket im proper tightening of the cylinder head bolts or warped cylinder head or block gasket surfaces Internal leakage can be detected by operating the eng...

Page 488: ...used make sure the cylinder head bolts are properly tightened to prevent possible water leakage into the cylinders Always remove the thermostat prior to pressure flushing A pulsating or reversed direc...

Page 489: ...never they become cracked rotted or have a tendency to collapse 1 Drain radiator then loosen the clamps at each end of hose to be removed Slide hose off radiator con nection and the cylinder head wate...

Page 490: ...lower hose and the heater hose to the water pump 5 Install the water pump pulley fan spacer and fan Torque the bolts evenly and alternately to specifications 6 Install ihe drive belt and ad just the...

Page 491: ...pump assembly is shown in Fig 1 1 Remove the hub from the im peller shaft Fig 9 FIG 1 Water Pump 6 Cyl FIG 2 Hub Removal 2 Position the pump on an arbor press and press the shaft and bearing out of th...

Page 492: ...IG 5 Shaft and Bearing Installation AND BEARING FIG 6 Seal Installation 6Cyl PART 11 2 WATER PUMP IMPELLER FIG 7 Impeller Installation FIG 8 Hub Installation Drift SMALLER DIAMETER THAN S IAFT FIG 9 H...

Page 493: ...10 FAN DRIVE CLUTCH DESCRIPTION The fan clutch Figs 12 13 and 14 permits use of a powerful fan without paying the penalty of power loss or noise The fan clutch is a mechanical device which provides ma...

Page 494: ...i Metal Spring and moves the control valve to the minimum slip position retaining a maximum amount of oil in the close clearance area MODULATING CYCLE As vehicle operation varies with heavy to light t...

Page 495: ...ard if so equipped 4 Remove the radiator support bolts and remove the radiator INSTALLATION 1 If a new radiator is to be in stalled remove the drain cock from the old radiator and install it in the ne...

Page 496: ...1 0 2 5 10 15 11 JJ NOTE Air conditioned vehicles are fitted with extra heavy duty radiators Prior to replacement of these units refer to the parts catalogue for correct part number THERMOSTAT 200 26...

Page 497: ...utch 250 CID 2V Auto A C 21 7 Cross Flow and Shroud 9 6 X I7 0 1 18 Yes Viscous Clutch 302 CID Manual 21 7 Cross Flow and Shroud IO 4 X I7 5 0 96 Yes 302 CID Auto 2I 7 Cross Flow and Shroud I2 4x I7 5...

Page 498: ...FALCON FAIRLANE w P EXHAUST SYSTEM GROUP 12 PAGE PART 12 1 General Exhaust System Service 12 2 PART 12 2 Exhaust Pipes and Muffler 12 3 PART 12 3 Specifications 12 19...

Page 499: ...ion in Part 12 2 for the clearance speci fications and location of components Perform the following procedure to adjust the exhaust system compo nents 1 Loosen the pipe connection clamps and the pipe...

Page 500: ...oop type support brackets are shown in the respective exhaust system illustrations The loop type support EJ REMOVAL AND INSTALLATION The replacement procedures given apply to all car models Typical ex...

Page 501: ...ove the temp orary support wire 4 Adjust the exhaust system components to conform to the clear ances shown in Figs 1 7 Working from the front of the car toward the rear progressively torque the retain...

Page 502: ...Til OA ENSION N1 25 I NLESS OTHE l MSE SJIOtw ro N LIR PO J 710NJNS OF 71 ElfHAIRT SYSTEM THE F Q l ll3oiTIO IS MUST 8E FOLLOW 711 MINtFOLO CO NECTION MUSr BE Sofi CJI If TIE INrE1lAAEDtt TF R 5A24ti...

Page 503: ...T BE UEJ D AND COV7tlC l PIMEAISICWS SHoWN W T 101 T 10 o JAN E ARt FOR QU LfTY AUDIT PURPOSE TilE 10 ERANC ON T ES DIM 1 0N ARE t 2S UVL SS OTHE SE SHOWW 7 1 N il IRC POSmONNG OF TN tSTEM TilE rol lO...

Page 504: ...at IN C1110E FOil fiVI LITY A JOlT PURPOSE TilE OtERANC 0A1 7JIE E DNEAJ 01 1 NU 2 IIVI IU OTHERIMSE SHOIIN TO N WR AOS 1 1 JNI o Q OF 71 El HAJJ8r EM THE O l lQolrA WS MIJ T ER UOW 0 THE MWti Ot D CO...

Page 505: ...ON SHOWN WfT 401 T 70LE PAN E ARE FOR LITY AIJDff PURPOSE 111 10t RN ICE ON THEM IENSJOA ARE 25 INLESS 011 EJ M ISE SHO MI 7D N UR Ali0 99 INS OF TN E XHAU T SISTEM THE F OPERQ IONS MUOT liE R IUOI f...

Page 506: ...Cr THESE CLEARANCES MUST BE HELD AND CoNTROlLED MENSK NS SHoW Wmour 10LERAN E 4 R JR IJALITY AUDIT i uflPOSE mE TOLERANCE ON niESE 0 MENS OIJS R 25 LA LESS OTHERWISE SJ OWAI TO AI J I RIJ t R P05ITJO...

Page 507: ...IW CE nJtll AUOIT PUilPOSE 1HE 7fXERANCE OAJ THESE DI I I JSI I JS IRE 25 I NLESS OTHERWI SHOWA ro PER PC61710NIAI6 cr nE EJCJWJ T SYSTEM 7NE I OIUJW N6 O MTIOIJS MCJSr BE RJI LOWED TilE NII JIFDLD CQ...

Page 508: ...HIIAI5 R ASsv 5A246 II ISTALLED TN MUFFLER ASSY 2 0 MID A LET Al lf EMZAGED S DICATED AND THE TN Pf lO BOOt R lAT1tJNSNIP IJEFlJRE A lcFR Eii U lJ t TASSY 5252 AND 71E Ct M4 SUJ2 All TIGHTENED VIBI IN...

Page 509: ...1oJSIONS SHOWN WITHOUT IOL RANCE ARE FOR QU UTY A JOIT PfmPOSE THE rot ERAAC ON T HES DIMCNSIOAIS ARE t 25 UVL E SS OTHEilW1 E SHOt IW 70 NSUI PJK PER ITIONIN6 OF TN O HAI J 1 SYS1FM TH A XLOW o G oP...

Page 510: ...ES MUST BE HELO MID CONTROLLED OtMENSKJIVS SHOWN WII IICIIT 10LERAACE ARE FOR QUAUTY AUOIT PURPOSE THE TOLERANCE DN THESE DIMENSIONS ARE 1 25 UNLESS OTHERWISE SHOWN TO NSUR PROPER POSITI It JING OF TH...

Page 511: ...HCUJ AND CCNTlKJLLED M NSKJIVS SHOWN WITHOIIT 70LERAAC ARE FOR QUAUTY AUDIT RJRPDSE THE 10 ER NCE ON niESE OIMENSIOAIS ARE t 25 l IYL SS OTH RWis SHOWW TO MUR PROPER POSITIONING oF 7H EXHAUST SYSTEM T...

Page 512: ...NGTH ro BE WED NTO MANJI OUJ T ESE a EARAM 5 MUST BE HELD AND C01o1T110i UD UMCNSIOIVS SHOWN WIT K IJT 10LfRAN E AR roR QUCUTY AUDIT PURPOSE THE TOLERANCE ON THESE DIMENSIONS ARE 1 25 I NLESS OTHE WIS...

Page 513: ...SE SHOWN TO INSURE PROPER POSITIONING OF THE EXH AlJ Sr SYSTEM TN FOLLOII IING OOERATIONS MUST BE fOLLOWED nt M Jin LD CONNE CTION Musr BE SKURE TilE WTERM 1 J IW GER AS5Y 5 246 NSTIV L 0 THE MUFFL R...

Page 514: ...NCES MUST BE HELD AND CONTROI LEC OIMEN SK N SHOWN WIT 10 T 10 _ERAI C ARE FOR f U U TY AUDIT PURPOSE THE mLEIMNC ON TWES DIMeNSIONS ARE 25 LNLESS OTHERWISE SJ IOWAJ TO IA Sl IRE PfKJPER POSITIONING O...

Page 515: ...ER IWET END OF STUD WITH SIORTEST TI REA D LENGTH TO BE SCREWED JNTIJ MAN FOLD THESE CLEARANCES MUST BE HELD ND CONTRolLED MENSJON SHOWN WITHO JT 7 0 ERANCE ARE FOR LITY AUOt7 PURPOSE THE Tl li ERA NC...

Page 516: ...d s Inlet Pipe to Inlet Pipe Extension Clamp Outlet Pipe to Muffler Clamp Support Brackets and Insulators to Frame Nut Support Insulator Bracket to Muffler Support Insulator Clamp to Tailpipe 250 2V E...

Page 517: ...REFERENCE TO SERVICE INFORMATION AND NOTES Date Letter No Page Brief Detail...

Page 518: ...T 13 1 General Charging System Service PART 13 2 Bosch Alternator PART 13 3 lucas Alternator PART 13 4 Bosch Alternator Regulator PART 13 5 lucas Alternator Regulator PART 13 6 Specifkations GROUP 13...

Page 519: ...is either oft or running at low idle corroded battery cables and connectors low water level in the battery or pro longed disuse of the battery which would permit self discharge are all possible reaso...

Page 520: ...positive connector to the battery positive terminal and then fit the negative connector to the negative battery terminal 3 High Rate Battery Charging Advisable to first disconnect the battery negativ...

Page 521: ...the alternator Repair or replace as necessary Lucas Remote regulator Remove wiring plug from the regulator Switch on the ignition and check voltage at F and IND terminals in wiring harness Battery vo...

Page 522: ...PECIFIC GRAVITY CHARGE BATTERY IF BELOW 1 230 OTHERWISE BATTERY IS OK LESS THAN SO POINTS O OSO BETWEEN CELLS ADD WATER IF NECESSARY AND CHARGE BATTERY PER CHARGING SCHEDULE AND REPEAT CAPACITY TEST T...

Page 523: ...FIG 7 I CHECK THE BATTERY TO FIELD WIRING SEE NOTE NO 5 C21 Tli ST ALTii ANATOR INDii Pii NDii NT OF YS HICU WIRING Uli FIG 7 FIG 5 Diagnosis Chart Charge Indicator Light Stays On I LIGHTS AND FUSES F...

Page 524: ...PUT TEST ON ENGINE When the alternator output test is conducted off the car a test bench must be used Follow the procedure given by the test bench equipment manufacturer When the alternator is removed...

Page 525: ...ad 1 Ensure that the ignition is switched off 2 Disconnect the battery earth cable 3 Remove the wiring plugs from the alternator Fig 9 4 Install the main terminal of the test connector to the terminal...

Page 526: ...PART 13 1 GENERAL CHARGING SYSTEM SERVICE 13 9 FIG 10 Output Test Bosch 9ATR Control F Ammeter I FIG 11 Output Test Lucas...

Page 527: ...are indicated 2 Test the rotor insulation by using a 12V battery and test lamp Fig 13 Place one prod on a slip ring the other on the rotor shaft The test lamp should not light TESTING THE STATOR 1 Tes...

Page 528: ...lamp does not light in either direction the diode is open circuited Take apecial care ot the aolder connection FIG 18 Bosch Rectifier Pack FIELD DIODES 1 Place one test probe on the diode terminal st...

Page 529: ...e a sin gle one piece cover which complete ly seals the top of the battery and the individual cell connectors This cover must not be pierced with test probes to perform individual cell tests A battery...

Page 530: ...essive play or roughness Load the bearings by hand pressure when checking for roughness and rotate the outer race at lea5 t six turns in this man ner Look for excessive lubricant leakage Replace beari...

Page 531: ...or winding OVERCHARGING A Regulator set too high Bosch B Regulator contacts welded Bosch C Regulator coil winding open Bosch D Regulator not effectively earthed Temperature Noise Output High Normal Hi...

Page 532: ...ack Alternator Terminals Fig 8 D Field diode junction for regulator D and indicator lamp DF Field terminal connection for regulator DF B Battery connection Radio suppressor terminal OPERATION With the...

Page 533: ...O Q 1 DRIVE END HEAD 2 STATOR 3 RECTIFIER PACK 4 SLIP RING END HEAD 5 BRUSH GEAR ASSEMBLY 6 RADIO SUPPRESSOR 7 ROTOR FIG 20 Bosch Alternator Exploded View w 0 w I I G m z m o I o G z G t m 3 m o m...

Page 534: ...r 11 For cleaning and inspection see Part 1 of this group ASSEMBLY 1 Position the drive end head bearing shielded side first in the end head Secure the retaining plate with two screws 2 Place the smal...

Page 535: ...d slip ring end heads The brush gear for the field system is mounted on the slip ring end bracket Two carbon brushes bear against a pair of copper slip rings which encircle the rotor shaft Rectificati...

Page 536: ...lip Ring End Bracket 6 Drive End Head 17 Brush Set 7 Fixing Through Bolt 18 Brush Box Moulding 8 Drive End Bearing 19 Field Diode and Terminal Plate Assembly 9 Drive End Bearing Retaining Plate 20 Pos...

Page 537: ...ire quickly unsolder the stator leads from the terminal strips on the recti fier pack and remove the stator from the slip ring end head 5 Remove the two rectifier pack attaching nuts spring and flat w...

Page 538: ...ged renew if nec essary using PVC sleeving cut to the abovementioned lengths Fig 25 Place the voltage regulator in posi tion and fit pan head screws with the lock washer under the screw on the right h...

Page 539: ...reactance of the stator no current limiter is required and as the rectifier diodes prevent reverse current flow from the battery no cut out is required either The voltage regulator is a double contact...

Page 540: ...e reduced influence of the electro magnet and they close This cycle is repeated 50 200 times per second and the voltage is maintained at a predetermined setting 3 Upper contacts closed field circuit g...

Page 541: ...ise operating temperature 9 Cycle the system by stopping and re starting the engine 10 With the ammeter reading 10 amps the voltmeter reading should be within 13 5 14 4 volts To check the regulating...

Page 542: ...of the tape underneath the over lap to prevent water ingress Mechanical adjustments To carry out the mechanical ad justments the regulator must be re moved from the vehicle See Fig 32 1 Armature air g...

Page 543: ...ual electro magnet and tension spring The unit incorporates a radio interference suppression cap acitor Since current can only flow in one direction through the alternator out put diodes no cut out re...

Page 544: ...ZENER DIODE 9ATR REGULATOR SURGE QUENCH DIODE F ___I_ I f FIG 35 Lucas Charging Circuit AC w I Y r t m z Q c w I...

Page 545: ...AC sipation would occur in the power transistor leading to problems of overheating For this reason it is desirable to operate the transistor either in the fully on or fully ff condition and this is t...

Page 546: ...that all wiring and connections in the charging circuit including battery terminals are tight and in good condition Voltage Regulator Test 9 ATR and 13 ATR 1 Connect a voltmeter across the battery te...

Page 547: ...tifier pack fixing screws Brush box fixing screws BOSCH REGULATOR MODEL U AD1 14V NEGATIVE 14 volts 40 amps 3 Star 12 4 2 2 ohms 0 21 1 ohm 35 15 1 24 33 47 in lbs 25 32 ft lbs 20 25 in lbs 20 25 in l...

Page 548: ...C Model 13ATR Solid state transistorized non adjustable Volt age setting 14 3 0 4 volts LUCAS ALTERNATOR 6 Cylinder Air Conditioning MODEL Earth polarity Nominal voltage Nominal output Stator phases 1...

Page 549: ...REFERENCE TO SERVICE INFORMATION AND NOTES Date Letter No Page Brief Detail...

Page 550: ...P STARTING SYSTEM PART 14 1 Ford Starting System PART 14 2 Ford Starting System Repair PART 14 3 Bosch Starting System PART 14 4 lucas Starting System PART 14 5 Specifications GROUP 14 PAGE 14 2 14 7...

Page 551: ...motors Where applicable read solenoid for relay A schematic diagram of the start ing circuit is shown in Fig 3 The majority of starting problems usually fall into one of the following situations the...

Page 552: ...S THE IGNITION SWITCH NEUTRAL STARTS TCH AND WI WIRING SEE NOTE NO 3 ENGINE CRANKS I IENGINE WILL NOT CRANK J REPLACE RELAY I STARTER ENGAGEMENT WEAK OR NO ENGAGEMENT I I REMOVE AND TEST THE STARTER R...

Page 553: ...uble is in the wiring or connections between the ignition switch and the starter neutral switch STARTER CRANKS ENGINE SLOWLY Refer to Fig 5 for this symptom I 1 1 BATTERY l ___ TO 3 IGNITION COIL 1 S...

Page 554: ...PECIFIC GRAVITY BATTERY SPECIFIC GRAVITY LOW PERFORM BATTERY TESTS CHARGE OR REPLACE THE BATTERY AS NECESSARY CHECK THE BATTERY AND STARTER RELAY FOR EXCESSIVE RESISTANCE CHECK THE STARTER CRANKING VO...

Page 555: ...sults of this test Make the test con nections as shown in Fig lO Crank the engine with the ignition OFF This is accomplished by disconnect ing and grounding the high tension lead from the spark coil a...

Page 556: ...tarter drive plunger lev er return spring and rear end housing to the starter frame and then tighten the through bolts to specifications 55 75 inch pounds 8 Position the starter drive plung er lever c...

Page 557: ...ure when it becomes necessary to completely overhaul the starter Fig 2 iilustrates a partially disassembled starter DISASSEMBLY 1 Loosen the brush cover band retaining screw and remove the brush cover...

Page 558: ...then stake the screws 3 Install the solenoid 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 terminal us ing rosin core...

Page 559: ...on the armature shaft rotate the pinion slowly to assist in engagement Should a tooth of the advancing pinion abut a tooth of the ring gear the engaging lever will compress the helical spring at the p...

Page 560: ...mechanism and electrical contacts for wear and replace worn parts Check electrical joints and con nections and repair where necessary 2 Field Coils Test field coils for open circuits with an incandesc...

Page 561: ...n increased wear of the bearings The end play is adjusted by plac ing or removing shims at the com mutator end between the end cover and circlip on the armature Adjust to specification Armature Brakin...

Page 562: ...ng the solenoid switching circuit energises the pull in and hold in solenoid windings The soft iron plunger is drawn in moving the engaging lever which in turn moves the drive assembly towards the rin...

Page 563: ...n one direction and rotate smoothly and easily in the other The assembly should move freely round and along the armature shaft splines without any roughness or tendency to bind Should the assembly not...

Page 564: ...lace a few drops of engine oil on the armature shaft bushes Smear Moly bond GSlO grease on the armature shaft and drive assembly helix Also on the pivot points of the pinion engaging lever Always use...

Page 565: ...specification 8 Assemble the field coil solenoid linking cable and tighten the nut PINION ENGAGING LEVER AD JUSTMENT a Disconnect the solenoid lead to the starter motor field b Energise the solenoid...

Page 566: ...ts Amp Volts R P M Short Circuit Test 395 445 6 0 Load Test 210 240 9 0 1150 1450 No Load Test 50 70 12 0 5900 7100 Total spindle travel 0 170 0 210 C ontact follow through 0 028 0 101 Commutator Out...

Page 567: ...e 15 lb pt Current draw 2 coils 60 amps maximum Current 430A Hold in winding 12 amps Terminal Voltage 7 0 v 1 Resistance Series winding 0 225 017 ohms Running Torque 7 lb ft 1000 r p m Resistance shun...

Page 568: ...UP 15 PAGE PART 15 1 General Lighting System Horns and Instruments Service 15 2 PART 15 2 Lighting System and Horns 15 7 PART 15 3 Switches Circuit Breakers and Fuses 15 12 PART 15 4 Instruments 15 14...

Page 569: ...beam selector switch INDIVIDUAL LIGHTS 1 Burned out bulb DO NOT LIGHT l Loose or broken wires to the bulb LIGHTS BURN OUT 1 Loose or corroded electrical REPEATEDLY connections l Excessive vibration I...

Page 570: ...PERATE INCORRECTLY TURN INDICATOR ANCELS IMPROPERLY c 1 Burned out bulbs or loose sockets l Loose or broken wire from ignition switch to flasher 3 Defective flasher 1 Burned out bulb l Loose broken or...

Page 571: ...d evenly DEFEq IVE CABLE CORE AND HOUSING 1 To check for a kinked cable core remove and wipe dry Lay the core out stra ght on a flat surface and roll it back and forth Any kinks or damage will be seen...

Page 572: ...to be held to 10 ohms for high indication Lower resistances will destroy calibration TEMPERATURE GAUGE TEST Start the engine and allow it to run at 1200 rpm for 30 minutes Place a thermometer in the c...

Page 573: ...l old grease Do not allow any clean Ing ftuld to contact the armature shaft and output shaft bearings l Wipe all other parts with a clean cloth 3 Inspect the gear housing for cracks or distortion Repl...

Page 574: ...in the driver s seat and a person in the passenger seat the car unloaded and the trunk empty except for the spare tyre and jacking equipment and recom mended pressure in all tyres Be fore each adjustm...

Page 575: ...15 8 GROUP 15 LIGHTING SYSTEM HORNS AND INSTRUMENTS l 1 _ _ t I I _ J I P fi i I l l F l I I i I 0 j s C c IV 0 0 u I I 52 LL...

Page 576: ...13088 CLIP H AOIAMP SPRING AA oA 2 2 0 1 300 7 BULB A 55Y N AOLAMP H13 G IJII B R INGA S5Y HCADIAMP HGH AM 1311 9 RING A Y UO D ANP H IGH BU M IJO l HOUSING ASSY 1 l ADLAMP t JIOI HOU StNC A S S Y HE...

Page 577: ...con rear lamp installations Whenever a sealed beam umt IS replaced or any other alterations are made to a headlight assembly the headlights should always be checked for alignment and adjusted as descr...

Page 578: ...onnect the horn wire to the horn terminal HORN SWITCH 1 Remove the two steering wheel centre pad horn switch retaining screws from the underside of the steering wheel spokes 2 Lift the pad horn switch...

Page 579: ...rt Switch Back Up Light Switch REYIISING LIGHT SWITCH The reversing light switch is incor porated in the inhibitor switch on automatic transmission vehicles In column shift manual transmis sion vehicl...

Page 580: ...tube Page 3 38 4 Cut slots in the steering lock attaching bolts with a hacksaw and remove the bolts with a screw driver or hammer and centre punch 5 Rotate the lock around the column tube until one e...

Page 581: ...e indicator light oil pressure indicator light speedometer high beam indicator light a left and right hand turn signal indicator light brake warning light and stop lamp and brake warning light CONSTAN...

Page 582: ...ges G T 4 Remove the housing from be hind the steering column by moving it toward the centre of the vehicle select 1st or 1 gears on column shift vehicles 5 Remove the four cluster retain 15 15 turned...

Page 583: ...T 54H WIN IN DIRCCTI W Lit JW S llfJWfN6 J R T IC III CONNt Cflt W iCtkJIMD 1 H W SfJUI AIIIJ N AtJI Jin lllltt ICJ TA N NO I HK I T WAIININ I AMI J0CK r A S SY J A r IVVItii6611 1J LDCATIONS INACCOif...

Page 584: ...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 6 Remove the turn indicator handle from the side of the st...

Page 585: ...s 3 Install the cowl panel 4 Install the Wiper Blade and Plrm J ssembly MOUNTING CLIP 5 Check the Pivot Shaft and Link operation FIG 22 Speedo Driven Gear IJ MAJOR REPAIR OPERATIONS Preslite FIG 23 Wi...

Page 586: ...rior with compressed air 2 Visually inspect for damage to the ceramic magnets replace motor housing assembly if necessary 3 Visually inspect the armature assembly for burned commutator bars galling or...

Page 587: ...assembly 2 4 Install solenoid to housing tak ing care that lever engages with slot in latch Ensure that solenoid is located in receiving slot in housing and solenoid wire is correctly posi tioned in h...

Page 588: ...a mains test lamp Fig 7 Lighting of the lamp indi cates faulty insulation If the commutator is worn it can be lightly skimmed while the arma ture is mounted in a lathe PART 15 4 INSTRUMENTS 15 21 1 Ne...

Page 589: ...from valve assembly and remove assembly 12 Remove rubber bulb upwards from housing TO ASSEMBLE 1 Replace rubber bulb in hous ing insert spring into bulb and screw on valve assembly 2 Replace locking w...

Page 590: ...21 6 21 6 21 21 10 10 10 4 5 Amps 5 Volts 0 4 Amps I 15 23 Location Rating Time Fuse Panel 8 8Amp Fuse Panel 6 8Amp Fuse Panel 7 16Amp Fuse Panel 4 8Amp Fuse Panel 2 8Amp Fuse Panel I 16Amp Fuse Pane...

Page 591: ...14 ER70 x 14 18 5x14 6 95 X 14 7 35 X 14 7 75 X 14 ER70x14 185 X 14 6 95 X 14 7 35 X 14 7 75 X 14 ER70 X 14 185 X 14 6 95 X 14 7 35 X 14 7 75 X 14 ER70 x 14 185 X 14 6 95 X 14 7 35 X 14 7 75 X 14 ER70...

Page 592: ...FALCON FAIRLANE w P VENTILATION HEATING ACCESSORIES PART 16 1 Ventilating and Heating PART 16 2 Air Conditioning PART 16 3 Radio Stereo Tape Player GROUP 16 PAGE 16 2 16 7 16 26...

Page 593: ...ts in the distribution box or windscreen demister outlets Fig 2 AIR AND TEMPERATU1tE CONTROL The control assembly is located on the dash panel in the instrument cluster assembly It contains two horizo...

Page 594: ...XED VENTILATION Should it be desirable with the right and left hand air vents full open cool air may be admitted to face level with warm air being directed to the screen or to the interior or both by...

Page 595: ...At CR 8 Tw N cor R I CO CR H 14T A MOTOR DASH PANCL OPENING APPLY 58 M4G 3 Z A f OA Sh PAN L TO liOAM WAT A Tlc H T AND OUST PAIXJF S AL a COOITIIll oNHfrTIVN ltiOZllL A Y DEFR05TER J Cltlfl JU MDNT o...

Page 596: ...e a smooth kink free installation for maximum heat ing HEATER HOSE REPLACEMENT To replace a heater hose drain the coolant remove the hose cut a new hose to the same length as the old hose install the...

Page 597: ...A ro t WI TCR IIALVC CAlLI All FIG 4 Heater Control HEATER ASSEMBLY INSTALLATION 1 Mount the heater assembly to the dash panel Pasten the heater in place with the 4 nuts spring anq flat washers 2 Conn...

Page 598: ...itions are maintained within the normal comfort zone CAPILLARY TUBE EXPANSION VALVE HIGH PRESSURE LIQUID tal LOW PRESSURE LIQUID HIGH PRESSURE VAPOR f lA LOW PRESSURE VAPOR FIG 1 Refrigerant Cycle Thi...

Page 599: ...level b EXPANSION VALVE The expansion valve is a pressure reducing control which regulates re frigerant flow to the evaporator High pressure freon enters the valve in the liquid state and leaves as a...

Page 600: ...freon until condition is corrected 2 Restriction at drier or in lines usually indicated by frosting at point of restriction or lines being cool on side of restriction away from compressor Replace faul...

Page 601: ...HEATER CONTROL SETTING Fl 4CTIONAL CONTROL LEVER POSITION A C HEAT OFF MAle FRESH FLOOR SCREEN ONI4 TO ONN TO OI EH TO OHN TO OUTSIH HC IAC OUTSIO Ra IRC NV v HV v A C POSITION Nil v WIAT POSITION f I...

Page 602: ...MOTOR FLOOR DEFROST WARM HEAT AC DOOR VAC MOTOR v FLOOR HEAT OUT MODE _ MAXIMUM AIR CONDITIONING RECIRCULATING AIR IN DOOR MOTOR HOT WATER VALVE CLOSED FRESH AIR IN RECIRC AIR IN WfJ MAX A C FRESH CO...

Page 603: ...VAC MOTOR FLOOR I DEFROST WARM 3 NOTE A C COMPRESSOR OPERATES ONLY WITH BLOWER ON HEAT AC DOOR VAC MOTOR v FLOOR HEAT OUT FIG 6 Fresh Air conditioning MODE FRESH OR RECIRCULATING A C 1 SHOWING TEMPER...

Page 604: ...ING A C VENTS bUT DEFROST OUT NV FLOOR DEFROST VAC MOTOR r M I FLOOR I DEFROST WARM HEAT AC DOOR VAC MOTOR FLOOR HEAT OUT MODE HEATER FLOOR MIDWARM HOT WATER VALVE FULLY OPEN AIR IN DOOR MOTOR FRESH A...

Page 605: ...DEFROST VAC MOTOR FLOOR I DEFROST WARM HEAT AC DOOR VAC MOTOR FLOOR HEAT OUl FIG lO Heater Floor Warm MODE HEATER MID POSITION FLOOR DEFROST AIR IN DOOR MOTOR 1 ili HOT WATER VALVE FULLY OPEN FRESH A...

Page 606: ...system with a good vacuum pump and charge the system with the proper amount of Refrigerant 12 No bubbles in the sight glass indicate either too much refrigerant or a complete loss of refrigerant While...

Page 607: ...O JII S uu gq CA8L SOTHATWH N INNCR CA IS PUSNCO rVLLY IN THC TCMP CONTROL LC VDf 15 APPFf OJt rRONI LH SrOP MV S T 8 riRMLY PUSHCDON TD VACtA N VALV VNTIL M L CUP 5 LOCK 1 tr N C 55AR Y APPLY A SIIML...

Page 608: ...PAS I I I I I I I L FIG 14 Installation A C Electrical Schematic STA ITER el To bATUJIY lol awwec srcwt EVAPORATOR ASSY 4 To Co lbt H41fr sw ftCH ere SlilotrcN Pf H L 1111 o I I iii 8 z 0 3 0 z z f J...

Page 609: ...mpressor beyond the clutch indi cates this type of leakage Replace the oil seal assembly Refrigerant 12 Leakage Refrigerant 12leakage through any part of the seal can be determined only by a leak dete...

Page 610: ...e oil check hole for a different mounting When checking the oil level on such a compressor angle the dipstick so that it bottoms against the lower side of the crankcase and not against the boss 4 Pull...

Page 611: ...cuum pump valve closed 3 Set the low pressure suction manifold gauge valve at the full counter clockwise or open position 4 Set the high pressure dis charge manifold gauge valve at the full clockwi e...

Page 612: ...me the more sensitive it is to leaks Therefore to ensure accurate leak indication keep the flame as small as possible The copper element must be red hot If it is burned away replace the element Hold t...

Page 613: ...h wire ener gize the clutch and torque the clutch mounting bolt to specification Tighten the compressor mounting bolts to specification 3 Install the belt and adjust and tighten the idler pulley 4 Ins...

Page 614: ...oles in the gasket Fig 24 3 Place the valve plate in position on the cylinder so that the dowel pins go through the dowel pin holes Fig 24 4 Apply a light film of clean re frigeration oil on each side...

Page 615: ...e carbon ring retainer facing out Move the seal in and out on the shaft a few times to insure a good seal between the seal and the shaft 3 Push the seal all the way on the shaft Be sure that the seal...

Page 616: ...compressor minimum A belt operated for a minimum of 10 minutes is considered a used belt Refrigerant charge 32 ounces Clutch current draw 3 75 amps When recharging the syst m add 28 ounces and check s...

Page 617: ...l cable 3 Shorted speaker lead or defective speaker Be sure to turn off the radio receiver before removing the speaker 4 If radio still will not play remove the receiver for a major repair NOISY OR ER...

Page 618: ...1 Remove instrument cluster housing 2 Remove radio knobs and surround 3 Remove heater control mount ing screws 4 Remove the wing nut attach ing radio to rear bracket 5 Remove 3 mounting screws at the...

Page 619: ...esidue oxide as the tape passes over the head This accumulation may need to be periodically removed as part of normal maintenance ifit causes weak or wavering sound The playback head can be cleaned wi...

Page 620: ...I _ PART 16 3 RADIO FIG 3 SpeakerInstallation Sedan and Wagon Typical 16 29...

Page 621: ...16 30 GROUP 16 VENTILATING AND HEATING WIR W t rHBJ M k SU Ell e J 7l BE CONN CTED TO T RJ AIIJI4L Atttt HC D FIG 4 Stereo speaker in cowl side card i i I II I...

Page 622: ...CON FAIRLANE w P BODY DOORS AND WINDOWS GROUP 17 PAGE PART 17 1 General Body Service 17 2 PART 17 2 Front Sheet Metal Bumpers Exterior Mouldings 17 12 PART 17 3 Doors Windows Tailgate and Deck Lid 17...

Page 623: ...account all points covered under dust leaks To determine the exact location of a dust leak it may be necessary to remove the following trim from the car 1 Cowl trim panel 2 Rear seat back and seat cu...

Page 624: ...adhesive cement for general purposes It is suitable for cementing rubber to metal rubber to cardboard or wood or rubber to rubber Surface to be cemented must be cleaned of all grease dust and mould c...

Page 625: ...epaint ing with either conventional air dry ing or low bake enamels or with acrylic lacquers When repainting metallic colors it is recommended that acrylic lacquer be used since a better color match c...

Page 626: ...NT MOUNTING HOLE FRONT IUHI EII HTG HOLE 72 71 PLAN VIEW 1 WAGON UTY VAN DIAGONAL DIMENSIONS MUST E EQUAL DIMENSIONS UNDER too HAVE A VARIATION OF t 0 6 EXCEPT AS NOTED BY AN ASTERISK DIMENSIONS OVER...

Page 627: ...G PITS AND POP UPS PATTERN BLISTERS DIRT IN PAINT CRATERS LINE CHECKING MILDEW THIN PAINT CHIPPING OFF COLOR RUNS AND SAGS BRUISES RANGE PEEL PEELING CRACKING OVERSPRAY FIG 2 Paint Defects SCRATCHES W...

Page 628: ...s that may partially or completely penetrate the surface of the finish coat of paint Acrylic Enamel Use polish re pair procedure for shallow penetra tion Refinish panels to correct con ditions of deep...

Page 629: ...the windshield wiper blades and replace them if necessary 9 Tighten the sill plate and gar nish moulding screws 10 Clean the seats door trim panels and headlining 11 Touch up or paint chipped or scra...

Page 630: ...ralise it Now wash over with warm soapy water Always dilute the acid quickly If ammonia is not readily available use a normal household detergent These usually contain a neutralising agent Blood Cold...

Page 631: ...safe hoisting the front post adapters must be positioned carefully to contact the centre of the lower suspension arms Fig 3 REAR To prevent damage to the shock absorbers the rear forks must con tact t...

Page 632: ...PART 17 1 FRONT SHEET METAL BUMPERS EXTERIOR MOULDINGS 17 J 1 FIG 5 Door Weather Strips and Seals...

Page 633: ...cowl panel 2 Remove the hinge to hood re taining bolts the retaining bolts at the fender apron and cowl Fig 1 and remove the hinge 3 Position the hood hinge on the body and install the hinge retaining...

Page 634: ...PART 17 2 FRONT SHEET METAL BUMPERS EXTERIOR MOULDINGS 17 13 I I I I b I I I FIG 2 Installation Hood Lock...

Page 635: ...17 14 Q Q E J Q c 0 u c 0 iO t c I M u GROUP 17 BODY DOORS AND WINDOWS...

Page 636: ...emove the licence plate lamp from the bumper 2 Remove the 6 bolts bumper support bracket to body 2 from beneath vehicle I from inside luggage compartment each side Fig 4 3 Remove the bumper stone shie...

Page 637: ...7 FIG 5 Installation Rear Bumper Sedan I 0 Ia 0 c I OJ 0 0 0 0 0 o z 0 z...

Page 638: ...the drive mechanism box spring plate over drive pinion connector rails and upper parts of the corner rails Pull out the cable with the rear slide from the guide rail Install a new cable lubricated wit...

Page 639: ...17 18 GROUP 17 BODY DOORS AND WINDOWS FIG 7 Drive Cable and Housing Installation Typical FIG 8 Removal and Installation of Rear Slide and Cable Typical...

Page 640: ...move radio 8 Unclip the wiring harness from the instrument panel 9 Remove two screws hand brake handle to instrument panel 10 Remove brace attachment bolts at the instrument panel II Remove bolts atta...

Page 641: ...17 20 GROUP 17 BODY DOORS AND WINDOWS FIG 9 A Grill and Front Ornamentation l H FIG 10 Exterior Ornamentation Sedan Wagon F Lane...

Page 642: ...PART 17 2 FRONT SHEET METAL BUMPERS EXTERIOR MOULDINGS 17 21 FIG 10 A Exterior Ornamentation Sedan F Lane 1...

Page 643: ...17 22 I I ____ J J I GROUP 17 BODY DOORS AND WINDOWS FIG 10 B Exterior Ornamentation Sedan F Lane f...

Page 644: ...l A 79560 SIC SGii I V 6 LOb 6 A i DU IIJ 11 29061 1 AI OUI D 1 16 ASSY IUAR QIJNIT R Ol 76 DE 1 1 REO URCD At 0 AL 71 MOCkL i A T TA _ H H M Q _ C N 6 WIT F AAC9QB e 4tA4e A REWNCR AR 00011 OUTSIDE M...

Page 645: ...17 24 z _ TYP 1 I I GROUP 17 BODY DOORS AND WINDOWS B 5ECA IVO Ir I noo s A BIC ooA C t f AU Mt IOEL S FIG 11 Body Side Stripe...

Page 646: ...PART 17 2 FRONT SHEET METAL BUMPERS EXTERIOR MOULDINGS 17 25 2 Lfl IF I I I FIG 12 Rear End Ornamentation Van and Wagon I I 0 8...

Page 647: ...17 26 I r r GROUP 17 BODY DOORS AND WINDOWS LF_J I 0 0 l I 1 I I i JU 0 FIG 12 A Rear End Ornamentation Ute and Fairlane nV JL J__ S 13 9XJ...

Page 648: ...PART 17 3 DOORS WINDOWS TAILGATE AND DECK LID 17 27 2 GV JL_ l ern 6 0 CSSJ ffl FIG 12 B Rear End Ornamentation Sedan...

Page 649: ...WS i _ _ I 2 SYioolo PART NO PART NAiooiE I 16AI08 9 looiOULDING FAONT FVIOER AIR COOP G T 2 1 01 6 PANEL FRONT FENDER l 6E106 7 DEFLECTOR FAT FENDER Alii SCOOP f3 7388 1iol NUT r SELF THREADING FIG_...

Page 650: ...J J IOOD AIR SCOOP OPENING 37 3888 540 NUT 12 REQD 16A70 J A LATCH NOOD D TERNAl 5 CTION CC 16A704 A8 SPRING 1 1000 l r JN A A f xTC rNAL LAT l 1 17 1 536 PIN GROOVED to I A fl V W B NOTE PIN S MUST B...

Page 651: ...STCR MAIN A j587 S 5 8 SCREW 8 15 38 CRS R C l ID WASHeR lJ V J88U 9 5l Nf T A SSY CA GC 1 18 UNC RCQ C 42758 5 36 SCI CW SHCR A SSY 6 8 t H 2S 536 WAS H f J 04810 r EPTA C L Aj Y VS I PANEl A JJ I 2...

Page 652: ...riker shC Jid not be adjusted to correct door s ag The lock strika hould he shimmed I l Ct the clearance hown in Fig I hetween the lock striker and the lock To check this clearance clean the Jock jaws...

Page 653: ...GROUP 17 BODY DOORS AND WINDOWS GLASS RETAINER REMOVAL PUSH BUTTON IN UNTIL PUSH RETAINER IN FIRMLY FLUSH WITH RETAINER GLASS RETAINER INSTALLATION N2179 B FIG 2 Front Door Ventless Window Mechanism T...

Page 654: ...screws move the lock as required to make good contact and r I o M 1 Ill IITJJ QJo Af ICJ r ll US rA SO l l t Tl IO vr 1 0 00 4 r tltP n w rc Tl ll JXD 1U M r CH ITA l lllltAWTlOII I ISr t a 111 191 1...

Page 655: ...r 14 Retainer Division Bar Assy Rear Door Glass Run 15 Retainer Division Bar Assy Rear Door Glass Run 16 Regulator Assy Rear Door Window Manual 17 Retainer Assy Rear Door Glass Run Front 18 Regulator...

Page 656: ...Remote Control vtew 4 Link Assy Door Lock Control Rod 5 Rod Rear Door Lock Push Button G 6 Knob Door Lock Control Rod 7 Bell Crank Assy Rear Door Lock Control 8 Handle Assy Rear Door Outside 9 Rod Was...

Page 657: ...ssy Front Door Outside 5 Plate Lever Assy Front Door Outside Handle Mounting D Clip Door Lock Rod Retaining 6 Knob Door Lock Control 7 Rod Door Lock Push Button 8 Ref Door Lock Pillar 9 Striker Assy D...

Page 658: ...LOCK REMOVAL 1 Remove the trim panel and position the water shield away from the access holes 2 Disconnect the door lock re mote control rod and door lock control rod at the door lock assem bly 3 Rem...

Page 659: ...out of the glass channel 3 Unsnap and remove the belt weatherstrips loosen the front run attaching bolt at the mounting bracket and remove the bracket attaching bolt from the inner panel 4 Remove the...

Page 660: ...g from inside the car loosen the weatherstrip from the window opening flange and push the window weatherstrip and moulding assembly out of the open ing 4 Remove the moulding and weatherstrip from the...

Page 661: ...indshield Installation 15 WI TH riSI Jl CONTACT TYPICAL NOTC tltR GUI AIItriCS 0 ll NIN WfD r 1 AlfL ACCEPTA6L NIOYIDING T L r DO NOT EW ECD THE I CIUOWIMI i NAX lENG nt lAC If ONC I PCR IS SCG fENT T...

Page 662: ...lass that will contact the sealer Refer to Fig 8 10 Place cartridge in caulking gun and pump out a 5 16 diameter bead along the sealing surface of the glass opening 11 Place glass in position using t...

Page 663: ...17 42 GROUP 17 BODY DOORS AND WINDOWS VIEW A RU68ER SPACER FOUR RECUIRED APPLY PRIMER TO UNDERSIDE AND EOGE OF GLASS AND TO METAL SURFACE FIG Windshield Replacement REFER VIEW 8 FOR PRIMER APPLICATION...

Page 664: ...hannel assembly and then clean the glass groove 2 Position the weatherstrip into the glass lower channel Install the weatherstrip and channel to the g lass 3 Position the window assembly in the gate a...

Page 665: ...MO Jl OING bACJt WINI OW OiJfj lJE U PlR R QU 4t O FVRAll 4 MCJ EL EXCtPT 5 1 ATTACH TO W STRIP A SHOWN 3 MOUlDING BACK WINDOW OUTS lOWEk lfEQIJ 1 fOR AlL 54 MObllS EXCEI T 44A ATrACH TO W STRIP AS 5...

Page 666: ...sy Back Window Glass Ru n 6 Retainer Back Window Moulding Outside Upper 7 Sealer Gray or Black 19 Dia 10 Places Vi ew 8 8 Alternate Sealer Pressure Sensitive on one Wide Side Only Applied Entire Lengt...

Page 667: ...Tailgate Check 7 Spring T gate Check Cable RH 8 Hinge Assy T gate RH 9 Striker Assy T gate Upper Latch LH 10 Hinge Assy T gate LH 11 Spring T gate Check Cable LH 12 Cable Assy T gate Check A Screw To...

Page 668: ...be wound to the closed out position The glass must be supported while in this position 4 Detach the spring clip and re move the switch assembly from the lock cylinder 5 The clip retaining the lock cyl...

Page 669: ...n the clearances shown in Fig 17 The fore and aft and up and down adjustment of the tailgate is accom plished at the hinge side by means of square holes in the body pillar backed by floating tapping p...

Page 670: ...ide LH 4 Bracket Assy Back Window Regulator 5 Bumper Back Window Stop 6 Run Retainer Assy Back Window Glass Lower Side RH 7 Handle Housing Assy T gate 8 Pad T gate Outside Handle 9 Bracket T gate Outs...

Page 671: ...iker Assy T gate Upper Latch LH 8 Striker Assy T gate Lower Lock 9 Shim A Screw Washer Assy Torque 25 38 lbs ft B Spacer T gate Upper Hinge on Body C Sealer Grey or Black 19 Dia or Bulk 14 Places D Nu...

Page 672: ...UPPDt LA rCII lTDC S Nl131 101 LA l CII WD R I CIWllt LA l CII 1 1 111 17 IS II OPEl POtm lOif lOrE ELICTRIC llJXN Jti CJJLA 11119 1 aT OPERATE WREI U PP ER Lo ICB I l Dt I8 II 01 1 PO JTIC 8 e lOft...

Page 673: ...onnect the linkage to the Iatch 8 Position the window assembly in the gate and install the regulator arms to the regulator channel Close latch pawl to engage the switch and lower the window into the t...

Page 674: ...ssary adjustment tighten the hinge attach ing bolts DECK LID LOCK 1 Unlock and open the deck lid 2 Remove the bolts retaining the lock assembly and remove the lock 3 Position the lock assembly t the d...

Page 675: ...switch and listen for the motor running free If tb e motor runs and the window does not move the rubber coupling or gear teeth have failed 2 If the motor does not run dis connect the wires at the moto...

Page 676: ...the sector gear from moving hen the motor and drive assembly 1s removed Remove the motor assembly from the regulator INSTALLATION 1 Lubricate the glass mechanism 2 Position the motor and trans mission...

Page 677: ...e four attaching screws 4 Install the motor bracket to door inner panel attaching screw 5 Insert the regulator arm roller in the equalizer arm bracket Position the bracket to the inner panel and insta...

Page 678: ...JNISNED ON CONTACTIN6 3UIVACI ASSIMtl j ICif AND ltOU JIIfG A U Y MOliN11NO l f AtC MI Tfi IJ OHM 11 llflQD l lllfCN D OW _G A U Y MOI IN11 116 hATe f l ll UI l IUQ b 11 f ltiN ASSY fOWl l WIN XJII f...

Page 679: ...EL OR TAILGATE KEY I PERFORM POWER WINDOW RELAY AND CONTROL CIRCUIT DIAGNOSIS AS OUTLINED ON CHART 1 IALl POWER WINDOWS DO NOT OPERATE NOTE VEHIClES WITH OTHER FUNCTIONAL POWER WINDOWS OR POWER SEATS...

Page 680: ...NIT IO N SWITCH ON DISCONNECT THE MOTOR CONNECTOR AND CHECK FOR FEED AT BOTH TERMINAlS WHILE ACTUATING THE BACK liTE KEY SWITCH USING A 12 VOLT TESTER HGNITION SW OFF LIMIT SW CLOSEOl OK DISCONNECT MO...

Page 681: ...N POWER BACK UTE DOES NOT OPERATE WITH THE TAILGATE KEY SWITCH BUT DOES WITH THE INSTRUMENT PANEL SWITCH AT THE POWER WINDOW RELAY BATTERY TERMINAL CHECK CONNECTION OF THE DIRECT BATTERY FEED BETWEEN...

Page 682: ...MOTOR DIRECTIONS OPERATING BY THE TAILGATE KEY SWITCH POWER TAILGATE AND DIAGNOSIS Cont STATION WAGON POWER BACK LITE DOES NOT OPERATE WITH TltE INSTRUMENT PANEl SWITCH BUT DOES WITH 1 AILGATE KEY SWI...

Page 683: ...VE CONNECTION AS REQUIRED POWER WINDOW SYSTEM DIAGNOSIS All POWER WINDOWS DO NOT OPERATE TURN IGNITION SWITCH TO THE ON OR ACCESSOftY POSITION CHECK FOR FEED THROUGH THE POWER WINDOW RELAY FROM BATTER...

Page 684: ...ECTOR USING A 12 VOLT TESTER OK NOTE BATTERY SHOULD BE FULLY CHARGED lABOVE 1 225 SPECIFIC GRAVITY CONNECT EXTERNAL POWER SOURCE TO THE MOTOR CONNECTOR S UP OR DOWN FEED AND CHECK WITH AMMETER IF MOTO...

Page 685: ...MASTER CONTROL SWITCH CHECK FEED CIRCUIT TO THE AFFECTED CONTROL SWITCH IN THE MASTER CONTROL SWITCH ASSEMBLY USING 12 VOLT TESTER NOTE BATTERY SHOULD BE FULLY CHARGED lABOVE 1 225 SPECIFIC GRAVITY CH...

Page 686: ...FALCON FAIRLANE w P TRIM SEATS GROUP 18 PAGE PART 18 1 Interior Trim and Vinyl Top Cover 18 2 PART 18 2 Seats 18 6...

Page 687: ...rter windows station wagon and unstick the headlining from the flange s Refer to Section 17 3 for rear window removal pro cedure With the station wagon remove the rear quarter panel trim mouldings and...

Page 688: ...PART 18 1 INTERIOR TRIM AND VINYL TOP COVER 18 3 A A FIG 1 Door Trim Panel and Water Shield Typical...

Page 689: ...OUTSIDE COVER REMOVAL 1 Remove the rear seat cushion and back 2 Remove the package tray panel and loosen the headlining in the quarter area sufficiently to permit access to the side belt moulding reta...

Page 690: ...ch drive nail holes at windshield and rear window open ings and install drive nails Existing holes may be used for the screws at each seam 5 Trim the excess cover material from around the entire perim...

Page 691: ...neral Information FRONT SEAT CUSHION AND OR BACK 1 Remove the front seat and seat track from the car if the cushion is to be replaced 2 To replace the seat cushion remove the seat assembly from the se...

Page 692: ...MONT J Jio T TRA I A JJUJTtNC 0 tJJiJ SPiflltiG FA JNT SlAT T fA I A IJT Fj TRKK A Y Htt NT SCAT fN 0 rRAt 1 A Sf ntDNT Sl AT L 1 1 0 lfAJia C A OSII rRONT XAr 1 VICK A lJVJTIH 0 PR NC TRONT SEA r TR...

Page 693: ...with hog rings 1 Fig 4 6 Install the seat cushion in the car NOTE Two types of rear seat and se t back springing are employed and 1f replacement of a frame and spring assembly is required it must be o...

Page 694: ...PART 18 2 SEATS 18 9 L su A FIG 3 Front Seat Back FIG 4 Rear Seat Cushion Installation Typical...

Page 695: ...18 10 GROUP 18 TRIM AND SEATS FIG 5 Rear Seat Back Typical...

Page 696: ...or seat tracks are performed out of the car and are usually limited to replace ment of torn or burned seat cov ers In a few instances the pads may be damaged and require re placement 1 Remove the seat...

Page 697: ...NT SEAT lACK COVER 1 Remove the l e t and track as sembly from the car and place it on a clean work area 2 Undo the two retaining screws and remove the side valance 3 Remove the four hog rings re tain...

Page 698: ...PORT A s SY R R SEAT tJA J I RH ILH REQ D B 74 49 S SCR W 4 REO D il 34 40 S MH SHE R 4 R Q D 1 56 320 S SC ROV RE Q D 58 11114G 2 A SEALER 4 PLACE S 6003 2 A S5Y R R SEAT I RED D 11 877 08 5 scRE W 4...

Page 699: ...e seat back from the car 3 Undo the hog rings retaining the lower filler flap and remove it from the seat back 4 Undo the hog rings retaining Sealer should be placed around all seat belt anchor bolt h...

Page 700: ...sh the webbing with any com mercial soap or detergent Do not use carbon tetrachloride naptha etc Bleaching or redyeing of the seat belts is not recommended because of deterioration which may 18 15 be...

Page 701: ...REFERENCE TO SERVICE INFORMAnON AND NOTES Date Letter No Paae Brief Detail...

Page 702: ...FALCON FAIRLANE w P MAINTENANCE SCHEDULE GROUP AND LUBRICATION CHARTS 19 PAGE PART 19 1 Lubrication and Maintenance Schedule 19 2...

Page 703: ...oil will provide the proper viscosity for all normal ranges of outside tempera tures OIL QUALITY Use only oils which have been tested and certified by the maker as satisfying automobile manufact urers...

Page 704: ...PART SYNC HRO TRANSM ISSION AUTOMATIC UNIVERSAL JOINTS ENGINE I NGINE OIL I ILLER BREATHER CAP E GINE OIL FILTER DISTRIBUTOR CAM L1fet1me steermg gear grease AutomatiC trans miSSIOn fluid Rubber grea...

Page 705: ...brake pads for wear re where necessary and adjust wheel bear1ng Remo ve and clean brake drum assembl1es C s heck and l1 n1ngs for wear and adjust hand brake mec Repa ck and adjust front wheel bear1ngs...

Page 706: ...just automatic transmission band and service 000 and 35000 Accelerator linkage and down shift valve control cable Check and adjust if necessary automatic X Gear change linkage Check and adjust if nece...

Page 707: ...REFERENCE TO SERVICE INFORMATION AND NOTES Date Letter No Page Brief Detail...

Page 708: ...FALCON FAIRLANE w P GROUP MAINTENANCE OPERATIONS 20 PAGE PART 20 1 Maintenance Operations 20 2...

Page 709: ...IG 2 Typical Cylinder Block Drain Plug V 8 coolant level will drop approxi mately one quart after the engine has been operated about 20 min utes at 2 000 rpm This is due to the displacement of entrapp...

Page 710: ...CRANKCASE VENTILATION SYSTEM COMPONENTS XA ZF vehicles are equipped with crankcase ventilation systems which have the components located at different points on each type of engine Fig 3 shows typical...

Page 711: ...tension Any belt that has operated for a minimum of 10 minutes is considered a used belt and when adjusted it must be adjusted to the reset tension shown in the specifications 1 Install the belt tensi...

Page 712: ...R DEFECTIVE FUEL PUMP TOO RICH A FUEL MIX TUR IMPROPERLY OPERATING HEAT RISER OR EXCESSIVE IDLING CAN BE CLEANED IDENTIFIED BY DARK GRAY BLACK YELLOW OR TAN DE POSITS OR A FUSED GLAZED COATING ON THE...

Page 713: ...park plug wires Check wire position in support brackets Press wires firmly into proper bracket slots Push all weather seals into position FIG 7 Cleaning Spark Plug Electrode FIG 8 Checking Spark Plug...

Page 714: ...tributor is equipped with dual breaker points adjust the dwell of each set separately in order to get the specified combined dwell The most precise method is to disconnect one set of points while adju...

Page 715: ...ith the cap 2 Fill the reservoir to i inch from the top with approved fluid 3 Install the filler cap making sure that the diaphragm is properly seated in the cap CHECK CLUTCH MASTER CYLINDER FLUID LEV...

Page 716: ...1 The engine and underhood tem peratures must be stabilized before idle adjustments are made Run the engine a minimum of 20 minutes at 1 500 rpm This can be done by positioning the fast idle screw or...

Page 717: ...se ventilation system c Valve clearance using the col lapsed tappet method for hy draulic valves d Engine compression 3 Mter verification of all engine systems has been made t lere may be isolated cas...

Page 718: ...CE STROMBERG WW SERIES Figs 21 and 22 Apply light closing pressure to choke valve then open throttle valves to wide open position The choke valve should open just enough to allow the insertion of dril...

Page 719: ...ixture MOTORCRAFT MODEL 4300 4V CHOKE PLATE PULL DOWN CLEARANCE 1 Remove the air cleaner then re move the choke thermostatic spring housing from the carburettor Tore move the thermostatic spring housi...

Page 720: ...burettor from the engine to adjust the pump stroke To check the pump stroke 1 Start the engine and run at idle to normalise engine temperature Set the engine to the correct idle speed This is importan...

Page 721: ...AXLE CHECK TRANSMISSION FLUID LEVEL Refer to Part 19 Maintenance Schedule for recommended fre quency of service MANUAL TRANSMISSION 1 Remove the filler plug from the side of the case 2 If lubricant d...

Page 722: ...securing the transmtsston oil pan and detach the oil pan and gasket Slacken the adjusting screw locknut move the servo lever out wards and place a 0 25 in gauge between the servo piston pin and the a...

Page 723: ...utilising the access holes in the suspension towers wipe off any accumUlated dirt from around the lubrication fittings and lubricate the inner bushes using a maximum of 3 2 grams per bushing CHECK STE...

Page 724: ...aged If the disc braking surface is excessively scored distorted warped worn or shows excessive runout it should be replaced If the caliper is cracked or otherwise damaged it must be replaced as a uni...

Page 725: ...d as a unit if damage to either is en countered 10 Thoroughly clean the spindle and the inside ofthe hub with solvent to remove all old lubricant Cover the spindle with a clean cloth and brush all loo...

Page 726: ...cifications If any of the linkage is worn or bent replace the parts 4 Check the front wheel bearings Ifany in and out free play is noticed adjust the bearings to specification Replace worn or damaged...

Page 727: ...the rear of the car between the rear axle and the side rail as shown in Fig 45 3 Install the wheel alignment equipment on the car Whichever type of equipment is used follow the installation and inspec...

Page 728: ...centric bolt nut and the s_ trut front nut to specification TOE IN AND STEERING WHEEL SPOKE POSITION ADJUSTMENTS Check the steering wheel spoke position when the front wheels are in the straight ahead...

Page 729: ...slot Insert the key and operate the lock several times to be sure that the lubricant has effectively worked in LUBRICATE DOOR HINGE AND HINGE CHECK Apply approved Engine Oil on the hinge pivot points...

Page 730: ...FALCON FAIRLANE w P SPECIAL TOOLS PART 21 1 Special Tools GROUP 21 PAGE 21 2...

Page 731: ...embly and quality workmanship or where sub stantiated time saving can be achieved by the use of the tool This part lists Special Service Tools in two categories MANDATORY These are tools which are con...

Page 732: ...earing Oil Seal REAR AXLE AGF 1225 A Re11r Axle Sh ft Be11ring Remover Repl11cer FIG 2 Axle Shaft Bearing Remover Replacer AGF 1225 A 1 t Rear Axle Shaft Bearing Remover Replacer Adaptor Use with Tool...

Page 733: ...eke Tool 3 M804 Reteining Spring Tool 4 M802 Return Spring Tool GROUP 21 SPECIAL TOOLS 2 4 3 FIG 5 Brake Tools Drum Brakes t FIG 6 Disc Brake Rotor Gauge R 1102 A FIG 7 Power Steering Pump Pulley Repl...

Page 734: ...wer Steering PumP Gauge All Models 21 5 t FIG 8 power Steering PumP PulleV Remover Pressure FIG 9 power Steering pumP Pressure Gauge XA 3526 A R em ov e lnPutSnaftSeal andSP A 3521 B ExtractorWormRace...

Page 735: ...er Input Shaft Bearing and Sector Shaft Seal FIG 17 Replacer Input Shaft Bearing and Sector Shaft Seal XA 3771 A Wedge Sleeve Coupling XA 3589 B Contractor Sleeve Rings 1 FIG 15 Contractor Sleeve Ring...

Page 736: ...l Se tor Sh ft Be riog Tool Guide FIG 20 Washer Sector FIG 19 Sector Shaft Shaft Bearing Tool FIG 22 Sector Shaft Bearing Bearing Tool Spacer Tool Guide FIG 23 Mounting Bracket XA 3589 A XA 3775 A XA...

Page 737: ...oint Tool FIG 27 Suspension Alignment Spacers SUSPENSION STEERING WHEELS AND TYRES ACX 3006 Remover Press Spindle Ball Joint All Models t ACX 3006 D Adaptor Spindle Ball Joint Press 4010 A Reor Axle S...

Page 738: ...ted Slip Rear Axle Torque Check Tooi T65K 4204 A PART 21 1 SPECIAl TOOLS FIG 30 Limited Slip Rear Axle Torque Check Tool T65K 4204 A FIG 31 Pinion Setting Gauge 4209 B t Pinion Setting Gauge All Model...

Page 739: ...one 4221 AR t Remover Pilot Differential Bear ing Cone t 4221 A 8 I Replacer Differpntial Bearing Cone All Models t 4621 B 2 Replacer Pinion Bearing Cone All Models FIG 33 Remover Pilot Differential B...

Page 740: ...ck Differentiai T68P 4946 A 4676 G Replacer Pinion Oil Seal All Models t FIG 37 Gauge Tool Traction Lock Differential T68P 4946 A FIG 38 Front Spring Remover Replacer MANDATORY TOOLS Front Suspension...

Page 741: ...Replt cer TMK 5781 82 Spt cer _ TMK 5781 B 1 Bolt T64K 578 1 83 Nut TMK 5781 84 Wt shers FIG 39 Remover Replacer Front Bushing Rear Spring f M470 Oil Ct rtridge Remover FIG 40 Oil Cartridge Remover E...

Page 742: ...ler 8 cyl t T70P 6B070 B Front Cover Seal Remover Reamer Valve Guide Reomer Kit Oversize Valve Guides 0 003 0 015 0 030 t 6085 B All engines FIG 43 Pilot Cylinder Block Front Cover I 1 I l J Cl t T70P...

Page 743: ...mshoft Beorings t T68P 6135 A Remover Replacer Piston Pin All engines FIG 49 Remover Replacer Camshaft Bearings FIG 50 Remover Replacer Adaptor Camshaft Bearing t Replacer Camshaft Rear Bearing Plug T...

Page 744: ...6306 AG Remover Crankshaft Pulley All engines FIG 53 Hydraulic Tappet Tester t FIG 54 T70P 6505 A Valve Stem Deburring Button FIG 55 Hydraulic Valve Lifter Bleed Down Tool FIG 56 Valve Spring Compres...

Page 745: ...cyl 6700 c Remover and Replacer Crank shaft Front Oil Seal 6 Cyl t FIG 57 T70P 6K517 A Water Pump Bypass Plate Installer t T70P 6564 A Tappet Bleed Down Wrench 8 cyl FIG 59 Remover Replacer Crankshaf...

Page 746: ...using Bush I 7111 c Ret11iner Ciuster Ge11r Roller Be11rings All Models FIG 62 Retainer Cluster Gear Roller Bearings ___ _ I t FIG 63 Gear Shift Linkage Grommet Pliers 7341 C Twin Disc Clutch Aligning...

Page 747: ...CYL Adaptor Replacer Extension Housing Bush 77 7 B GROUP 21 SPECIAL TOOLS FIG 66 Adaptor Replacer Extension Housing Bush t 77047 Bl Input Shaft Oil Seal Replacer VB 3SPD f Replacer Input Shaft Oil Se...

Page 748: ...PART 21 1 SPECIAL TOOLS I FIG 68 Remover Replacer Adaptors C4 Auto Trans Bushings T66L 7003 B I I I 21 19...

Page 749: ...63L 77837 A 6 Replacer Transmission Extension Housing Oil Seal Assembly T61L 7657 A 7 Automatic Transmission Clutch Spring Compressor T65L 77515 A 8 Replacer Transmission Extension Housing Bushing AT...

Page 750: ...h Cradle Adaptor PART 21 1 SPECIAL TOOLS 21 21 1 5 16 Socket 3 8 Drive Socket Clutch Race to Case Bolb 2 AF2 440S TV Crowfoot Wrench Vacuum Control Unit 3 W BTension Wrench Model 32008 FIG 71 Rear Ban...

Page 751: ...ssor All Models t BW 38 Hydraulic Pressure Test Gauge Kit All Models FIG 75 Banjo Adaptor Detail1 FIG 76 Banjo Adaptor Detail 2 FIG 73 Clutch Spring Compressor FIG 74 Hydraulic Pressure Test Gauge Kit...

Page 752: ...IG 77 Rear Clutch Piston Replacer BW 42 Front Clutch Piston Replacer FIG 78 Front Clutch Piston Replacer BW 548 1 Torque Screw Driver Adaptor FIG 79 Torque Screw Driver Adaptor AUTOMATIC TRANSMISSION...

Page 753: ...Pump Shaft Bearing 6 Cy l t FIG 82 T70PG 8564 A Installer Water Pump Seal 6 Cyl 8620 B Drive Belt Tension Gauge C _ __ t FIG 81 T70PG 8530 A Remover Replacer Water Pump Shaft Bearing 6 Cyl T OPG 8564...

Page 754: ...ifter TM F 42006 Windshield Upper Moulding Re mover 3 Carburettor Tools 6 Cyl I 9533 A Jet Wrench 2 9550 A Float Arm Setting Tool 3 9A516 A Discharge Jet Re mover FIG 84 Carburettor Tools AGI6 Vacuum...

Page 755: ...21 26 GROUP 21 SPECIAL TOOLS FIG 87 Windshield Caulking Gun BODY SP 1832 12 Windshield Coulking Gun All Models...

Page 756: ...Contractor Piston Ring XA 3544 A 14 Installer 8 cy I T70P 6B070 A 45 Contractor Sleeve Rings XA 3589 B 15 Front Cover Seal Remover Ring Spanner XA 3707 A 16 8 cyl T70P 6B070 B 46 Replacer Input Shaft...

Page 757: ...1 79 Bush Seal 6 cyl 7657 G 65 Front Servo Adaptor Typical BW 548 2 A 80 Replacer Extension Housing Bush Seal 8 cyl T61 L 7657 A 65 COOLING SYSTEM Adaptor Replacer Extension Housing Bush 6 cyl 7657 G...

Page 758: ...REFERENCE TO SERVICE INFORMATION AND NOTIES Date Letter No Pa1e Brief Detail...

Page 759: ...REFERENCE TO SERVICE INFORMATION AND NOTES Date Letter No Page Brief Detail...

Page 760: ...FALCON FAIRLANE w P SCHEMATICS PART 22 1 Schematics GROUP 22 PAGE 22 2...

Page 761: ...CH tNSTRVI AENT PAIVEt_ I I I I rTt 5 1 I I I G 4 7 IO Z J 9s I 197 K Y C PERATEC SIN lTC TAIL GATE I I 5 ol 1 76 3C I s F I 1 I ROAA 1 AAIN L 8 l A FIG 1 Electric Tailgate Window I r I lr 402 T I I I...

Page 762: ...0 T JI AA L o FIG 2 Electric Door Windows R l l Q AQ OOOQ l ti AQ OOOQ I J RIGJI iT 00012 Mf C OW MOTOQ A t4 ST et C 10 _ ON VP 1 y OC C Q 7 4J 0 I 31 414 573 I 571 I SWITCH I I SNrrci 1 S 6 I 317 ON...

Page 763: ...22 4 GROUP 22 SCHEMATICS r 7 5 r f llr 5 F FIG 3 Printed Circuit G T Falcon and Rallye Pack Only...

Page 764: ...PART 22 1 SCHEMATICS HI L H SEAM 77 RN IND FIG 4 Printed Circuit Fairlane Only 39 22 5...

Page 765: ...GREEN STRIPE 58 WHITE 12 GREEN BLACK 63 RED 13 RED BLACK 140 BLACK RED 14 BROWN 234 BLUE 15 RED YELLOW 16 RED LT GREEN 262 BROWN RED 17 WHITE 450 YELLOW BLACK 18 YELLOW RED 482 BLUE RED 19 BLUE BLACK...

Page 766: ...A P F A lk L ONE ONL Y ARCJ CJJF 130 A A L RI I L 1 f CW U VII G p _COl 01 L Y L J CII AA 4P tlf IL _ f OtNL Y IS IJ A5 1Etvt8J 16 5 AQCJ ilCF I 4 01 ENGINE CO vf TMENT l lfl IIB TOR CON CT i _ _ 0 1...

Page 767: ...CK l ii PCJ c L Y Q m F JkS IS S70 _ rt t c _ ___ 4 r i m 18 Wc r rAe 10 eu e oiOJ 4 L 7 _ 1 ooo 11 1 J IV ro 1__ 11 II _ f 1 l l J OQ c oo JJ 0 vfANI J L QA NktS TOR CON T Q TR AN SMI SSI ON SI ICAT...

Page 768: ......

Page 769: ...f t L Ct 4 S ii1 L b a tJ T PI IV 1 4f J r l 67 S Or1 1 6 1 CU OeJ NO 911 e ea N C7 CIIie 610 II bOIO I I A NO Oet ZF 1l O J Lf4J j f lfi u oo CINMIJII tll _ _ A O v t w r f IVC _ J fD ec w 011 10 NO...

Page 770: ......

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