Ford Thunderbird 1966 Page 19 Shop Manual Download | Manualshive

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Summary of Contents for Thunderbird 1966

Page 1: ...1966 FORD SHOP MA ...

Page 2: ...to or r This product was created from the original Ford Motor Company s publication Every effort has been made to use the original scanned images however due to the condition of the material some pages have been modified to remove imperfections Disclaimer Although every effort was made to ensure the accuracy of this book no representations or warranties of any kind are made concerning the accuracy...

Page 3: ...RANSMISSION mH ENGINE WL mjB nKmKKMmmmmMm mm a m simWimK aBMkm iwm am mm mwm Mmwm m mwKM IGNITION SYSTEM BB FUEL SYSTEM ITS1 121 1 COOLING SYSTEM MM EXHAUST SYSTEM J Mj CHARGING SYSTEM STARTING SYSTEM UGHTJNG SYSTEM HORNS AND INSTRUMENTS VENTILATING HEATING AND ACCESSORIES BODY DOORS AND WINDOWS TRIM SEATS AND CONVERTIBLE TOP fTTI haWaaal MAINTENANCE SCHEDULE MAINTENANCE OPERATIONS LUBRICATION CHA...

Page 4: ...d repairs in vehicle adjustments overhaul etc Specifications and recom mended special tools are included Refer to the opposite page for important vehicle identi fication data The descriptions and specifications in this manual were in effect at the time this manual was approved for print ing The Ford Motor Company reserves the right to discontinue models at any time or change specifications or desi...

Page 5: ...harts that follow list in detail the various vehicle data codes M 1088 C Fig 2 Vehicle Identification Number Location VEHICLE DATA The vehicle data appears in a line across the top of the warranty plate Fig 1 The first two letters and a number identify the Body Style The following one or two letters identify the Exterior Paint Color The next code consisting of two numbers or a letter and a number ...

Page 6: ...P8 Gold and White Pearl Vinyl P9 Palomino and White Pearl Vinyl TRANSMISSION CODE Code 4 EXTERIOR PAINT COLOR CODES M 32J Code Number Color A 1724 A Black B 1911 A Lt Beige Met E 1446 A Med Silver Mink Met F 1226 A Lt Blue G 1905 A Brite Blue Met H 1912 A Lt Beige K 1903 A Dk Blue Met L 1917 A Ivy Yellow M 1619 A White N 921 A Platinum P 1910 A Med Palomino Met Q 1624 A Med Blue Met R 1879 A Dk Gr...

Page 7: ...each model year begins with consecutive unit num ber 100001 and continues on for each unit built ASSEMBLY PLANT CODES Code Letter Assembly Plant A Atlanta B Oakville Passenger C Ontario Truck D Dallas E Mahwah G Chicago H Lorain J Los Angeles K Kansas City L Michigan Truck MODEL YEAR The number 6 designates 1966 Code Letter Assembly Plant N Norfolk p Twin Cities R San Jose S Pilot Plant T Metuchen...

Page 8: ...s the pedal and hold it in the applied position Start the engine If the vacuum system is operating the pedal will tend to fall away under foot pressure and less pressure will be required to hold the pedal in the applied position If no ac tion is felt the vacuum booster system is not functioning 4 With the engine shut off ex haust all vacuum in the system Depress the brake pedal and hr d it in the ...

Page 9: ...uid in System or Caliper X X Loose Wheel Bearing Adjustment X Damaged or Worn Caliper Piston Seal X X X Improper Booster Push Rod Adjustment X Excessive Lateral Run Out of Rotor X Rotor Excessively out of Parallel X Frozen or Seized Pistons X X X X Brake Fluid Oil or Grease on Linings X X X Shoe and Lining Worn Below Specifications X Booster Inoperative X Caliper Out of Alignment with Rotor X X Lo...

Page 10: ... Pedal or Shoes X X Brake Line Restricted X X X X Leaks or Insufficient Fluid X X X X Improper Tire Pressure X X Distorted or Improperly Adjusted Brake Shoe X X X X X X X Faulty Retracting Spring X X Drum Out of Round X X X Lining Glazed or Worn X X X X X X X Oil or Grease on Lining X X X X X X Loose Carrier Plate X X X Loose Lining X Scored Drum X X Dirt on Drum Lining Surface X Faulty Brake Cyli...

Page 11: ...the push rod assembly re U CLIP CABLE HOUSING END SPRING SEAT CABLE SPRING LEVER TO CABLE ADJUSTING NUT EQUALIZER ROD EQUALIZER LEVER CABLES TO REAR WHEELS H1307 A FIG 1 Parking Brake Adjustments mains in the original unit However when a new push rod is used or the push rod assembly is transferred to another unit the distance from the end of the adjustment screw to the mounting surface of the boos...

Page 12: ...inder res ervoir cap install an adapter cap to the reservoir and attach the bleeder tank hose to the fitting on the adapter cap An adapter cap can be fabricated by cutting a hole in the center of a res ervoir cap and soldering a fitting at the hole The adapter cap must be se curely seated and completely sealed on the master cylinder or leakage will occur 3 Position a 3 8 inch box wrench on the ble...

Page 13: ...ment of both as a unit REAR BRAKES 1 Remove the wheel from the drum and remove the drum as out lined in Part 2 2 Section 2 Wash all the parts except the brake shoes in a cleaning fluid and dry with com pressed air 2 Brush all dust from the carrier plate and interior of the brake drum 3 Inspect the brake shoes for ex cessive lining wear or shoe damage If the lining is worn to within 1 32 inch of th...

Page 14: ...inst the pistons in the calipers front wheels or in the wheel cylinders rear wheels The pistons in turn convert hydraulic pressure back into physical force at the discs and brake shoes DISC BRAKE ASSEMBLIES FRONT WHEELS RELATION AND FUNCTION OF COMPONENT PARTS The disc brake is a fixed caliper opposed piston non energized ven tilated disc type actuated by a hy draulic system Fig 1 There is no late...

Page 15: ...rom the shoe approximately 0 005 inch to relieve the force of the lining against the rotor and thereby provide the required running clearance Also in herent rotor runout contributes to the maintenance of running clearance Automatic adjustment is achieved by the pistons sliding in the seals out ward from the cylinder bores The pis ton gradually changes its position rel ative to the seal as the lini...

Page 16: ...The anchor pins are fixed and non adjustable BOOSTER SYSTEM DESCRIPTION The tandem diaphragm type Master Vac is a self contained vacuum hy draulic power braking unit It is of the vacuum suspended type which utilizes engine intake manifold vacuum and atmospheric pressure for its power Adjustment of the push rod is the only service permitted on this booster The booster unit is to be exchanged when i...

Page 17: ...FOLD VACUUM H1313 A FIG 6 Connections For Auto matic Parking Brake Release IN CAR ADJUSTMENTS AND REPAIRS After any brake service work ob tain a firm brake pedal before moving the car Riding the brake pedal com mon on left foot applications should be avoided when driving the car FRONT DISC BRAKE SHOE AND LINING REPLACEMENT REMOVAL 1 Remove the wheel and tire from the hub and rotor assembly Be care...

Page 18: ...g 4 Bleed the brake system as outlined in Section 2 1 Check the master cylinder fluid level and the specified brake fluid as required 5 Pump the brake pedal several times to actuate the piston seals and to position the shoe and lining as semblies 6 Install the wheel and tire 7 Roadtest the car FRONT WHEEL HUB AND ROTOR ASSEMBLY REMOVAL 1 Remove the wheel and tire from the hub and rotor assembly Fi...

Page 19: ...ing valve 3 Working underneath the left fender remove the bolt that attaches the proportioning valve to the fender apron and remove the valve through the access hole Fig 9 RETAINING BOLT PROPORTIONING VALVE MOUNTING TANG FENDER APRON H1365 A FIG 9 Removing or Installing the Proportioning Valve INSTALLATION 1 From underneath the left fender install the proportioning valve through the access hole in...

Page 20: ...brakes as outlined un der Brake Shoe Adjustments in this section and install the brake drum 3 Install the three Tinnerman nuts and tighten securely Install the wheel on the axle shaft flange studs against the drum and tighten the retaining nuts to specifications Install the wheel cover 4 Complete brake adjustment as directed under Brake Shoe Ad justments REAR BRAKE SHOE REPLACEMENT REMOVAL 1 Remov...

Page 21: ...ng should be at the edge of the hole Connect the loop end of the spring to the adjuster lever hole 13 Pull the adjuster lever cable and automatic adjuster spring down and toward the rear to engage the pivot hook in the large hole in the sec ondary shoe web Fig 4 14 After installation check the ac tion of the adjuster by pulling the sec tion of the cable between the cable guide and the adjusting le...

Page 22: ...Remove the brake shoe and ad juster assemblies and the wheel cyl inder as outlined in this section On the rear wheel disconnect the parking brake lever from the cable 3 Rotate the axle shaft so that the hole in the axle shaft flange lines up with the carrier plate attaching nuts and remove the nuts Pull the axle shaft assembly out of the housing with tool 4235C and a slide hammer Part 4 2 and then...

Page 23: ...eparate the master cylinder from the booster unit and make sure that the master cylinder does not rest on the push rod 3 Remove and discard the rubber seal from the outer groove at the end of the master cylinder 4 Remove the push rod from the power unit Do not disturb the adjust ing screw INSTALLATION 1 Apply a light coating of lub ricant COAZ 19584 A to the piston end of the hydraulic push rod an...

Page 24: ...and the BUSHING 2461 2 REQD PEDAL ASSY 2455 REF WASHER BOOSTER ASSY PUSH ROD LINK 374759 S 34367 S8 H1382 A FIG 17 Broke Booster and Pedal Installation push rod link in through the holes in the dash panel Fig 1 7 2 Working inside the car below the instrument panel install the mounting bracket to dash panel retaining nuts and washers Leave the nuts loose un til after the pedal assembly has been con...

Page 25: ...cable housing from the bracket 2 Lower the car In the passenger compartment remove the retaining screws and the left kick pad Remove the four screws that retain the air duct to the inner cowl panel and then re move the air duct to obtain access to the brake control assembly Remove the control cable from the air duct 3 Disconnect the hose from the vacuum power unit 4 Remove the control assembly to ...

Page 26: ...evis pin from the clevis Disengage the clevis from the ball end of the cable Remove the control assembly from the cable and cable housing 7 Push the cable and housing down through the hole in the floor pan and remove it from under the car INSTALLATION 1 From the underside of the car guide the upper end of the re placement cable into the hole in the floor pan 2 From the inside pull the new cable an...

Page 27: ...e kit Ford replacement linings are ground and no further grinding is required 4 Check the clearance between the shoe and lining The lining must seat tightly against the shoe with not more than 0 005 inch clearance between any two rivets MASTER CYLINDER DISASSEMBLY 1 Press in against the piston re moving the snap ring retainer and then remove the piston assembly cup spring residual check valve and ...

Page 28: ...stalled thoroughly clean the contact area on the caliper housing and apply Loctite Sealant Grade H to the retainer surface that seats in the housing Install the retainer in the caliper housing 3 Apply a film of clean brake fluid to new caliper piston seals and install them in the grooves of the cylinder bore The seal should be positioned at one area in the groove and gently worked around Do not us...

Page 29: ...icator Runout Exceeds 0 007 inch Rotor Runout Replace if Runout Exceeds 0 002 inch TORQUE LIMITS DISC BRAKE SHOE AND LINING DIMENSIONS INCHES Description Ft Lbs Front Brake Hose Bracket to Chasis Bolt 10 15 Rear Brake Drum to Rear Axle Shaft Flange Hand Push Fit Rear Wheel to Axle Shaft to Drum 75 110 Rear Brake Carrier Plate and Bearing Retainer to Axle Housing 50 70 Master Cylinder to Booster 12...

Page 30: ...Ford Tool No Former No Description Rotunda HRE 8650 _ Brake Adjusting Gauge Brake Cylinder Retaining Clamp 2018 A Brake Adjusting Tool 2162 Adapter Cap 2035 N 2086 L Brake Shoe R R Spring TOOL 33621 33621 Internal Snap Ring Pliers Milbar 1112 144 In lb Torque Wrench Bendix 73800 Booster Disassembly and Assembly tool A C Tool T00L 4235C 4235C Axle Shaft Remover HYDRAULIC FLUID AND LUBRICANT Descrip...

Page 31: ...ionary When checking the pos sible causes check item 1 tire pres sure and item 2 tire size before proceeding with the other items in dicated Table 2 lists steering gear trouble symptoms and possible causes Refer to Table 3 for Movable Steering Column Trouble Symptoms and Possible Causes POWER STEERING PRELIMINARY CHECKS The following preliminary checks should always be made before per forming any ...

Page 32: ... Center X X X 8 Broken Rear Spring Tie Bolts X X X X X X X 9 Rear Spring Front Hanger Mislocated X X X 10 Bent Spindle Arm X X X X 11 Bent Spindle X X X X 12 Lack of Lubrication X X X X X 13 Air in Power Steering 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 16 Loose or Worn Suspension Arm Bushings X X X X 17 Binding Front Suspension Ball Joi...

Page 33: ...rect steering gear adjustment Obstruction in power steering lines or within the steering gear Steering gear valve spool binding or out of adjustment HARD TURNING WHEN STATIONARY Low fluid level or fluid leakage Insufficient power steering pump Obstruction in power steering lines pressure or within the steering gear POWER STEERING GEAR DIAGNOSIS GUIDE Low fluid level or fluid leakage Loose steering...

Page 34: ...ification replace the pump as sembly If pressure is as specified and steering efforts are heavy the gear and or control valve could be at fault 8 Remove the tachometer TABLE 3 Movable Steering Column Trouble Symptoms and Possible Causes BINDING ROUGH OR RASPING COLUMN Track to column bracket mis Locking plate out of adjustment alignment rubs pawl Shroud interference with instrument panel HARD COLU...

Page 35: ...is neg ative The correct caster angle or tilt is specified in Part 3 5 The maximum difference between both front wheel caster angles should not exceed 1 2 However a dif ference of not more than 1 4 is pre ferred CAMBER Check the camber angle at each front wheel The camber angle is the amount the front wheels are tilted at COMMON ADJUSTMENTS AND REPAIRS WHEEL ALIGNMENT ADJUSTMENTS After front wheel...

Page 36: ...s listed in the specifications Re move the suspension alignment spacers TOE IN AND STEERING WHEEL ALIGNMENT ADJUSTMENTS Check the steering wheel spoke position when the front wheels are in the straight ahead position If the spokes are not in their normal posi tion they can be properly adjusted while toe in is being adjusted The toe in specification is specified in Part 3 5 1 Loosen the two clamp b...

Page 37: ...balance each wheel as required 6 Check the action of the shock absorbers If the shock absorbers are not in good condition the car may not settle in a normal level position and front wheel alignment may be af fected WHEEL INSPECTION Wheel hub nuts should be inspected and tightened to specification at predelivery Loose wheel hub nuts may cause shimmy and vibration Elongated stud holes in the wheels ...

Page 38: ... for flushing the steering system when in stalling a new pump 1 Remove the power steering pump and pulley as outlined in Part 3 3 2 Install a new pump and con nect only the pressure hose to the pump Part 3 3 3 Place the oil return line in a suitable container and plug the reser voir return pipe 4 Fill the reservoir with lubricant C1AZ 19582 A 5 Disconnect the coil wire to prevent the engine from s...

Page 39: ...r ball joints which are mounted to an upper and lower arm respective ly The upper arm pivots on a bushing and shaft assembly which is bolted to the underbody The lower arm pivots on a bolt mounted in a bracket which is bolted to the underbody Fig 1 A coil spring seats between the upper arm and the top of the spring housing A double acting shock ab sorber is bolted to the upper arm and the top of t...

Page 40: ...g linkage If the adapters are placed un der the crossmember a piece of wood 2 x 4 x 16 inches should be placed on the hoist channel between the adapters This will prevent the adapt ers from damaging the front suspen sion struts UPPER BALL JOINT REPLACEMENT ARM IN CAR 1 Raise the front of the car and position safety stands under the chas sis 2 Remove the wheel and tire 3 Loosen the upper stud ball ...

Page 41: ...LLATION HOISTING INSTRUCTIONS Damage to suspension and or steering linkage components may oc cur if care is not exercised when positioning the hoist adapters of 2 post hoists prior to lifting the car If a 2 post hoist is used place the adapters under the lower arms or the NO 1 crossmember Do not allow the adapters to contact the steering linkage If the adapters are placed un der the crossmember a ...

Page 42: ...he dash panel brace Remove the shock absorber guide plate and lower bracket as an as sembly INSTALLATION 1 Position the shock absorber and guide plate assembly through the top of the spring housing so that the three lower mounting studs enter the holes in the suspension upper arm Install the lower attaching nuts on the studs 2 Install the two bolts that attach the guide plate to the dash panel bra...

Page 43: ...the spring housing so that the shaft screw goes through the top of the coil spring with the tool upper plate holes going over the studs as shown in Fig 6 4 From under the car place the tool lower plate under the fourth coil from the bottom Secure the plate to the coil by installing the tool retainer to the groove in the tool shaft screw 5 Compress the spring by turning the tool shaft nut clockwise...

Page 44: ...washers and plates and dis connect the strut from the lower arm Fig 9 8 Remove the cotter pin and loosen the lower ball joint stud nut Place a box wrench over the end of Tool T57P 3006 A and position the tool 180 from the position shown in Fig 3 wrench at the top The tool should seat firmly against the ends of both studs not against the upper stud SHIM PIVOT RETAINING BRACKET NUT m BRACKET RETAINI...

Page 45: ...shock absorber from the i Com press the shock absorber and remove it from the car 3 Remove the nut outer washer and bushing that secure the shock ab sorber to the mounting bracket and remove the bracket 4 If the shock absorber is service able and requires new bushings re move the inner bushing and washer from the shock absorber upper mounting stud INSTALLATION 1 Place the inner washer and bushing ...

Page 46: ... dam age Replace the parts as required Replacement arms come with the bushings inner shaft and ball joint installed If the original arm is to be used these components should be re placed on the bench BUSHING AND INNER SHAFT REPLACEMENT Always replace both upper arm bushings if either bushing is worn or damaged Install only new bushings when replacing the inner shaft 1 Position the upper arm inner ...

Page 47: ...m procedure under Removal 2 Remove the ball joint from the arm If the ball joint is riveted to the arm drill a 1 8 inch pilot hole com pletely through each rivet and then drill off the rivet head through the pilot hole with a 3 8 inch drill Drive all rivets out of the holes 3 Clean the end of the arm and remove all burrs from the hole edges Check for cracks in the metal at the holes and replace th...

Page 48: ...ng unit is a torsion bar type of hydraulic assisted system This system furnishes power to reduce the amount of turning effort required at the steering wheel It also reduces road shock and vibrations The torsion bar power steering unit includes a worm and one piece rack piston which is meshed to the gear teeth on the steering sector shaft The unit also includes a hydraulic valve valve actuator and ...

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