Ford Mustang V8 1964 thru 1973. Automotive Repair Manual

36048 (357)

• •

•

Ьу

J

Н

Haynes

Member of the Guild of Motoring Writers

Вгисе Gilmour аnd Мarcus S

Daniels

Models covered: AII Mustang va models •

ISBN

О

85696 357 7 •

©

Haynes North Ameгica, 'пс. 1979 With permlssion

•

'roт

J.

Н . Науп еs

& Со. Ltd .

All rlghts reselVed. No part of this book тау ье reproduced ог transmlned '" апу form ог Ьу апу meenl, elec:tronlc ог mechenlcal, Includlng photocopylng, recordlng ог bv апу information Itorвge ог retrlвvaJ .уяет. wlthout permllllon 1" wrltlng from the copyrlght holder. Pгinted

in the USA "СОЕ

(10Z3 - 36048) (357)

'OНU

ю.мNO РО

,

•

Haynes PubIishing Group Spaгkfoгd Nr Yeovil Someгset ВА22 7JJ

England

Haynes North America, Inc. Lawгence Dгive Newbuгy Paгk Califoгnia 91320 USA

861

•

Acknowledgements Thanks аге due to the Ford Motor Сатрапу in the USA 10г the supply of technical iпfОП11аtiоп and certain iIIustrations. Тhe bodywork

repair photographs used in this

Мапиаl

were provided

Ьу

Lloyd's

Industries Umited who suppJy "Turtle Wax", "Dupli-color Holts", and other Holts range products.

Special thanks аге al50 due to all those people at Sparkford and in the USA who helped in the ргoduсtiоп of this Manual. Par1icular1y, these аге Brian Horsfall and Les Brazier who carried out the mechaniсаl work and took the photogгaphs respectively, Pete Ward who edited the text and Stanley Randolf who planned the page layout.

About this manual Its aims The aim of this Мапиаl i5 to help you get the best value from your саг. It сап do за in sеуегаl ways. It сап help you decide what work mU5t Ье done (еуеп should you choose to get it done Ьу а repair statlon), provide "in10rmation оп routine maintenance and servicing, and give а logical course 01 action and diagnosis when random 1ault5 occur. However, It is hoped that you will use the Manual Ьу tackling the work yoursel1. Оп 5impler jobs it тау вувп Ье quicker than booking the саг Into а гераlг station, and яо1пя there twlce to 'еауе and collect It. Perhaps most impOr1ant, а lot of money сап Ье saved Ьу avoiding the costs the garage must charge to соувг it5 lаЬог and overheads. The manual has drawings and descriptions to show the function of the varlous components so that their layout сап Ье understood. Then the tasks аге described and photographed in а step-by-step sequence 50 that еуеп а поУlсе сап do the work.

Its arrangement The Мапиа' Is divlded Into twelve Chapters, еас" covering а logical sub-dlvislon 01 the vehicle. The Chapters аге each dlvided Into

Sections, numbered with single ligures, ео 5; and the Sections into paragraphs (ог sub-sесtiопsJ, wlth decimal numbers 10Howing оп Irom the Section they аге in, ео 5.1, 5.2, 5.3 etc. It is 1гее1у illustrated, езресiаllу in those par1s where there Is а detailed sequence 01 operations to Ье carried out. There аге two 10гms 01 illustгation: figuгes and photographs. The figures аге numbered in 5equence with decimal пumЬегз, accordlng to their position in the Chapter: eg Fig. 6.4 is the 4th drawing!i1Iustration in Chapter 6. Photographs аге numbered (either individually ог in related groups) the same as the Section ог 5ub-section 01 the te)(t where the operation they show 15 de5cribed. There Is ап alphabetical inde)( at the back 01 the manual as well as а contents 11st at the front. References to the 'left' ог 'rlght' 01 the vehicle аге in the sense 01 а регзоп in the driver's seat 1acing 10rwards. Whilst every саге i8 taken to еП8иГ8 that the Informatlon in thi8 manual i8 correct по liabIlity сап Ьв 8ccepted Ьу the 8uthors ог pubIishers for 1088. damage ог injury caused Ьу апу еггов in. ог omissions from. the information given,

Introduction to the Ford Mustang The orlginal Mustang design was created Ьу Ford's chie1 stylist Joseph Огоз and when the finished саг was introduced to the market 1п April 1964 it caused еуеп тоге interest and e)(citement amongst the Amerlcan motoring 1raternity than Its predecessor the Thunderbird. With its гасу and definitely masculine арреагапсе , the low price t8g and not least the e)(cellent cholce 01 name, the Mustang was а phenomenal success. 'П fact, Ьу 1966, the sales ligures were nearing the two million ligure. When lirst introduced, the Mustang was available with ап option 01 1оиг engine capacities. For the owner with good gas mileage иррег­ mозt in mind, Ford offered the 170 си in ог 200 си in six-cylinder engines, while the 260 си in and 289 си in V8 engines were available to the customer whose prime consideration was acceleration. For those who required еуеп тоге power beneath the hood, а tuned version 01 the 289 cu in engine was obtainabIe which developed 271

brake horsepower at 6000 грт. Beneath the attractive bodyshell the mechanical layout 01 the Mustang was quite conventional, comprising а Iront-mounted engine driving the геаг wheels via the transmission unit, driveshaft and differential unit. А choice of either three- ог 10ur-speed manual transmission, ог three-speed automatic transmission was offered. Front suspension оп а" models is the independent соВ spring and wishbone type, while the геаг a)(le is located оп leaf springs. Telescopic shock аЬ50гЬегз аге litted а" round. For 1967 / 1968 the 'агоег capacity 302 and 390 V8 engines became optional and these were 101l0wed Ьу the poweгful 427, 428 and Boss 429 engines. InevitabIy, as engines got larger, so the body size increased unti1 it could по 10nger Ье described as а compact SP0r15 саг. Because it had 105t the original Mustang individuality, sales inevitаЫе dropped and in 1974 Ford launched the Mustang Series 11.

•

Contents Page

•

ACknowledgements

2

About this manual

2

Introduction to the Ford Mustang

2

Buying spare parts and vehicle identification numbers

6

Jacking and towing

7

Tools апd working facilities

8

Recommended lubricants and fluids

12

Routine maintenance

13

Chapter 1 Engine

15

1

Chapter 2 Cooling system

46

2

Chapter 3 Fuel . exhaust and emission control systems

52

3

Chapter 4 19n;tion system

91

4

Chapter 5 Clutch

101

5

Chapteг

106

в

Chapter 7 Driveshaft

126

7

Chapter 8 Аваг axle

129

8

Chapter 9 Braking system

138

9

Chapter 1 О Electricalsystem

153

10

Chapter 11 Suspension and steering

232

11

Chapteг

264

6 Transmission

------------------------------------------------------------ , •

12 Bodywork and fittings

Safety first!

284

Index

286

4

-

••

•

." ' . ••

•

. . ~: •....: . .." (~ . ч.' ;.i.;..~· '""'., ..'' .~~• ~ Ч. '" • • •

-

"

•

1966 Mustang ConvertibIe, 289 cu in

1967 Mustang Hardtop

5

• ,

,

I

- -- --=

--

-

-

1971 Mustang Sports Roof

_"-

--" ..

-

1972 Mustang Hardtop

-

Buying spare parts and vehicle identification numbers А

Buying spare parts Replacement parts аге availabIe from тапу sources, which generally lall inlo опе 01 two categories - authoгized dealer paгts departments and independent retail auto parts stores. Ош advice concerning these parts i5 ав foJlows: Retail auto parts stores: Good auto parts stoTes will stock frequently needed components which wear out relativeJy fast, such ав clutch сот­ ponents, exhaust systems, brake parts, tune-up parts, etc. These stores often supply new ог reconditioned parts ОП ап exchange basis , which сап ваув а considerabIe amount 01 топеу. Discount auto рапв stores аге often уегу good places 10 buy materials and parts needed for general

vehic!e safety certificBC;on IвЬе! is attached to the геаг face of the left hand door оп later models only. This gives the Gross Vehicle Weight Ratin9 (GVWR) and the Gross Axle Weight Rating (GAWR) for that particular саг. The епи;пе питЬе, оп аll models prior to 1968 Is stamped оп the left side of the cylinder block. Оп 1968 and later models the engine number is stamped оп а metal ta9 adjacent to thв ignition coil. The transmiss;on питЬег IS stamped оп а small metal plate which is riveted to the right sidв of the transmission casing.

MFD. ВУ FDRDMDTDR CD.IN U.S.A. ОАТЕ: 08/72 GVWR 5892 GAWR : FRDNT 2964, REAR 2928

vehicle maintenance such ав oil, grease, liller5, spark plugs, belts, touch-up paint, bulbs, etc. They also usually sell tools and general ас­ cessories, have convenient hours, charge lower prices and сап often Ье found not far from home. Authorized dea/er parts depat1ment: This is the best source for parts which аге unique 10 the vehicle and по1 generally available elsewhere (such as major engine parts, transmission parts , trim pieces, etc. ). Warrantyinformation: If the vehicle is still covered under warranty, Ье sure that апу replacement parts purchased - regardless of the sourcedo поl invalidate the warranty! То Ье sure of obtaining the correct parts, have engine and chassis numbers available and, if possible, take the old parts along 'ог positive identification.

ТНIS VEНlCLE CONFORМS ТО

ALL APPLICABLE FEDERAL MOTOR VEНlCLE SAFETY STANDARDS IN EFFECТ ON ТНЕ ОАТЕ OF MANU· SHOWN АВОУЕ .

Vehic/e identification numbers

~

Modifications аге а continuing and unpubIlcized process in саг manufacture. Spare parts catalogs and lists аге compiled оп а numerical basis, the individual vehicle numbers being essential to correctly identify the сотропеп! required. А vehicle identific8t;on deca! is located оп the геаг edge of the left hand door оп all Mustang m odвls . The decal gives the vehicle serial number and coded information regarding the engine, transm ission and bodywork. Refer to the accompanying examples showing the type of deca ls used and а key to the coding.

ASSEMBLY PLANT •

MODEL YEAR

~BOOY

СООЕ

SERIAL

(UNIТED

Vehicle identification/safety certificetion decal {later modelsl

1 2 3 4 5 6

Consecutjve un,t по. 80dy 5е,;.' code Model уевг code AssembIy plant code Engine Сodе 80dy rype code

7 Colo, code

8 9 10

11 12

Vehicle type Djst,;ct - specia/ equipment Rear axle code T,ansmission code Т"т code

СООЕ СООЕ

СООЕ

UHIТ

HUMBER

•

•

TRANSMISSION ОНЕ СООЕ

ВООУ ТУ РЕ СООЕ--"

COLOR

СООЕ

REAR AXLE

СОО

TRIM

СООЕ

DI5TRICT о, DISTRICT "НО SPECIAL EQUIPMENT СООЕ

Vehicle identification decal (е8гliег typel

СООЕ

"

Jacking and Towing Jacking points

Towing points

ТО

change а wheel in ап emergency, use the jack supp1ied with the саг . Ensure that the roadwheel nuts аге released before jacking up the саг and make sure that the tap 01 the jack i5 fuHy engaged with the body cutout, and that the base 01 the jack is standing оп а 1irm surface . The jack supplied with the vehicle Is not suitabIe 1ог use when raising the vehicle 1ог maintenance or repair operatlons. For this work , use а trolley, hydraulic or screw type jack located under the 1ront crossmember. bodyframe side-members ог геаг axle caslng, as illustrated. Always supplement the jack with jack stands or bIocks be10re craV'Jling beneath the саг.

If your vehicle 1$ being towed , make sure that the tow горе 15 attached to the lront crQssmember. If the vehicle i5 equipped with automatic transmission, the distance towed must по1 exceed 15 miles (24 km) , пог the speed 30 mph (48 km/h), otheгwise serious damage 10 the transmission may result. If these limits аге likely to Ье exceeded, disconnect and гетоуе the propeller shaft. 11 you аге towing another vehicle. attach the tow горе to the spring

mounting bracket а1 the axle tube.

АЕАА

LQWER SUSPENSION l

ААМ

CQNTACT ААЕА

)

о

"

FRQNT FRAME CQNTACT ААЕА I

,"

Front jacking агеаа to Ье used when raising the vehicle 1ог mBintenBnce purposas

РАИК САИ

АЕАА

AXLE Аеаг jackjng 8re8S to Ье used whеп raising the vehicle for m8intenBnce purposes

с

15" FROM СиИВ ТО

CHAHGE TIR

'..!::...-/

"

DO NOT LIFТ ТНЕ CAR ВУ ТНЕ FRONT OR REAR BUMPERS U sing the jack supplied with the car

Tow rope 8tt8chment point 8xle

оп

геаг

Tools and working facilities /ntroduction А

selection of good tool5 is а fundamental requirement for апуопе contemplating the maintenance and repair of а саг. For the owner who does not possess апу , their purchase will ргоуе а considerabIe 8хрепзе , offsetting some of the savings made Ьу doing-it-yourse1f. However, provided that the tool5 purchased аге of good quatity, they will 185t for тапу years and ргоуе ап extremely wo"hwhile invest-

ment. ТО

help the average owner to decide which tools аге needed to сапу out the various tasks detailed in this Manual, we have compiled three lists of tool5 under the following headings: Ма ;п tепапсе and minor гера;', Repair Bnd overhau/, and Special. The newcomer to practical mechanics should start off with the Maintenance and minor гера;' tool kit and confine himself to the simpler jobs aTound the саг. Then, аз his confidence and experience grow, he сап undertake тоге difficult tasks, buying extra tools аз, and when, they аге needed. 'П this way, а Maintenance and minor гера;' tool kit сап Ье bu ilt-up into а Яера;' and overhau/ tool kit оуег а conslderabIe period of time without апу major cash outlays. The experienced do-it-yourselfer will havв а tool kit good enough for most repair and overhaul procвdures and will add tools from thв Specia/ category when he feels the ехрепзе is justilied Ьу the amount of use to which these tools will Ье put. It {з obviously not possibIe (о соуег the subject of tools lully here. For those who wish to 'еагп тоге about tools and their изе there {з а book entitled How (о Choose and Use Саг Tools availabIe from the publishers 01 this Manual.

Maintenance and minor repair too/ kit The tools given {п this Нзt should Ье considered аз а minimum requirement 11 routine maintenance, servicing and minor гера!г орега ­ tions аге to Ье undertaken. We recommend the purchase 01 сотЫпа­ tlon wrenches (ring опе end , open-ended the other); although тоге expensive than open-ended ones, they do give the advantages of both types 01 wrench.

Combination wrenches - t (о bl in AF AdjustabIe wrench - 9 inch Engine оп pan/ transmission!rear axle drain plug key (where app/icвЫе)

Spark plug wrench (with гиЬЬег insert) Spark p/ug gap adjustment tool Set 01 'ее/ег gauges Brake adjuster w,ench (whe,e аррНсаЫе) В,а/(е bIeed nipple w'ench Sc,ewd,ive, - 4 in long х t in dia (!Iat bIade) Sc,ewd,ive, - 4 in long х t in dia (c,oss bIade) Combination p!iers - 6 inch Hacksaw, junio, П,ерumр П,е

p'essu,e gauge Grease gun ОП сап

Fine еmегу cloth (1 sheetJ Wi,e brush (smalf) Funnel (medium s;ze)

Repair and overhau/ tOO/ kit These tools аге virtually eS5ential for апуопе undertaking апу major repair5 to а саг, and аге additional to those given {п the Maintenance and mino, ,ера;' list. Included {п this Ilst {з а comprehensive set of sockets . Although these аге expensive they will Ье found invaluabIe а5 they аге 50 versatile - particularly if various drives аге included j п the 5et. We recommend the t jп 5quare-drive (уре , аз this сап Ье used with most proprietary torque wrenches. 11 you cannot afford а socket set, еуеп bought piecemeal, then inexpensive tubular Ьох wrenches а ге а useful alternative. The tools in this Hst will occasionally need to Ье supptemented Ьу tools from the Specia/li5t.

w,enches) (о coverrange t 1i in AF Reve,s'-bIе ,atchet d,ive (10' use with sockets) Extension р'-есе, 1О inch (10' use with soc/(ets) Universa/ joint (10' use with soc/(ets) тo'que wrench (Ior use w'-th sockets) Self-grip wrench - 8 inch В а" pein hammer Soft-Iaced hammer, plastic ог гuЬЬег Screwdriver - 6 in long х А '-П dia (fIat bIade) S crewdriver - 2 in long х А in square (fIat bIadeJ S crewdriver - 1t in long х t in dia (cross bIade) Screwdriver - 3 in long х i in d'-a (e/ectric'-ans) Pliers - electric;ans s'-de cutters Pliers - needle nosed P!iers - snap-ring (inteгnal and exteгnalj Cold chisel- t '-nch Scriber Scraper Centre punch Pin punch Hacksaw Valve grinding (ооl Steel rule/straight edge Allen keys Select'-on 01 files Wire brush (Jarge) Jack stands Jack (strong scissor ог hydraulic (уре) Soc/(ets

(о, Ьох

Specia) tOO/s Тhe

toOl5 in this Hst аге those which аге not used regularly; аге expensive to buy, ог which need to Ье used {п accoгdance with their manufacturers' in5tructions. Unless relatively difficult mechanicat jobs аге undertaken frequently, it witl not Ье economic to buy many 01 these tools. Where thi5 is the с азе , you cou ld consider clubblng together with friends (ог ап automobile clubI to make а jolnt purcha5e , ог borгow ing the toOl5 against а deposit lгот а 'осаl repair station ог tool hire 5pecialist. The following list contains only those tool5 and instruments freely availabIe to the pubtic, and not th05e 5pecial tool5 produced Ьу the vehlcle manulactuгer specilically for its dealer network. You will find occasional references (о these manulacturers' 5pecial too15 in the text of thi5 Manual. Generalty, ап alternative method of doing the job

Tool. and working facilities 'А

·'1Out е vehicle manufacturer's speciat 1001 is given. HowBver. 5Of'"'e Imes there is по alternative 10 using them. Where this is the сая and the relevant 1001 cannot Ье bought ОГ borrowed you will have

9

Wrench jaw уар compari50n

(аЫе

J8W g8p (in)

WT8nch SiZ8

0·250 0·275 0·312 0·315 0·340 0·354 0·375 0·393 0·433 0-437 0·445 0·472 0·500 0·512 0·525 О· 551 0·562 0·590 0·600 0·625 0·629 0·669 0·687 0·708 0 ·710 О · 748 О· 750 0·812 0·820 0·866 0.875 0·920 0·937 0·944 1·000 1·0 1 О 1 ·023 1·062 1 ·100 1 ·125 1 · 181 1·200 1·250 1·259 1·300 1 ·312 1·390 1 ·417 1·437 1·480 1· 500 1 ·574 1 ·614 1·625 1·670 1·687 1·811 1 ·812 1·860 1 ·875 1·968 2 ·000 2 ·050 2·165 2·362

t

to entrust the work 10 а franchised dealer.

VlIlve spring compressor

Piston ' ;ng compressor 8 IJlljoint separator

UnivBrsal hubIbearing puller /трасс

screwdr;ver

Micrometer and/or

veгnier

gauge

Carbuгetor flow ba/ancing device (where вррJiсаЫе)

Dial gauge

Stroboscopic tim;ng light Dwellangle meter/ tachometer Universal electrical multi-meter Cylinder compression gauge Lifting tackle rrolley jack иум

в uying

t

with extension fead

tool5

For practically all 10015, а tool factor is the best source since he will have а уегу comprehensive range compared with the average garage ог accessory shop. Having said that, accessory shops often offer excellent quality tools at discount prices, so it pays to shop around. Remember, you don 't have to buy the most expensive items оп the shelf, but It Is always advisabIe 'о steer clear of the уегу cheap tools. There аге plenty of good tools around at reasonabIe prices, so ask the proprietor ог manager of the shop for advlce before making а purchase.

Working facilitie5

t

Not to Ье forgotten when discussing tools, is the workshop itself. If anything more than routine maintenance is to Ье carried out, some form of suitabIe working агеа becomes essential . It is appreciated tha!' many ап owner mechanic is forced Ьу circumstances to гетоуе ап en9ine ог similar item, without the benefit of а 9ага9е ог workshop. Having done this, апу repairs should always Ье done under the соуег of а roof. Wherever possibIe, апу dismantling should Ье done оп а clean flat workbench ог 'аЫе at а suitabIe workin9 height. Апу workbench needs а vise: опе with а jaw opening of 4 (п (100 mm) is suitabIe 'ог most jobs. As mentioned previously, some clean dry storage space is also required for tools, as well as the lubricants, cleaning fluids, touch-up paints and so оп which become necessary. Another item which тау Ье required , and which has а much more general usage, is ап electric drill with а chuck capaci1y of а1 least ,\ (п (8 mm ). This, together with а good range of twist drills, is virtually essent ial for fitt;ng accessories such as wing mirrors and reversing tights. last, but not teast, always keep а supply of old newspapers and clean , lint-free rags ауаВаЫе , and try to keep апу working агеа as clean as possibIe.

Саге and maintenance о' tool5 Having purchased а reasonabIe tool kit, it is necessary 'О keep the tools in а clean serviceabIe condition . After use, always wipe оН апу dirt, grease and metal paгticles using а clean, dry cloth. before putting the tools away. Never 'вауе them Iying around after they have Ьееп used. д simple tool rack оп the garage ог workshop wall, for items such as screwdrivers and pliers is а good idea. Store all погтаl wrenches and sockets (п а meta l Ьох. дпу measuting instruments, gauges, meters, etc, must Ье carefully stored where they саппо! Ье damaged ог Ьесоmе rusty. Take а little саге when tools аге used. Наттег heads inevitabIy Ьесоте marked and screwdrivers lose the keen edge оп their bIades from time to time. А little timely attention with emery cloth ог а lile will soon restore items li ke this to а good serviceabIe finish .

•

in AF 7 mmAF ii in AF 8mmAF ~ (п AF;t (п Whitwoгth 9 mmAF t in AF 10mm AF 11 mm AF in AF i in Whitworth;t (п BSF 12 mm AF t in AF 13 mm AF t (п Whitworth;,\ (п BSF 14 mmAF А in AF 15 mmAF А (п Whitwoгth; t (п BSF t in AF 16 mmAF 17 mmAF М in AF 18 тт AF i (п Whitworth; , in BSF 19 mmAF t in AF in AF in Whitwoгth; t (п BSF 22 mm AF t in AF t in Whitwoгth;" in BSF in AF 24 mmAF 1 (п AF ii in Whitwo"h; t in BSF 26 mmAF 1~ inAF; 27 mm AF t (п Whitworth; bl (п BSF 1t in AF ЗО mmAF bl (п Whitwoгth; t (п BSF Ч in AF 32 mmAF t (п Whitworth ; t (п BSF ' . in AF ~ (п Whitwoгth; fI (п BSF 36 mmAF in AF t (п Whitworth; 1 (п BSF Ч in AF 40 тт AF ; i (п Whitworth 41 mmAF Ч in AF 1 (п Whitworth; 1t (п BSF , М in AF 46 mmAF 1 in AF 1t (п Whitwoгth ; 1t (п BSF Ч in AF 50 mmAF 2 (п AF Ч in Whitwo"h; Ч in BSF 55 mm AF 60 mmAF

4

n 4

3

'4

n

10 --------------------------------------------------------~

STEERING LIHKAGE REMQVE PLlJGS Т О LUBRICATE

POWER BALl JO INT

BALL JOIHTS Rt::MQVE PLUGS ТО LUBR ICATE

FRONT

ClEAN

дно

REPACK

I

STANDARD TRANSМISSIOН

FLOOR

SHIFT LINKACE

LUBR IСА ТЕ AS

STEERING STOP PADS

LUBRICATE SURFACES

I

ТYPlCAL

SHIFТ

LINKAGE

LUBRICATE А> REQUIRED.

CLUTCН

LIHKAGE

-ТУPlСАL

LUBR ICATE LEVER днс ROO С()J'llNЕСПONS AS RE.QUlRED.

IHTEGRAL CARRIER AXLE

МANUAL TRAHSМISSIOН

PARKING BRAKE LINKJoGE

LUBRICATE CABLE GUIDES, LEVERS дно LINКAGE ДS REQUIRED.

Cha8sis lubricatlon points

А

LUBR ICATION POINT

,------------------------------------------------------------------11 F ILL

ТО

F1LL ТО COLD FILL

• BE LOW R1NG

6REA.KER POINT САМ

МARK

1

CROSS FLOW RADIATOR

USE HIGH TEMPE RAT URE LU6RICдNT

',е"с FLOW RAOIA TOR

ENGINE OIL LEVEL OIPSТICK

PUMP FLUID SHOULa

ACCELfRATOR LINKAGE ШВ Е POtNTS

ВЕ

6EТWEEN дао

FULL

МARKS

СОдТ GASKEТ

WIТH

!

ENG1NE 01L

I

CНANGE ДТ

t

RECOММENOED

lNTERVA L

-, ,,

('

,

_-- ,

, ....,<-'

, , , ,

OIL FIL TER ,;L,OWER

,-/

B0l Т

..,,~

I

_~. г

UPPER COI/ER BOLT

I

~~~'

FlllER PLUG

~d-~ AUTOМA TIC

TRANSМISSION

",'

{СНЕСК WITH ENG1NE l.EVEL SHOULO ВЕ дао дно FULL

.'

ТYP 1CA.L МANUAL

."'"

STEERING GEAR

RUNNING) BETWEEN МARKS

LATIQN REGULATOR VALVE CHANGE ДТ RECCWМENaEo INTERVAl УЕНТI

I

•

ENGINE DRAIN PLUG

CYLINOER ( FШIO

LEVEL 1/ 4"

FROМ тор)

AIR CLEANER CНA NGE ELEMENT

CНдNGE ДТ

RЕСОММЕNDЕD1NТЕRVДL

Engine lubrication and servicing points

OIL

АТ

RECOММENDEDINTERVAl

12 --------------------------------------------------------------------~

LUGGAOE

СОМРААТМЕНТ

LATCH

SEAT TRACK LATCHES

LOCK CYLINOERS

ВАПЕRVСД8LЕS

CARBUREТOR СНОКЕ

LINKAGE

DOOR HINGES

НООD '-АТСН

Generallubrication point

Recommended lubricants and fluids Campane"t

Description

Ford Specification

Campane"t

Description

Ford Specific8tion

Hinges. hinge check and pivots

Polyethyfene

ESB-M 1 С106-В

Ford automatic

ЕSW-М2 СЗЗ-F

grease

Automatic transmission

transmission fluid

Туре

Brake master

Heavy duty

ЕSW-М2С 8З - В 0<

cylinder

brake fluid

transmission

Ford manual transmisstion oil

Front suspension balljoints, front wheel bearings and clutch linkage

balljDint and multi-pu rpose grease Engine

Eng ine

Hood latch and

Polyethylene

ESB-M 1 С1 06-В

Engine coolant

ESE-M97B18- C

auxiliary catch

gгеаэе

Ford cooling systern fluid

ESB -M2C2 0-A

Steering gear

Hypoid gear oil

ESW- M2C105-A

Power steering

ESW- M2C128-B

,

ESA-M6C25-A

ESA-M1

С75-В

Мапиаl

оН*

F

ЕSР-М2С8З-С

ESE-M2C101 - C

•

Lock cylinders

Lock lubricant

housing (manual and power)

Аваг

axle : Conventiona I

Traction- lok

Hypoid gear oil Hypoid gear oil

Power steering • ритр reservolf

fluid

О оог

Silicone lubricant

weatherstrip

ESR-M 1 3 14-А

ESW- M2C 105-А ESW-M 2C119-A

• Note engine оп о' д viscosity suitabIe 'аг the amblenl temperature must Ье used. Consult the operates handboak suppfied with the

саг.

11

I

Routine maintenance Introduction The Routine Maintenance instructions аге basically those recommended Ьу the vehlcte manufacturer. They аге supplemented Ьу additional maintenance tasks ргоувп to Ьв песеззагу. It muзt Ье emphasised that jf апу paгt 01 the engine ог its ancillary equipment involved wlth emission control 'з disturbed, cleaned ог adjusted the саг must Ье taken (о the tocal Ford dealer for checking to епзиге that It stlll meets legal requirements. Tssks '" the maintenance instru ctions marked with ап asterisk (-) must Ье entrusted to а Ford dealer.

Every 260 miles 1400 kml. weekly ог ЬМог.

8

long journey

Check tyre ргеззигез (when cold) Examine tyres for wear and damage Check steering for smooth and 8ccurate operatian Check brake reservair fluid level. If this has fallen naticeabIy, check far fluid leakage Check far satisfactory brake operation Check operatian of all tights Check operation of windscreen wipers and washers Check that the harn operates Check that all instruments and gauges аге operating Check the engine oHlevel ; top-up if necessary Check radiator caolant level (photo) Check battery electrolyte level

Radiator filler сар (cross-flow typel

, EV8ry 3000 miles (5000 km) ог 3 months

,

The following maintenance items must Ье carried out at this mileage/ time intelVal if the саг is being operated in зеуеге conditions . These аге considered to Ье: •

(в) (ь) (с)

Outs;de temperature remains below 10°F (-12.2 С) (ог 60 days ог тоге and most trips аге less than 1О m;Ies If в trailer having 8 total weight о' тоге than 2000 'Ь is towed оуег 'оnу distances Extended per;ods о' idling ог low speed operat;on 0

Complete the checks in the weekly inspection plus the following: Change the engine oil Install а new оН filter (photo) Far погта1 саг operation these selVice items mау Ье carried out at 6000 miles (1 0000 km) ог 6 month iпtеlVзls

Location of engine oil filter

Routine maintenanca

14

Checking the hood ритр fluid 'вуеl (convertibIes only)

Rear axl. filler plug

Evsry 6000 mile. (10 000 km) ог 6 month8, whlchever ОСсиг& 11r8t Change engine oil and filter Check trensmission fluid levels (photo) Check brake fluid 'еувl Дdjust clutch pedal free-play, If necessary ·Check fuel deceleration valve jf 50 equipped *Аdjuзt engine idle speed and mixture Check the torque of intake manifold bolts Lubric8te exheust control va lve If 50 equipped Check operation of throttle and choke linkage

Every 18000 miles (ЗО 000 km) ог 18 months, whichever оссига first In5pect distributor сар and rotor Check tightness of геаг spring mountings

Every 24 000 тilва (40 000 km) ог 2 уеага, which8ver occurs first Dismantle . lubricate and adjust front wheel bearings Aenew crankcase filter '" air cleaner Aenew air cleaner element Inspect filler сар and fuelline for deterloration ог leakage ·Check thermactor system If 50 equlpped Check cooling svstem hoses for leakage In5pect disc pad5 and геаг brake lining for wear In5pect all brake hoses and lines

Aenew fuel filter Check 811 drlvebelt tensions

Check fluid level of hood hydraulic pump reseгvoir (photo)

Every 12000 mil88 (20000 km) first

ог

12 month., whichever occura

Adjust engine valve clearances Check carburetor air cleaner element Renew 811 spark plugs Inspeet spark plug leads *Check spark control systems and delay valve *Check EGA system and delay valve Check condition of coolant Inspect аll drivebelts for wear and install new ones If necessary *Inspect evaporatlve emission canister (lf 50 equipped) Check the torque of all englne-drlven accessoгy mounting bolts Check front suspension and steering linkage for abnormal slackness ог damaged seals ·Adjust automatic transmission bands Inspect exhaust system and heat sh ields for corrosion ог damage

•

Еуегу ЗО

000 mil8S (50000 km)

ог ЗО

months, whichev8r

оссига

first Lubricate front suspension and steering linkage Drain and refill automatic transmission fluid Aenew coolant Examine 811 brake h05es and pipes. and renew if nece5sary Check wheel cylinders and master cylinder for leaks. 8nd renew seals where necessary Aenew brake fluid

•

Chapter 1 Engine Contents

I

Camshaft - removat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Camshaft and camshatt bearings - examination and renovation Connecting rods and piston pins - examination and renovation .. Crankshatt - examination and renovation .. . . . . . . . . . . . . . . . Crankshaft (main) bearings and connecting rod bearings examination and renavation ............ " ..... ,...... Crankshaft damper - removal ..... . ..... .. ............ Crankshaft геаг оН seal - renewal ...............•. • .... Cylinder bores - examination and renovation .........•.... Cylinder heads - dismantling of valves and springs .....•.... Cylinder heads - removal with engine in саг ....... . . . •.... Cylinder heads - removal with engine out 01 саг ............ Cylinder heads and piston crowns - decarbonization ......... Engine - inltla l start-up after overhaul ог major гераlг ....... . Engine - removal with automatic transmlssion attached ...... Engine - removal with manual transmisslon attached ........ Engine - removaJ without transmission . . . . . . . . . . . . . . . . . . Engine anciНaries - removal . . . . . . . . . . . . . . . . . . . . . . . . . . Engine components - examination 10г wear ............... Engine dismantl ing - general . . . . . . . . . . . . . . . . . . . . . . . . . Engine геаззеmЫу - camshaft and crankshaft . . . . . . . . . . . . .. Engine геаззеmЫу - general ......... . ..... . .......... Engine геаззеmЫу - pistons, connecting rods and oil pump .... Engine reassembIy - геаг plate, crankshatt, damper, 011 рап and flywheel ... • . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine reassembIy - timing chain and timing cover .......... Engine reassembIy - valve gвar, cylinder heads and intake mani10ld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...... Engine reassembIy - i пstаШпg апсillагу components .........

20 35 34 30 з1

15 25 32 12 1О 11 41 53 7

6 5 9 29

8 44 43 45 47 46 48 50

Engine Installation - without transmission ........•.•.•... Engine installation - with manual transmission ..... • •• ••.. . Fault diagnosis - engine ......... .... ...... . . • . •.•.. . Flywheel ring gear - examination and renovation ......•.•... Flywheel- removal .. .. .... .. ........... . ...... ~ . .. Front cover - removal . . . . . . . . . . . . . . . , ..... , . . . . . . . .. General descriptlon ......... , ..... ', .... , ..... ,.... Lubri cation and crankcase ventilation systems - description . " . Main bearings and crankshaft - removal .... .. ............ Major operations with engine instatted . . . . . . . . . . . . . . . . . . ' Major operations with engine removed ... ... • . •.. " , . . . . . Methods 01 engine removal .... ,... .. .. . . . . .... . . ..... ОВ filter - rвmoval and instatlation .........•. • .•. ••. •... ОН рап - rвmoval . . . . . . . . . . . . . . . . . , ... .... ... .. .. .. ОН pump - overhaul ........ . ..............• . ....... ОН pump-removal ." . . . . . . . . . . . . . . , . .. . . , ... . •... Piston pin - removal . .. . . . . . . . . . . . . . . ... ... . .... • . ,. Plston rings - rвmoval ... . . . . . . . . . . . . . . . . . . . . . . . • . . . Pistons and piston rings - examination and rвnovation ........ Pistons, connecting rods and bearings - removal .... .. ,..... Aocker gear - examination and renovation . . . . . . . . . . . . . . . . Timing chain and sprockets - examination and renovation ..... Timing chain and sprockets - removal . " . . . . .... .... ... . Valve lash - adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . , Valve lifteгs - examinatlon and renovation . . . . . . . . . . . . . . . . Valve lifters - removal ... ...... ......... ... . ,....... Valvв rocker shatt assembIy - dismantling .. . ....... ,. . ... Valves and valve seats - examination and renovation ... ,.....

51 52 54 39 16 18 1 27 26 2 3 4 28 17 40 21 24 23 33 22 42 38 19 49 36 14 13 37

1

o o o

351 Firing order 1-3-7-2-6-5-4-8

0

0

0

(2)

0

0

Allothers Firing order 1-5-4-2-6-3-7-8

о

Cylinder location and distributor rotation

Specificetions

Еngine

(general)

Engine types .......... . , ...... , ...... .. . , ........ . Е пglПе

·

..

capacltles ............. . ............ .. .... .

V8,

ovвrhead

valve

260. 289 , 302.351 , 390, 427 , 428 and 429 cu in

Engine data (260 си in) Compression ratio , .... , ............ . . ... ... . .... . в ore

8.8 : 1

. . .............. . . .. ...• . . .. . ... . . ....... . . . .

3 .80 in 196.5 mml

Stroke ........ . ...... .• . ... . ...... . . .. . . . ....... .

2 ,87 in (72. 8 mm )

Firing order ..... ...... . ... . . . .... . . ..... • . ........

1, 5, 4 , 2 , 6 ,3, 7 , 8 (No. 1 cylinder nearest radiator)

Oil pressure (hot)

... , .. .... .... .. ..... .......... . '

,

•

оп

right-hand bank,

35 to 60 Ibf/in2.

Pistons Diameter: Color coded red . , . .... " ..... , ColorcodedbIue", .... , ..... . ....• . •. . .... , .. , . . . . Piston-to-cylinder Ьоге clearancв ....... , , ..•. • . ..... , , , .. .

... ...... .......... .

3.7976103.7982 in (96.45 10 97.47 mml 3.7988103.7994 in (96.48 10 96.50 mm l 0.0021 100.0039 in (0.053100.099 mml

Chapt8r 1 En9in8

16

Pi8ton rin9. Ring side

сlеагапсе:

Торппо·,,········ ·············· ··· ··· · · ·· · ·····

Second ring ...... , ..... . . . . . . . ...... . , . . . . . . . ... . Oil ring ., ..... ....•. •.. ...... .... ..... . ........ . Ring оар: Тор rJng .............•.•............•.•...•...... Second ring ....... , ........ . .... " ..........•.... Oilring ............................•.• , . . . . . . . . .

Crank8haft

.

Мв!п Ьеаг1по Jоuгпаl

diameter . ..... . .•.. . .... ... • .•...•.. Connecting rod Journal diemeter . . . ............. .... . , .... .

0.0019'0 0.0036 in (0.048 ,о 0.091 mm) 0.001 ,о 0 .004 in (0.025 ,о 0 .1 01 mm) Snug fit 0.01 О ,о 0 .032 in (0.254 ,о 0.812 mm) 0.010 ,о 0 .032 in (0.254 ,о 0.812 mm) 0.0 15 ,о 0 .067 in (0.381 ,о 1.701 mm) 2 .2482 - 2.2490 In (57.104 - 57.124 mm) 2 .1228 - 2.1236 in (53.919 - 53.939 mm)

Engine data (289 си in) Comprs8sion r8tio ......... , . ..... . . . . . ... .... ... .

9.3 : 1

80r8 ................... .......... . ...... , ....... .

4.00 in (101.6 mm)

Stroke ....... " . ..... ........ , ................ ,.,

2.870 in (72.8 mm)

Firing order ..... , . , ........... , , . .............. , ..

1,5,4,2,6,3,7,8 (No. 1 cylinder оп rlght-hand bank, nearest radiator)

Oil pr8.8ur8 (hot) ... . ................... .. ........ .

35 ,о 60 Ibf(on'

Pi.ton8

. . . . . . . . . .. . . .. .. ..

Diameter: ... . ....., .. Color coded red . ColorcodedbIue ., ....... " . . .. .. , ...•. . . . ....... , . Piston-to-cylinder Ьоге clearance .... .•... , .. ..•.•.• . •... "

...

3.9984103.9990 in (101.5510101.57 mm) 3.9996 10 4.0002 in (101.58 ,о 101.60 mm) 0.0018 ,о 0.0026 in (0.045 ,о 0.066 mm)

Pi.ton. rin9. Aing side clearance: Тор ring , . , , . ............ ' ...... , ........... .. . , , Second ring .............. ' .. ..• . . ......• ' ....... . 011 rlng ,., ...........•.• ........ , ...•. . . . . . . .... Aing gap: Topring . . , ...........•. . . . . .... . ................ Second ring . ... .. .....•.• .. . . . . ..........• '.' .... Oilring .......•. . ........•.•.•.......... . '.' •...

0.0019'0 0.0036 in (0.048 ,о 0 .091 mm) 0.002 ,о 0.004 in (0.050 ,о 0.1 01 mm) Snug fit

0.010'0 0 .020 in (0.254 ,о 0.508 mm) 0.010'0 0.020 in (0.254 ,о 0.508 mm) 0.015 ,о 0 .055 in (0.381 10 1.397 mm)

Crank8haft Maln bearlng journal dlameter ... ..• ' . .•... , .. . .•......... Connectlng rod journal diameter . ...• ' . . • .... , ...•.•. . ...•.

Engine data (302

си

2.2482 2 .1228

2.2490 in (57.1 01057.12 mm) ,о 2 .1236 in (53.91 ,о 53.93 mm) ,о

in)

Compression ratio . . . , . . . .. . ' .. '\.' .. , ,'. .......... . .

8.0 : 1 (10. 5 : 1 Boss)

Bore .......................................... , ..

4.0 in (101 .6 mm)

Stroke ....... , ........ , . . .. . . . ... ..... . . . ..... . . .

3.0 in (7 6.0 mm )

Firing order . .................. ' ... . .. , , , . . ...... . '

1, 5, 4 , 2 , 6,3,7,8 (No. 1 cyllnder оп rlgh'-hand benk, nearest radiator)

Oil pr888ur8 (hot) ..... .. .......... .. ...... . . . . . . . . .

40 to 60 Ibf/in 2

Piston8 (standard 302 8n9in8) Diameter: Color coded red .................. . .......... . .•.. ' Color coded bIue .. , , , ........ . . .. .. ..... . . . . ... . . . . Piston-to-cyllnder Ьоге clearance ., , .... •.. .. ......•..... . .

Piston8

(В088

4.0004 ,о 4.0052 in (101.61 ,о 101 .73 mm) 3.9996 ,о 4.0002 in (101.58 ,о 101 .60 mm) 0.0018 ,о 0 .0026 in (0.045 ,о 0 .066 mm)

302 8n9in8)

Diameter: Color cocled red .... , ..... " , ...... .. ............. . ColorcodedbIue , ... " ..... , ....... , ...... , ......• . Piston-to-cylinder Ьоге clearance ...... ... . .•.•... " " , . ...

3 . 996В ,о

3.9974 in (101.51 ,о 101.53 mm) 3.9980'0 3.9986 in (101.54 ,о 101 .56 mm) 0 .0034 ,о 0.0042 in (0.086 '0 0.106 mm)

Pi8ton rin98 (all 302 8n9in88) Aing side clearance : Тор ring ... , ...... . , . .... . , .....•............ .... Se.;ond ring , , ...... • .... ... ... ......• ............ 011 ring .... ,., . ........... , .. . .... ' •........ , .. .

0.002 10 0.004 in (0.050 ,о 0.101 mm) 0.002 10 0.004 in (0.050 ,о 0.101 mm) Snug fit

•

Ch&pt&r 1 Engin& R;"g gap: Торппя · ····· · ,·", · · ········ · · ·· · ····, ·· · · ···· . Seconclring ... . ... , . . .. " .......• ' . . . .... . . . . . .. . Oilring . . . . . . . . . . . . . ... . ... .. ..•. . .•............

17

0 .010100.020 in 10.254 10 0.508 mm J от0 10 0 .020 in 10.254 10 0 .508 mmJ 0 .015 10 0 .089 in 10.381 10 1.752 mmJ

Cr_nksh&ft Main bearing journal diameter .... , .......... .... . . . .... . . Connecting rod journal dlameter .......... , , .. . .. , , . , .... . . Connecting rod Journal diameter (Boss engine) ...•.•. ,., ..... .

Engine data (351

си

2 .2482102 .2490 in 157.1О 1057.12 mmJ 2 .1228 - 2.1236 in 153.91 - 53.93 mm J 2.1222 - 2.1230 in 153.90 - 53.92 mmJ

in)

Compression ratio ., .............. , . . . ....... .. . . .

9.5 : 1 110.7 : 1 C-Iype}

Bor. . . .. ......... "" . ....... . .. . , ..... , ........ .

4 .0 in 1101.6 mmJ

Stroke .. ...... . ...... . . . ... ... . .. . .. . .. ... . ..... .

3.5 in 188.9 mmJ

Firing order . . , ........ . ... , , .. . .... ... .. , , , ...... .

1, З , 7, 2 , 6 , 5, 4 , 8 (No. 1 cy1inder оп

гight-hапd bank,

nearest radiator)

Oil pre8SUre (hot) .. ... . . ... . .... . . .. . .. .. ......... .

45 to 751bf { п 2

Pistons Diameter: Color coded red • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • Colour coded bIue .... . ............•. . . . . . ...... .. .. Piston-to-cylinder Ьоге clearance • • • • • • • • • • • • • • • • • • • • • • • • • •

3.9978103.9984 in 1101 .54 10101.55 mmJ 3.999010 3.9960 in 1101.57 10 101.49 mmJ 0.0018100.0026 in 10.045 10 0 .066 mmJ

Piston rings

,

Ring slde clearance: Тор ring ........... •.. . . .......... ... . . .... ... ... Second ring ........ . . • .•..........•. . .•.... . ..... 011 ring ............ . •. .. ........ . •... •. ......... Ring gap: Topring ...... . .. ... . .. . . . . . ..•. . .•. ... .. . .. ..... Second ring .... . . ..•. ..• . ...... ... • . •. . .... .. .... Oilring ....... .. . . •. . . •.. ..... ... •. . . . ..........

0.002100.004 in 10.050 10 0.101 mmJ 0.002100.004 in 10.050 10 0.101 mm} Snug fit

0.01 О 10 0.020 in (0.254100.508 mmJ 0.01 О 10 0.020 in 10.254 10 0.508 mmJ 0.015100.069 in (0 .381101 .752 mmJ

1

Cr&nksh&ft Main bearing j ouгnal diameter (35 1 W ) ........•.•... . . . .. .•. Main bearing journal diameter (351 С ) .. . ...... .•.• . . . ... . . . Connecting rod journal diameter . . ... . . . ... . .. ... ... ...... .

2 .2994103.0002 in 158.40 10 76.20 mm} 2.7484102.7492 in 169.80 10 69.82 mm J 2.3103102.3111 in 158.68 10 58.70 mm}

Engine data (390 си in) Compression r&tio . . .. . . .. . .. . .. .... ... .. . . ...... .

10.5 : 1

Bore ...... . .. . .. ... . . . .. . .. ... . . .. . . . ....... . . .. .

4 .050 in 1102.87 mm J

Stroke ... .. .................•....................

3.784 in 196.11 mmJ

Firing order ... . . ... ....... . ..... ... .. ..... . .... . . .

1, 5, 4,2 , 6, 3. 7, 8 (No. 1 cylinder nearest radiator)

Oil preSSur&

35 1060 IЫ(! п'

• • • •

•• ••

••

• • • • • • • • •

•••

•

• • •

• • • • • • • • • • • •

оп

right-hand bank.

Pistons Diameter: Color coded red ..... .. ........... . ......... .. .... . Color coded bIue ..... . ..........•. . .......... . ..... Piston-to-cylinder Ьогв clearance . .. ..•. •.... .. .... . . . .• ...

4.0484104.0490 in (102.82 10 102.84 mmJ 4 .0496104.0502 in (102.8510 102.87 mmJ 0 .0015100.0023 in (0 .038 10 0 .058 mm)

Piston ring. Ring slde clearance: Topring ......... • .•.•.•..........•. • ............ Second ring ......•. . . . . . ........•.• . •. . .......... 011 ring ...... . . . .. . . .... . . . • .. . •. . . .... . . . . . . .•. R!ng gap; Тор ring . .......... . . . . • ...... .... •. . . . . . .. . .... . Second ring ........• . •. . ........ .. • . . .• . . . .. ..... Oilring . .......... • . ... . . .......... . . . . . ........

0 . 0О210 0 . 004;п

10.050 10 0.101 mm J 0.002100.004 in 10.050 10 0.1 01 mm J Snug fit

0 .010100.020 in 10.254 10 0.508 mmJ 0 .01 О 10 0 .020 in 10.254 10 0 .508 mmJ 0 .01510 0.055 in (0 .381101 .397 mm)

Cr&nksh&ft Ма ! п

bearing journal diameter ... . .... . ...... ... . . ....... . Connecting Гod jouгnal diameter .. .... . ....... . . • .•.•.... ..

2.7484102.7 492 in 169.801069.82 mmJ 2.4380102.4388 in (61 .92 10 61 .94 mmJ

,

Chapter 1 Engine

18

Engine data (427

си

inJ

Compression ratio .. .. . . . .. . . .... ....... .. .. .... . .

10.9 : 1

80r8 ........ . ..... , ...... . . . . . ..... ...... . . . .... .

4.236 in (107.59 mml

Stroke .. . . ... . . . . ...... ... . . . . .. , ... ..... , . ..... .

3 .781 in (96.03 mml

Firing order . . , ... . ..... ...... . . ...... ... , ... . . . .. .

1, 5, 4, 2, 6, 3, 7 , 8 (No, 1 cylinder оп right-hand bank nearest radiator)

Oil pre8sure . . ,

. . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. .. ..

35 to 60 Ibf/in 2

Pistons Diameter:

Color coded red • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • Color coded bIue . ............ . . .... . ... . . ....•. . . . . Piston-to-cylinder Ьоге c l e aran cв . ........•... . ........•.•.

4.2298104.2299 in (107.43 10 107.44 mml 4.2305104.231 1 in (107 .4510 107.46 mml 0 .0030100.0038 in (0.076 10 0 .096 mml

Piston rings Ring side clearance : Тор ring ..... . ... . . ... .. .. . . .. . .. Second ring .. .... • . . ... . ...... . .. Oil ring .......... , •. . .. . ...... , • Ring gap: Topring ." ... .• . • ....•.. .. . • . • . . Second ring . ... .. . ' . . . . . . , . ... . ' . Oilring .... .... .. , . .... ', .. ... , .

... . .. . .. . .... . . . . . ... . ...... ... .• , . " .... . ... . ,

0.0024100.0041 in (0.060 10 0.104 mml 0.0020100.0040 in (0.050 10 0.101 mml

..... . . . • .• . • . •. . . . . . , . ....... , , . . . • .... . .......

0 .01 О 10 0 .031 in (0.25410 0 .787 mml 0.010'0 0.020 in (0.254 ,о 0.508 mml 0.015100.066 in (0.381 10 1.676 mml

Snug fit

Crankshaft Main bearing jouгna l diameter ..... . . • ...•. ....... .. • .. . .. Connecting rod journal diamete r .... , , , . . . • ' . . . . . .. , . , .... .

2.7484102.7492 in (69.80 10 69.82 mml 2 .438010 2.4388 in (61 .92 10 61 .94 mml

Engine data (428 си inJ Compression ratio " ., ... , . .. . . , .. .. . . , ........ . . .

10.6 : 1

Bore ... ,." , .. .. ,., ..• '.' . ... ,., .. . . . '. ' .. . . ", ..

4.130 in (' 04.90 mml

Stroke "." ... . ....... , . . . . . .......... . . . . . . , . .. '

3 .984 in (101 .19mml

Firing order .. . . . , , . , ... ' . ' . .. ' , , ..... . ' . .. . . .... . .

1, 5, 4 , 2, 6, 3, 7, 8 (No, 1 cylinder оп rlght-hand bank, nearest radiator)

Oil pressure

,

. . . . . . . .... . . . . . . .. ....... . ... . . . . . ,

'

I

з 5 to 60 lыЛп 2

Pistons Diameter: С о 10Г coded red " , ... , ... .... ' .. . . , ........ . . . . . . . Color coded bIue .. , .. . , .. ..... . ...... . . .. . . . .. . . . . . Piston-to-cylinder Ь о ге с1еагапсе . . , , . . . . , , , . . . . . . ..

...

... .

4 .1284104.1290 in (104.8610 104.48 mml 4.1296 10 4.1302 in (104.89 10 104.90 mml 0 .0015100.0023 in (0.038 10 0 .058 mml

Piston rings Aing side clearance : То р ring , .. . ... , , . . , .. ' . .•. . ' .. . . .. . . , . Second ring . . ..... .. . . . . .. .. . . . .... . . . . Oilring .. .. . ... ... ... . . ' .... • . . . . . . . .. Aing gap : Тор ring . . . , .... . . . ... ' , , , ...• ' . ' •..... Second ring . , . , .. .. . .. . ..•.. . •... .... . . Oil ring ., ...... , . , ..... , ... ,., . ' .. . ...

. • . . .. . .. . . . . . . • . ... .. , .. . . ".

0 .002 100.004 in (0 .050 10 0 .101 mml 0.002100.004 in (0.050 ,о 0.101 mml

. ......... . . . . . .. •. . , ......•..

0 .01010 0 .020 in (0.254 10 0 .508 mml 0 .010100.020 in (0.254 10 0 .508 mml 0 .01510 0 .035 in (0.381 100.889 mml

Snug fit

Crankshaft Main bearing journal diameter ., .. . ..... ' . . .. , .. " .. ,' ... . Conne cting rod journal diameter .. , .... . .... . .... , ..... ... . •

Engine data (429

си

2.7484102.7492 in (69.80 10 69.82 mml 2.438010 2.4388 in (61 .92 10 61 .94 mml

inJ

Compression ratio ........ . .. . ..... . . . ........... .

10 .5 : 1

Bore ...... ..... ", .. , . . . . . ... " .. .. . . . . . .. . , ... , .

4.360 in (110.74 mml

Stroke .... . . " .. , .... . , .. . ..... , .. . . . . . . . , . . . . , .,

3 .590in (91 .18mml

Firing order . .......... ... .... , ... , . , , , , . ....... , , .

1. 5. 4, 2. 6. З . 7, 8 (No, 1 cylinder nearest radiator)

Oil pressure , . . . ....... . .. . .. . . . ',., .. ... . ' . .. ' . . .

45 to 60 Ibf/ in 2

оп

right-hand bank,

Chapter 1 Engine

19

Pistons Oiameter: Color coded red .......•.•• . ..•.•......•.•.•...•... Color coded bIue ... ....•... , . .• • •..•.... .• . •.•... ..

4.3569 'о 4.3575 in (110.66 4.3581 'о 4.3587 in (110,69

'о 'о

110.68 mm) 110.71 mm)

Piston rings

,

Ring side clea rance: Topring .............• ..• • • ·.·· ·········, .·· · ··· . Second ring , .........•......• . ••..••. , .•• • • ••• . .. Oil ring . . . . . . . . • . . . . • . .......•.•••.. . .•.•.•.•.•. Ring gap: Тор ring . , ..... . •....•........• , •. , ..... , ..•.•.• . Second ring ....•.•.•••......•.•.•......•.•.•.•.•. Oil ring ... . . . . . . . . . . . . . . . • . . . ...• .•.•.• . . . . . . . . .

0.002 0.002

'о 'о

0,004 in (0.050 'о 0.101 mm) 0.004 in (0.050 'о 0.101 mm)

Snug fit

0.010 'о 0.020 in (0.254 'о 0.508 mm) 0.010 'о 0.020 in (0.254 'о 0.508 mm) 0.010 'о 0.035 in (0.254 'о 0.889 mm)

Crankshaft Main bearing journal diameter ..... , .•.•..........•.•.•.•. Connecting rod journal diameter ....•.•..........•.•.•.... ,

2.9994 2.4992

'о 'о

3.0002 in (76.18 2.5000 in (63.47

'о 'о

76.20 mm) 63.50 mm)

Lubrication Engine oil capacity

•

•

•

• • •

•

• • •

•

о

О

•

•

•

Engine oil type .............

о

••••••••••

• • •

• •

• •

•

•

•

•

•

• О

•

•

• •

•

О

О

•

• • •

••

,

Torque wrench settings Cylinder head bolt5 : 260.289 . 302 cu in ........•. ..• •.•.....••. .•..•.• • 390.428 си in ..... .....•.•••..•••... .. •.•.....• .. 351cuin . . . . . . . . . . . . . . . . • . . . . ........ • .•. . . . . . .. 429cu in ......... . ......•. •.• .. . ....... • . •.•.•. . 429 cu in В055 ............•.•.•..........•. • .•. . .. Connecting rod bearing bOJt5: 260. 289 . 302 cu in ... .....• • •.•..• • • .. . ..•.•. • .• .. 302 cu in HP ..... . .........•.•.•..........• . •.•..

351 , 390, 429cuin ............

о. о

••••••••••

о. о. о

••

429 cu in 8055 ............•.•.•.•........•.•.• . • . . 428cuin .... . . . . . . . . . . . . . . •.•.•.••.•.. . •.• . • • • .. Main bearing bolt5 : 260,289. 302 cu in ...... .. ....•.•.•............... 302 cu in 805S (outer bolts) ... ... .• . •.•..........•.•..

351 , 390, 427 , 428 , 429cuin , .. ,.

о . о. о

•••••

,

••

О. О, О"

429 cu in 80ЗЗ ................•.•...• . . . . ....•.• . . Crankshatt pulJey bolts : All engine types . . . . . . • . . . . . . • . • . • . . . . . . . . . . . . . . • .. Flywheel bolts: AII engine types ... , .. • ........ •. •.•.•. . . ........ .. Exhaust manifold bolts:

260, 289 , 302 с" in ..... ......... о • 351 , 390, 427 , 428cuin .. ....... .. .

о

••• •••••••

0.0

,

,

о

,

•

•••••••••••••

429cuin ... . . . . . . . . . . . . . . . . . . . . . • . • . . . . . . . . . . . . . Intake manifold bolts: 260, 289 . 302 cu in ...• . ..•• . ... . ..•..••• • • . . .. .. .. 351cuin ... ........•.• .. ..• . . . ..•.• ... ••........

390, 427 , 428

с"

in ...

о

•

о

••••••••••••

о

•

о

•••••••••••

429cuin . . . . . . . . . . . • . • . . . . . . . . . . . . • . • . . . . . . . . . . .

5 US qts/4lmp qts (including 1 ql filter capacity) Multigrade

IbIft

kgfm

65 'о 70 80 'о 90 95to 100 130to 140 90 'о 95

8.9 'о 9.7

19 'о 40 'о 40 'о 85 'о 53 'о

2.6 'о 3.3 5,5 'о 6.2 5.5 'о 6.2 11,7 'о 12,4 7,3 'о 8

24 45 45 90 58

11t012.4

13 'о 13.8 18 'о 19.3 12.4t013

60 'о 70 35 'о 40 95 'о 105 70 'о 80

8.2t09.7 4.8 'о 5.5

70 'о 90

9.7 to 12.4

75 'о 85

10.3

15 'о 20 18 'о 24 28 'о 33

2 to 2.8 2.5 'о 3.3 3.9 'о 4.5

20 to 22

2.8 to 3

'о 'о

1

131014.5 9.7t011

'о

11 .7

25 35

3.2 'о З.4 4.4 'о 4.8

251030

3.4104.1

23 32

о

•

1

General description

The engines covered in this Chapter compri5e the 260, 289 , 302 , 351,390, 427 , 428 and 429 cu in V8 units. Also covered аге the 80ЗЗ variants of the 302 , 351 and 429 си in engines and the Cleveland 351 cu in version. AII the above engines аге simi lar in basic design having of four cylinders set in а V-configuration . The cylinder machined directly into the cast iron cylinder bIock which with the crankcase. The one-piece crank5haft is suppprted crankcase оп five renewabIe shell-type bearings.

two banks Ьогез аге

is integral within the

The valve gear is actuated Ьу а five-bearing camshaft located in the center of the cylinder banks, and is chain-driven from а sprocket оп the front of the crankshatt. А gear оп the front of the cam5haft drives the distributor which in turn drives the oil pump via ап intermediate shatt.

The most widely used engines аге the 260, 289, 302 and 351 cu in units. These аге "егу compact motors incorporati ng stud- mounted valve rockers, hydraulic valve litters and wedge-shaped combustion chambers. The 260 cu in version was dropped from production in 1965 and the 289 cu in was last used in the Mustang in 1968. '" 1967 the 390 cu in engine became ауаilаЫе and the following уеаг 5aw the intToduction of the still larger 427 and 428 си in СоЬга Jet units. 1969 saw the introduction of the special Boss version of the 302 cu in engine. This is basically the 302 unit fitted with cylinder heads from the 351 Cleveland engine. It was built 10 quatify for sedan racing purp05es and had а limited production. It was later replaced Ьу а high-performance Boss ver5ion of the 351 Cleveland engine. 'П 1969/70 а limited number of Mustangs were equipped with the powerful Boss 429 cu in unit. This unique engine features specially modified combustion chambers with oversize valves and ports. The valve rockers operate оп individual shafts and the aluminium cylinder heads use O-rings and chevron seals in place of head gaskets. Each of the main bearing caps is 5ecured Ьу four bolts.

•

20

Fig. 1.1 302 engine; 260 and 289 engines 8te simi18t

I

•

Fig . 1 .2 351 engine

•

•

----------------------------------------------------------------------21

Fig .1 .З

390 engine with thermactor pump; 427 and 428 engines аге similar

1

Fig . 1.4429 engine

Chapter 1 Engine

22

the refrigerant radiator and positlon it forward out of the way. 00 2

Major operations with engine installed Тhe

following major operations

the engine from the (а)

тау Ье

саг:

о{ the

(ь)

Removaland installation Remova/and installation

(с)

Removaf and ;nstalfation

о{ the

(d)

Яеmоуа'

(е) Яеmоув!

carried Qut without taking

cylinder heads о( the timing gea( front engine mountings

and installation о( the гевг mounting and installation

о{

the camshaft

(f) Аеmоувl and installation о( the оп рап

and ;nstallation о( the connecting rod besrings (h) Rеmоvаlапd ;nstallation о( the pistons and connecting rods fi) Rеmоvа/апd installation о( the оН рumр (у) Яеmоуаl

по!

disconnect the refrigerant hoses. 14 Detach the terminal connector at the геаг 01 the alternator. Slacken the mounting bolt5 and push the alternator towards the engine. Lift away the fanbelt. Аетоуе the alternator mounting bolts and 11ft away the alternator. Note: Оп cars 'itted with а power steer;ng

and thermactor рuтр, the dr;vebelts 'аг these un;ts wiJI h8ve (о Ье removed first (ге'ег (о Chapter 2). 15 Аетоуе the alternator bracket securing bolts and spring wa5her. and lift away the bracket and ground саЫе from the side 01 the cylinder bIock. 16 Оп some 428 СоЬга Jet engines and all 429 Super СоЬга Jet, Boss 302 and Boss 429 engines, disconnect the inlet and outlet pipes fгom the engine oil cooler, гетоуе the retaining btacket and lift out the cooler a5sembIy. 17 АетоУе the cooling lап and drivebelt pulley (refer to Chapter 2 il песеззагу).

з

Major operations with engine removed

Although it would Ье possibIe to caгry out some of the following oper8tions with the engine installed if the transmission and clutch were removed, it is deemed inadvisabIe: (а) (ь) (с)

4

Remova/and installation о, the flywheef Remova/ and installation о, the геаг main bearing оП seal RemovaJ and instalJation о, the cranksha't and crankshaft main bearings

Methods of engine removal

The engine тау Ье lifted out together with the transmission ог separated from the transmission and lifted out Ьу itself. If the transmission is left attached the disadvantage is that the engine has to Ье tilted to а уегу steep angle to get it out, particularly when automatic transmission Is instal'ed. Unless both the engine and transmission аге being repaired ог overhauled together, there is по other reason for removing them as а unit.

5

Engine - removel without transmission

This task takes about three hours. 'С is essential to have а good ho;st. If ап ;nspection ри is not avaifabJe, two axle stands wi/lalso Ье required. 'П the later stages, when the eng;ne ;s be;ng separated 'гот the lransm;ssion and lifted, the assistance о, another person ;s mOS( use'uJ. 1 Ореп the hood. 2 Place а container of suitabIe size under the radiator and опе under the engine, and drain the cooHng system , as described in Chapter 2. 00 not drain the water in the garage ог the place where the engine is {о Ье removed il receptacles аге not at hand to catch the water. 3 Place а container of 8 US quarts (4 liters) capacity under the oil рап and гетоуе the drain plug. Let the oil drain for 1О minutes and then in5tall the plug. 4 Place old blanket5 оуег the fenders and acr05S the cowl to ргеуеп! damage to the paintwork. 5 U5ing а pencil , mark the outline of the hinges оп the hood. 6 Undo and гетоуе the fouг nut5, washers and bolt plate5 that эесиге the hinges to the hood. is easier if two a5sistants аге avai lable 50 that the hood сап Ье supported whilst the hinges аге being released . 7 Carefully lift the hood away lгот the саг and place It against а wall ои! 01 the way. 8 Oisco nnect both batteгy termlnal5, release the battery claтp and Hft out the battery. 9 Аеlег to Chapter 3 and гетоуе the air cJeaner and intake duct assembIy. 1О Slacken the clips that 5есиге the иррег and lower radiator hoses; carelully гетоуе the h05es. 11 Оп cars equipped with automatic tran5misslon , disconnect the oil cooler lines а! the radiator and plug the end5 to prevent dlrt ingress. 12 Аетоуе the radiator and shroud as described in Chapter 2. 13 11 air-conditioning i5 installed, unbolt the compressor and p05ition it out of the way without di5connecting the refrigerant h05es. Unbolt

18 Slacken the heater hose сliрз а! the inlet manilold and water pump unions, detach the h05e5. 19 Аетоуе the engine ground саЫе securing bolt from the engine and тоуе the ground саЫе to опе side. 20 Disconnect the main fuel line lгот the inlet side 01 the lиеl pump and plug the end 01 the line to prevent syphoning of gasoline. 21 Oetach the accelerator саЫе ог linkage а! the carburetot in5tallation and inlet manifold. Further information will Ье found in Chapter 3. 22 When ап automatic transmission i5 in5talled, disconnect the downshift linkage. 23 Make а note of the саЫе connections to the ign1t10n соН, water temperature sender unit and detach lгот the terminals. Also release the oil pressure gauge pressure р1ре . 24 Oetach the уасиит h05e to the brake servo unit (where аррliс­ аЫе) lгот the inlet manil01d. 25 Di5connect the emission control pipes and electrica l connections lгот the carburetor and inlet manil01d. 26 Аетоуе the two hoses and electrical connectot from the choke therm05tat housing. 27 Undo and гетоуе the nuts that secure each exhaust downpipe to the exhaust manilolds, release the clamp plates and тоуе the downpipes to the side 01 the engine compartment. 28 Chock the геаг wheel5, jack ир the lront 01 the саг and 5Upport оп firmly based axle stands. То give better acce5S, гетоуе the front wheels. 29 Make а note 01 the саЫе connections to the 5tarter motor. Oetach the cabIes lгот the starter motor terminal5. 30 Undo and гетоуе the bolts and spring washer5 that 5есиге the starter motor to the engine. Lift away the starter тotor. 31 Undo and гетоуе the engine front mounting through Mbolts at the insulator (Fig. 1.5).

Automatic transmission 32 Undo and гетоуе the bolts and spring washers that secure the converter inspect10n соуег to the housing. Lift away the in5pection соуег.

INSUlATOR

'!

CRQSSМEMBER

INSUlATQR BRACKET

Fig. 1.5 Front engine mounting btacket - tvpical (Sec. 9)

•

Chapter 1 Engine

23

remove the bolts that secure the torque сопуегtег to the ftywhee ' эdарtог plate. It will Ье necessary to rotate the crankshaft us.ng а large wrench оп the crankshaft pulley securing bolt. 34 Undo and гетоуе the converter housing-to-engine bIock securing botts аnd spring washers. Note: The uррег converter housing bolts аге BccessibIe through p/ugged holes;n the "оо( рап. 35 Detach the downshift rod from its bracket. ЗЗ

иndo аnd

Мапиаl

transmission

36 Pull back the clutch (eleaSB агт rubber boot, if appticabIe. Slacken the locknut and adjustment nut. Detach the inner саЫе from the (ele8se arm and withdraw the саЫе assembIy. 37 Undo and гетоуе the bolts and spring washers securing the clutch bellhousing to the engine. А" models

38 Install the wheels and lower the lront 01 the

•

саг.

39 Wrap горе slings around the exhaust manilolds ог, il chains аге to Ье used, mount brackets оп the exhaust manilold and then attach the chain hooks to the brackets. Take up the slack. 40 Place а jack under the transmission unit to suppoгt its weight. 41 Check that аll саЫез and controls have Ьееп detached and аге salely tucked out 01 the way. 42 Raise the engine sJightly and then draw it 10гward. When automatic transmission is instal'ed, make sure that the torque соп­ veгter remains attached to the transmission un;t. 43 Continue lifting the engine taking саге that the backplate does not 10ul the bodywork (photo). 44 With the engine away from the engine compaгtment, lower to the ground ог bench and suitabIy support зо that It does not roll over. 6

5.43 Hoisting out the engine

STANDARD "'1

ТRANSМISSЮN

Engine - removal with manual transmission attached

1 Proceed exactly аз described '" Section 5 up to and including paragraph 21, then 23 through 31, and linally paragraph 36. 2 Unscrew the transmission drain plug and allow the oil to drain away 10г five minutes. Install the drain plug. 3 Disconnect the gearshift rods lrom the transmission shift levers. 11 10ur-speed transmission is installed, remove the bolts securing the shift control bracket to the extension housing (зее Chapter 6). 4 Support the weight of the transmission using а small jack located adjacent to the drain plug. 5 Undo and remove the center bolt which locates the transmission extension housing into the support member. Then, making sure that the transmission support jack 'з firmly in position, undo and remove the two bolts and washers that secure the crossmember to the underside of the body. Lift away the сгоззте тЬег (Fig. 1.6). 6 Remove the muffler inlet pipe bracket-to-housing bolt. 7 With the сгоззтвтЬег removed It is now ап еазу task to disconnect the speedom eter cable lгот the transmlssion Ьу removing the clamp bolt and withdrawing the cable. 8 Detach the back-up 'атр cable connector at its зпар connector, 9 Wrap горе slings around the exhaust manil01ds ог if chains аге to Ье used, mount brackets оп the exhaust manifold and then attach the chain hooks to the brackets. Take up the slack. 1О Check that аll cables and controls have Ьееп detached and аге safely tucked out 01 the way. 11 With the jack under the transmission still in position staгt Hfting and а! the зате time, опсе the lront mountings have Ьееп cleared, move the engine 10гward until the ргореllег shaft 'з withdrawn from the end of the transmission. Support the shaft оп а wooden bIock, 12 Due to the fact that the transmission is attached , the engine will have to Ье lifted ou t at а much steeper angle than for removing the engine оп its own. дз the weight is more towards the геаг, it will Ье fairly еазу to achieve the песеззагу angle, 13 Continue to raise the engine and move It 10гward at the песеззагу angle. At this stage the 10гward edge 01 the clutch bellhousing is likely to catch against the front сгоззтетЬег and the tail of the tгапsmiзsiоп will need raising until the whole unit '$ 10гward and clear 01 it. 14 FinaHy the whole unit will rise clear and, if the maximum height of the 1ifting tackle ha$ Ьееп reached, it will Ьв песе$загу to swing the unit $0 that the tail сап Ье lifted clear whilst the hoist is moved away ог the саг lowered lгот its axle s1ands and pushed from under the unit. 15 The whole unit should Ье lowered to the ground (ог bench) аз зооп аз possibIe, and the transmission тау then Ье separated lгот the engine.

1

",<:....-INSUL A TDR

Fig. 1.6 Rear transmission suppOr1 member (Sec. 9)

7

Engine - removal with automatic transmission attached

It '$ recommended that the engine should not Ье removed whilst still attached to the automatic tгапsmiзsiоп, ЬеС8uзе 01 the weight involved. 11 it ,з песвззагу to remove both unit$ refer to Chapter 6 and remove the transmission unit lirst. Then remove the engine а$ described in Section 5 but disregard inlormation оп detachment from the transmission unit.

8

Engine dismantling -

оепега'

1 tdeally, the engine should Ьв mounted оп а ргорвг stand 10г overhaul but it is anticipated that most owners have а strong bench оп which to place it instead. If а sufficiently large strong bench 'з not ava ilabIe then the work сап Ье done а1 ground level. It 'з eS8entl81, however, that some 1огт 01 substantial wooden surface 'з availabIe. Timber should Ье а1 1east f inch thick, otheгwise the weight 01 the englne will cause projectlons to punch holes straight through it. 2 It will save а great deal of time 1ater il the exterior of the engine ,з thoroughly cleaned down Ьеlоге апу dismantling begins. This сап Ье done Ьу using kerosene and а stiff brush ог more easily, Ьу the U$e of а proprietaгy solvent which сап Ье brushed оп and then the dirt swilled off with а water jet. This will dispose of аll the heavy grime and gr11 опсе and 10г аll зо that later cleaning of individual components will Ьв а relatively clean ргосвзз and the kerosene bath will not Ьвсоте соп­ taminated with abrasive metal.

Chapter 1 Engine

24 з

As the engine is stripped down. clean each

ра" 85

it comes off. Тгу

to 8void immersing рапз with ollways in kerosene, аз pockets of liquid could remai" and cause оН dilution in the critical first few revolutions

after reassembIy. Clean oi!ways with pipe cleaners ог, preferabIy, ап alr jet. 4 Where possibIe, avoid damaging gaskets оп removat, especialty if new ones have not Ьееп obtained . They сап Ьв used as patteгns if new ones have to Ье speclatly cut. 5 It 'з helpful to obtain а few bIocks of wood to support the engine whitst it is '" the ргосезз of belng dismantled. Start dismantting at the top of the engine and then tuгn the bIock оуег and deal with the оН рап and crankshaft etc., afterwards. 6 Nuts and bolts should Ье re-instatled in their locations where possibIe to avoid confusion later. дз ап аJtеrпаtivе keep each group of nuts and bolts (аН the timing яеаг соуег bolts for example) together in а jar ог сап. 7 Мапу items dismantled must Ье re-instalted in the same position, if they аге not being renewed. These include valves, rocker arms, valve lifters, pistons, pushrods, bearlngs and connecting rods. Some of these аге marked оп аззетЫу to avoid апу possibility of mix-up during оуег­ haul. Others аге not, and it is а great help if adequate preparation is made in advance to classify these рапз. SuitabIy labelled cardboard boxes ог trays should Ье used. The time spent in this preparation wil1 Ье amply repaid later.

9

Engine ancill8ri.8 - removal

Before beginning а complete overhaul, ог jf the engine 15 being exchanged for а work5 reconditioned unit, the following items shou ld Ье removed:

Fuel system components: C8rburetor InС8ке Bnd exhBust mBn;folds Fuelpump Fuellines

Ignition system components:

3 4 5

Oisconnect the accelerator linkage from the carburetor. Refer to Chapter 2 and drain the сооliпя 5ystem. Oetach the НТ leads from the 5park plugs, release the distributor сар securing clips and гетоуе the distributor сар. б Slacken the clips and disconnect the hose from the water pump to the water outlet. 7 Oetach the vacuum pipe from the distributor body and carburetor in5tallation. 8 Refer to Figs. 1.7, 1 .8, 1.9 , 1.1 О , 1. 11 , 1 .12 and remove the саг­ buretor and intake manifold assembly. This will necessitate removal of the di5tributor. 9 Remove the two rocker covers Ьу undoing and removing the securing screws and lifting away together with their respective gaskets. 1О Оп cars equipped with air-conditloning, remove the mounting bolts and drivebelt, and position the compressor out of the way. Caution: ОО not disconnect the refr;ger8nt lines. If there ;s not enough slBck ;n the refr;gerant p;pes to еnвЫе the compressor Со Ье positioned out-оf-thе-w8У, the aiг-conditioning system wiJI h8ve to Ье drained Ьу а trained seгviceman before the pipes сап Ье disconnected. Under по ciгcumstances should this tas/( Ье attempted Ьу the home mechanic. 11 If power steering is installed, геrnоуе the hydraulic pump and bracket and tie the pump out of the way taking саге not to spill the fluid from the reservoir. 12 Remove the alternator mounting bracket, the ignition соВ and the air cleaner inlet duct from the right-hand cylinder head. 1 3 Оп cars equipped with the thermactor exhaust control system, remove the air риrnр and mounting bracket, and disconnect the hoses from each cylinder head m8nifold. 14 Оп 811 engines except the 390, 427 , 428 and Boss 429 , sl8cken the rocker arm stud nuts just enough to епаЫе the rocker arms to Ье rotated to опе side . 15 '" the case of the 390, 427 , 428 and 80ss 429 engines, remove the nuts securing the rocker shaft pedestals to the cylinder heads and carefully lift оН the rocker arms, shafts and pedestals. Aetain them in their correct sequence to ensure that they аге re-installed in their original position5. 1б Lift out the pushrods and keep them in the correct order of гетоуаl to ensure that they аге re-installed in their original positions.

SpBrk plugs Distr;butor СоП

Electгicsl

system components (if not гemoved slresdy):

Alteгnator

and mounting bt8ckets Staгter motor

8

Cooling system components:

'.!НТ

5

I

Fan end 'ап рu//еу WSt8f рumр, thermostat housing and thermostat

Water (еmрегаtuге sender unlt

4

Engine:

1

Crankcase ventilllt/on шЬе ОП filter

e/emant ОП pressure sender un!t

Oil/eve! d/pstick ОП 'illег сар

Eng/na mounting br8ckets

Clutch: Clutch pressure plate BssembIy Clutch fr;ction, pfSt8 8ssembIy ораоnаl

2

equipment:

Aiг-condit/oning

3

,

compfBssor

Power steering рumр Thermactor рumр •

10 Cylinder h88d. - removal with engine '"

св,

1 For safety rea50nS disconnect the battery. 2 Remove the air cleaner from the carburetor in5tallatlon, аз described in Chapter З.

8

7

Fig. 1.7 Correct IIBck_ning Bnd tight_ning ••quence of inteke mBnifold bolt8 - 260. 289 Bnd 302 engine. (Sec. 9)

Chapter 1 Engine

25

ф@

,,

..

$Н I(1

STUO

FRONT О,

ENGINE

+

\..)

0Q)@®0 0

•

Fig. 1.8 Correct slackening

апd

tightening sequenC8 01 intake manifold bolts351W engine (Sec. 9)

Fig. 1.9 Correct slackening and tightening sequence 01 intake manifold bolts - 351 Cleveland engine (Sec. 9)

+

6

FRONT I

3

9

•

14

13

8

7

3

1

7

10-+

-9

4-+

_1

6-+

-5

12-+

+--14

1

4 Fig. 1.10 Correct slackening and tightening sequenc8 01 intake manifold bolts - 390. 427 and 428 engines (Sec. 9)

Fig. 1.11 Correct slackening and tightening sequence 01 intake mапifоld bolts - Воав 429 engine (Sec. 91

I

I

Fig. 1.12 Correct slackening and tightening sequence 01 intake manifold bolts - 80В8 302 engine (Sec. 9)

I

17 Detach the exhaust downpipes from the exhBust manifotds. Оп the 351W and 427 engines it will Ье necessary to unbolt the exhaust mani10lds 1гот the cylinder heads and tie them out 01 the way. 18 Taking each cylinder head in turn, slacken the holding down botts in the order shown in Fig. 1.1 З. When аll аге free of tension remove 811 the bolts. 19 Оп occasions the heads may have stuck to the head gasket and cylinder bIock, in which сазе if pulling up оп the exhaust manifolds daes not free them they should Ье struck smartly with а soft faced

hammer in order to break the joints. 00 nо! try to ргу them off with а bIade о{ аnу description or damage wiIJ Ье caused to the (aces о ( the head or bIock, Qr both. 20 With the help of ап assistant, lift off the cylinder heads, remove them from the саг and place them оп the workbench. Аетоуе the exhaust manifolds if still attached to the cylinder heads. 21 Remove the cy1inder head gaskets; new ones will reassembIy.

Ье

required far

Chapter 1 Engine

26

FROНT

•

6 Fig. 1.1 3 Correct s8quence far slackening and tightening the cylinder head bolts - 811 engines {Sec. 10) ROCKER ARM

___

SТUD

..._ _ FULCRUM

NUT

60LT

(~ FULCRUM SEAT - ••

ROCKER д"м

ROCKER ARM

• Fig. 1.14 Rocker 11 Cylinder heads -

агт апd

гвтоуаl

Fig. 1.15 Bolt-type roeker агт ISee. 12)

retaining nut {See. 121

with engine out 01 саг

Follow the sequence given in Section 10. paragraph 5 through 21. disregarding information оп parts mentioned that have Ьееп previously removed.

з

Refeгring

to Fig. 1.16, withdraw the wa5hers, rocker агтз, support5 and springs from the shaft. Кевр all the components in the соггес! order of removal so that they сап Ье re-installed in their originat positions.

14 Velv8 lift8rs - r8moval 12 Cylinder heads - dismantling of valV8S

апd

springs

1 Оп engines equipped with stud-mounted rockers, remove the rocker агт retaining nuts and lift off the fulcrum seats and rocker arms. Note that оп зоте engines the rocker arms аге retained Ьу а bolt, and oil deflectors аге installed (see Figs. 1.14 and 1.15). 2 lay the cylinder head оп it5 side and using а ргорвг valve 5pring сотргв550Г place the U-5haped end оуег the 5pring retainer and the 5crew оп the valve head 50 аз to сотргв55 the 5pring. 3 Sometime5 the retainer will 5tick, '" which са5е the end of the сотрге550Г over the spring should Ье tapped with а hammer to release the retainer fгom the locks (collet5). 4 As the spring 15 compre5sed, two tapered locks will Ье exposed and should Ье taken from the гв се55 in the retainer. 5 When the compressor is released the spring тау Ье removed from the valve. lift оН the retainer, spring and oil seal. Withdraw the valve from the cylinder h'ead. 6 1I is essential that the valves, spring5, retainers, locks and seals аге all kept in order 50 that they тау Ье re-in5talled in their original positions.

13 Valve rocker shaft аззетЫу - dismantling 1 Оп engines equipped with shaft-mounted rockers, Ihe 5haft5 and rockers should Ье dismantled, cleaned and inspected for wea r. 2 With the rocker shaft оп the bench , гвтоуе Ihe cotter pins from each end of the shaft.

1 The valve lifters тау now Ье removed from the cylinder bIock Ьу pushing them up from the camshaft (which сап Ье revolved if песеззагу to raise the valve lift8fS) and lifting them out. Note: With

the engine in the саг а magnet mау Ье required to withdraw them, (see Fig././7J. 2 If necessaгy the pushrod bearing сарs in each valv8 lifter сап Ьв taken out Ьу first extracting the retaining snap-ring . 3 Make sure that аll the valve lifters аге kept in order зо that they may Ьв replaced in their originallocations. 4 Note that ceгtain high peгtormance versions of the Mustang engines аге equipped with solid (non-hydraulic) valve lifters and these obviously cannot Ьв dismantled.

15 Crankshaft damper - removel 1 Undo the retainlng bolts and remove the pulley wheel from the front of the damper. 2 Remove the bolt and washer locating the damper to the front of the crankshaft. The damper is keyed to the crankshaft and must Ье drawn off with а ргорег sprocket puller. Attempts 10 lever it off with 10ng bIaded articles such аз screwdrivers ог tire levers аге по! suitabIe in this сазе because the timing соуег behind the damper is а light and relatively fragile casting. Апу pressure against It could ceгtainly crack it and p05sibIy make а hole in it. 3 The damper may Ье removed with the engine in the саг but it will Ье necessaгy to remove the radiator, and drivebelts. 4 Recover the Woodruff key from the crankshaft позе.

•

Chapter 1 Engine

27 SPRING WASHER

WASHER LOCkwASHER------~

WASHER ROCKER ARM

SPRING BAFfLES

SUPPORT

BOLТ

I

HOLES

\.

PLUG

СОПЕR

PIN

SНAFТ

Fig. 1.1 в Shaft-mounted rocker 8зветЫу used оп the 390. 427.428 and Boss 429 engine8 (Sec. 13) securing the No 2 crossmember and lift away the crossmember. 8 Автоуе the 011 рап securing bolts and lower the oil рап as far as possibIe. If the оН ритр obstructs the гетоуаl of the 011 рап, unbolt the ритр from 1nside the crankcase. Allow it 10 drop into the 011 рап and withdraw the оН рап complete with риmр . It тау Ье necessaгy 10 rotate the crankshaft to pгovide sufficient clearance for removal of the oil рап .

MAGNETIC LIFTER

390,427, 428,429 and 1971/1973302 and351 9

i

Fig. 1.17 Removing

I

8

valV6 lifter using 8 magnet (Sec. 14)

16 Flywheel - removal

•

1 Аетоуе the clutch assembIy as described in Chapter 5. 2 The flywheel is held in position to the crankshaft Ьу six borts and а loc8t ing dowe l. 3 Аетоуе the six bolts, taking саге to support the weight 01 the flywheel as they аге slackened off in CBse it slips off the lla"ge . Аетоуе It carefully, taking саге not to damage the mating surfaces оп the crankshaft and flywheel .

Remove the 011 level dipstick. Jack-up the front of the саг, support it оп axle-stands and drain the engine oil into а suitabIe container. 1О Remove the front stabllizer Ьаг as described in Chapter 11 . 11 If the radiator 1з equlpped with а fan shroud, detach it from the radiator and position it оуег the fan . 12 Remove the nuts and lockwashers securing the front engine mountings to the support brackets. 13 If the саг is equipped with automatic transmission, disconnect the oil cooler liпез from the radiator. 14 Place а flat bIock of wood beneath the front of the оН рап to prevent damage, and using а floor jack f8ise the engine approx1mately 1 t in (31 тт). In5ert а 1 in (25 mт) bIock of wood between the engine mount1ngs and crossmember and геmоуе the jack. 15 Remove the 011 рап securing bolts and lower the рап аз far as possibIe. Aemove the inlet tube and filter зсгееп from the 011 pump. 16 Rotate the crankshaft to provide clearance 1f necessary and withdraw the oil рап. 17 Автоуе the 011 рап gasket. Д new опе must Ье obtained for reas5embIy.

18 Front СОУ8Г 17 Oil

, I

рап

- removal

1 With thв eng ine removed (гот the саг, f1rst make sure that all the oil is drained. 2 With the engine invвrted гетоуе the retaining bolts and 11ft away the oil рап. If it is stuck, carefully insert а knife bIade 1п the gasket joint and work 1t along to break the seal. After removing the oil рап, d1scard the gasket. 3 11 the oil рап is to Ье removed w1th the eng1ne in the саг, refer to the appropriate sub-section following.

геrnоуеl

1 With the engine out of the саг, гетоуе the oil рап , and crankshaft damper. 2 Undo and гетоуе the water pump retaining bolts and lift the water pump from the fгont соуег. 1I mау Ье necessary to tap it with а soft-faced hammer if а joint1ng compound has Ьееп used. 3 Undo and гетоуе the front соуег securing bolts and lift away. If it is 5tuck, саггу out the instructions in paragraph 2. Remove the fгont соуег gasket. 4 If Ihe engine is slill 1п the саг it will Ье песеззагу to гетоуе the front oil рап bolts which гип through the timing соуег. 1I will also Ье necessary to remove the fanbelt, crankshaft damper and fuel pump.

260, 289, 302 and 351 engines through 1970

I

the о111еуеl dipstick. Jack-up the front of the саг , support оп axle-stands and drain the engine 011 into а suitabIe container. 5 Аеmоуе the front stabllizer Ьаг as descr1bed in Chapter 11. 6 Disconnect the starter саЫе and геmоуе the starter motor. 7 Оп models fitted w1th the 351 С eng1ne, геmоуе the two bolts

4 1t

Аеmоуе

19 Timing chein and sprockets - removal 1 Аетоуе the front timing chain соуег аз described in the previous Section and withdraw the оil sJinger from the front of the crankshaft.

1

Chapter 1 Engine

2в

2 Undo the camshaft sprocket securing bolt and гemove the fuel pump eccentric from the sprocket. 3 Using а suitabIe puller, withdraw the crankshaft sprocket and, if necessary, the camshaft sprocket; гетоуе both sprockets and chain as а complete assembIy, (Fig. 1.18). 4 Аесоуег the Woodruff key from the groove in the crankshaft. 5 ТО test the chain 10г wear, refer to Section 38 01 this Chapter.

20 Camlhaft - r8movBI The caтshaft camshaft renewel

hau/ other parts

сап Ье

removed with the engine in the

саг.

Ье necesseгy it wШ ргоЬаЫу Ье necessaгy о, the engine too. If this is the C8se engine

(Should to over-

removaJ

should Ье considered). 1 Refвr to Chapter 2 and remove the radiator.

.

.

2 Detach the spark plug leads from the spark plugs, release the сар securing clips and place the сар to опе side. 3 Detach the distributor vacuum 11пе and then remove the distributor аэ described in Chapter 4. 4 Aemove the alternator аэ described in Chapter 10. 5 Undo and remove the screws that secure each rocker cover to the cylinder heads. Lift away the rocker covers and gaskets. 6 Refer to Chapter 3 and remove the inlet manifold and carburetor installation. 7 Оп engines equipped with shaft-mounted rocker arms, remove the bolts securing thв rocker shaft supports to the cylinder heads. This should Ье done in а progressive таппег to avoid straining the shaft. Lift away the rocker shaft assembIies not1n9 оп which head each shaft was Installed. 8 Оп engines equipped with stud-mounted rockers, slacken the rocker агт retaining nuts (bolts оп some engines) just enough to епаЫе the rocker arms to Ье rotated to опе side . 9 Aemove the pushrods and note the 10cation from where they сате and also which way up. Кеер them in order and the right way up Ьу pushing them through а piece of stift рарвг with valve numbers marked. 10 Aefer to Sectlon 18 and remove the front coveT. 11 Aefer to Section 19 and remove the camshaft timing gear. 12 Undo and remove the two screws which secure the camshaft thrust plate to the cylinder bIock face. Lift away the plate and spacer. 1 3 Using а magnet, recover the valve lifters from the 'Vee' in the cyl inder bIock. Кеер them in order as they must Ье re-installed in their QГiginal positions. 14 If апу valve 11fters cannot Ье rem oved, retain in their maximum height positions with сliрэ. 1 5 The camshaft тау now Ьв drawn forwards through the cylinder bIock. Take саге that the sharp edges of the сатз do not damage the bearings.

21 Oil

Fig. 1.18 Withdrawing the timing chain and sprockets (Sec. 19)

•

риmр

- removal

1 Aefer to Section 17 and remove thв оН рап. 2 Undo and remove the two bolts that secure the pump to the crankcase. Lift away the pump and recover the gasket. 3 The long hexagonal section driveshaft will соте out with the pump. This 1э driven Ьу the distributor shaft .

. . . - - - _ ·rн,Ш5, Т PLA ТЕ

CHAIN ANO SPROCKET

FUEL PUМP ECCENTRIC

Fig. 1.19 Camshaft and associated components ISec. 20)

•

•

Chapta, 1 Engine

25 Crankshaft

29

геаг оН

5eal- renewal

1 It is possibIe to remove the crankshaft ге аг oil seal with the engine in ог out of the саг. Where the engine 1з being eompletely removed, refer to Section 26 and remove the crankshaft. Remove the two halves of the seal from the upper геаг main bearing and сар. 2 То remove the seal with the engine still in the саг, drain the engine оН , and remove the oil рап and pump as described in Section 17. 3 Undo the two bolts and carefully ргу the геаг main bearing сар from the erankshaft. Aemove the оН seal from the сар and, if а locating pin is fitted in the bottom of the groove in the сар, drive It out using а pin puneh . 4 Slacken аll the main bearing сар bolts to епаЫе the crankshaft to drop down slightly, but not тоге thsn -9 in (0·8 mmJ. 5 Using а piece of brass rod, push опе end of the upper half of the oil seal upwards to rotate 11 around the crankshaft. When the other end of the зеаl is protruding sufficiently, grip it with а pair of pliers and carefully pull it out while continuing to push оп the 01her end with the гod . Great саге must Ье taken not to scratch the crankshaft оН зеаl

Fig. 1.20 Location of oil pump - typicel (Sae. 21)

I

22 Pistons. connecting rods

I ,

,

апd

bearings - removal

1 Pistons and connecting rods may Ье removed with the engine in the саг, provided the oil рап and cylinder heads аге first removed. The bearing shells тау Ье removed with the heads оп . 2 Slacken the two nuts holding each bearing сар to the connecting rod. Use а good quality socket wren ch for this work. А ring wrench тау Ье used for гетоуа' but not for installation which calls for а special torque wrench. Having slackened the nuts two ОТ three turns tэр the сарз to dislodge them from the connecting rods. Completely гетоуе the nuts and lift away the end caps. 3 Each bearing сар normally has the cylinder number etched оп опе end аз does the connecting rod. However, this must Ье verified and if in doubt the сар should Ье marked with а dab of paint ог punch mark 10 ensure that its relationship with 1he connecting rod and its numerical position in the cylinder bIock is по! altered. 4 The piston and connecting rod may then Ье pushed out of the top of each cylinder. 5 The connecting rod bearing shells сап Ье removed fгom the соп­ necting rod and сар Ьу sliding them round in the direction of the notch at the end of the shell and lifting them out. If they аге по! being renewed it is vital they аге not interchanged - either between pistons ог between сар and connecting rod.

•

23 Piston rings -

I

гетоуаl

1 Aemove the pistons from the engine. 2 The rings come оН over the top of the pistons. Starting with the top опе, 11ft опе end of the ring out of the groove and gradually ease it out all the way round. With the second and third rings ап old feeler bIade is useful for sliding them over the other grooves. However, as rings аге only normally removed If they аге going to Ье renewed it should not matter if breakages occur.

suгface.

6 Clean out the oil seal grooves in the cylinder bIock and сар using а suitabIe solvent. 7 Soak the new rubber seals in clean engine оН prior to installation. 8 Install the upper half of the зеаl in the eylinder bIoek with the inner lip facing towards the front of the engine (see Fig. 1.33). Slide the зеаl around the crankshaft until t in (9 тт) protrudes from the base of the bIock. 9 Aepeat the procedure for 1he lower half of the seal, allowing ап equal amount of the seal to protrude beyond the opposite seal of the bearing сар , (see Fig . 1.33) . 1 О Install the гваг bearing сар and seal ensuring 1hat the protruding ends of the seats correctly enter the respective grooves. Apply а bead of sealer to the геаг eorners of the btock and sides of the сар аз shown in Fig. 1.34. 11 Tighten аН the main bearing сар bolts to the specified torque wrench set1ing. 12 Fit new oil рап seals and gaskets, and install the oil pump and oil рап as described in Sections 45 and 47 respeetively.

1

26 Main bearing5 and crankshaft - removal 1 The engine should Ье removed from 1he саг and the oil рап, cylinder heads, timing gears and pistons removed. 2 With а good quality socket wrench undo the bolts holding the five main bearing caps. 3 When а" the bolts аге removed lift out the caps. If they should Ье tight, tap the sides gently with а pieee of wood ог soft maltet to di sl odge them . 4 Оп some engines the main bearing caps аге marked from 1 to 5. However if they аге not, identify the location of each сар with paint marks ог tight eenter punch marks to ensure correet reassembIy. 5 Lift out the crankshaft from the cylinder btock taking саге not to scra1ch the journals. 6 Slide out the bearing shetls from the cylinder btock and bearing сарв , n01ing that the eenter shells also function аз thrust bearings.

27 Lubrication and crankcase ventilation systems - description 24 Piston pin -

I I

гвтоуаl

The piston pins need removing if the pistons аге being renewed. New pistons аге supplied with new pins for fitting to the existing соп­ necting rods. The piston pin is semi-floating - that is, it is а tight shrink fit with the connecting rod and а moving fi1 in the piston. То press 11 out requires considerabIe foree and under usual circumstances а ргорег press and special tools аге essential , otheгwise piston damage will occur. If damage to the pistons does not matter, then the pins may Ье pressed out using suitabIe diameter pieces of rod and tube between the jaws of а vise. However, this is not recommended as the connecting rods migh1 Ье damaged also. It is recommended that piston pins and pistons аге removed from , and refltted to, connecting rods, Ьу а dealer with the necessary fасШtiеs.

The oil pump is located оп the crankcase and is driven from the distribu10r Ьу а hexagonal driveshaft. Ап 011 pressure relief valve is incorporated in the pump body. Oil under pressure is direeted via а fullflow filter to the main, connecting rod and camshaft bearings and 10 the hydraulic valve lifters, (where аррliсаЫе) pushrods and rocker arms. А drilling in the front cylinder bIock face enabtes oil to pass through to the timing ehain and sprocket. Oil from the valve gear drains down over the camshaft 10Ьез and distributor drivegear before passing back into the oil рап. The cylinder bores аге lubricated Ьу а squirt of оН from а drilling in each connecting rod. The piston pins аге lubricated continuously Ьу the оН mist thrown up inside the crankease. The crankcase has а positive ventilation (PCV) system. Instead of

~

зо

•

•

-

Н 7 18 '!1

•

I,

, •

-\~

/

•

Fig. 1.21 Engine lubrication system - typical (See. 27)

/' FRONT

УЕНТ ASSE MBl у

CRANKCASE

Qll FILLER

..-__

САР

CRANKCASE VENT

HOSE

ре

- ..... VIEW

V VAL УЕ HOSE BRACKET

ELBOW

VIE W А

""""" "'

CRANKCA SE УЕНТ HQSE

CRANKCдSE

УЕНТ

I

А

",- / (

УI

Fig. 1.22 Crankcase ventilation system (See . 27)

EW 8

•

Chapter 1 Engine a"owing engine tumes to

еsсаре

1"to the atmo5phere they

аге

31

drawn

back in10 the engine via а hose and vent valve connected between the oil filler сар оп the lвft-hапd rocker соуег and the carburetor intake flange. Д second hose connects the air cleaner to the right-hand rockвr covег ( sвe

Fig. 1.22).

28 Oil filt.r - remoY81and installation Тhe

oil filter i5 а complet8 throwaway c8rtridge screwed 1"to the left-hand side о, the engine bIock. Simply unscrew the old unit, сlеал the seating ОП the bIock and screw the new опе in, taking саге ПО1 to с гозз

the thread, Continue until the sealing ri"g just touches the bIock

face. Then tighten опе half turn. Always гип the engine and check 10г signs of leaks after i"st8118tion.

I

29 Engine components - examination for wear When the engine has Ьееп stripped down and 81 1 parts properly cleaned, decisions have to Ье made as to what needs renewal and the following sections tell the examlner what to look for. '" апу borderline сазе It is always best to decide in favour of а new part. Еуеп if 8 part тау stlll Ье serviceabIe Its life wilJ have Ьееп reduced Ьу wear and the degree of troubIe needed to renew It In the future must Ье taken into consideration. However, these thlngs аге relative and It depends оп whether а quick 'survlval' job is being done ог whether the саг as а whole 15 being regarded as having many thousands of miles of useful and economical life remaining.

30 Crankshaft - examination and renovation 1 Look at the eight maln bearing jouгna ls and the eight crankpins; If there аге апу scratches ог зсоге marks then the shaft will need grinding. Such condltions will nearly always Ье accompanied Ьу similar deterioration in the matching bearing sheHs. 2 Each bearing journal should also Ье round and сап Ье checked with а micrometer of саliрег gauge around the peripheгy at several polnts. If there is тоге than 0.0004 in (0.01 mm) of ovallty regrinding is necessaгy . 3 А main Ford agent ог motor engineering specialist wlll Ье аЫе to decide to what extent regrinding is necessaгy and also supply the special under-slze $hell bearings to match whatever тау need grinding off the journals. 4 Before taking the crankshaft for regrinding, check also the cylinder bores and plstons а$ it тау Ьв more convenlent to have the engineering operations peгformed at the same time Ьу the same engineer.

31 Cr8nkshaft (main) bearings 8nd connecting rod bearings 8X8mination and renovation With careful seгvic ing and reguJar 011 and filter changes, bearlngs wШ last for а уегу long tlme Ьи! they сап stHI fail for unforeseen гвазопз. With connecting rod bearings the indications аге а regular rhythmic loud knocking from the crankcase, the frequency depending оп engine $peed . It is partlcularly noticeabIe when the engine is under load. Тhis symptom 1$ accompanled Ьу а fall in 011 pre$sure although this is по! norma lly noticeabIe unless ап 011 pressure gauge is flned. Ма!п bearing failure is usually indicated Ьу seriou5 vibration . particularly at higher engine revolutions, accompanied Ьу а more significant drop in 011 pressure and а 'ru mbIing ' noise. 2 Bearing shells in good condition have bearing зигfасез with а smooth, еуеп, matt $ilver! gray color а" оувг. Worn bearings wiJI show patches of а different color where the bearing metal has worn away and exposed the underlay. Damaged bearings wШ Ье pitted ог scored. It is nearly always well worthwhile fitting new shells аз their cost is reJatively low. /f the crankshaft is '" good condition It 1з merely а question of obtaining another set of standard size. А reground cranks as will need new bearing shells as а matter of course. 1

32 Cylinder ЬОГ88 - eX8mination and renovation 1

А

new cylinder is peгfectly round and the walls parallel throughout •

Fig. 1.23 Installing

а

new 011 filter (Sec. 27)

its length. The action of the pistons tends to wear the walls at right angtes to the gudgeon pin due to side thrust. This wear takes place principally оп that section of the cylinder swept Ьу the piston rlngs. 2 It is possibIe to get ап indication of Ьоге wear Ьу removing the cylinder heads with the engine still in the саг , With the piston down in the Ьоге first signs of wear са п Ье seen and felt just below the top of the Ьоге where the top piston ring reaches and there will Ье а noticeаЫе lip. If there is по lip it is fairly reasonabIe to expect that Ьоге wear is low and апу lack of compression ог excessive оН consumption is due to worn ог broken piston rings ог pi$tons (see next Section). If it 'з possibIe to obtain а Ьоге measuring micrometer, measure 3 the Ьоге in the thrust plane below the lip and again at the bottom of the cylinder in the same plane. If the difference is more than 0.010 in (0.254 mm) then а геЬоге is necessaгy . Similarly, а difference of 0.005 in (0.127 mm) ог more across the Ьоге diameter is а sign of ovality calling for а геЬоге. 4 Апу Ьоге which is significantly scratched ог scored will need reboring. This symptom usually indicates that the piston ог rings аге damaged in that cylinder. '" the event of only опе cyHnder being in need of reboring it will still Ье ne ce ssaгy for all eight to Ье bored and supplied with new oversize pistons and rings. Уоиг Ford dealer ог 'оса' engineering specialist will Ье аЫе to геЬоге and obtain the necessaгy matched pistons. If the crankshaft 'з undergoing regrinding it is а good idea to let the same firm renovate and reassembIe the crankshaft and pistons to the bIock. А reputabIe firm normally gives а guarantee for such w ork. '" cases where engines have Ьееп rebored already to their maxlmum, new cylinder liners аге availabIe which тау Ье installed. 'П such cases the same reboring processes have to Ье followed and the services of а specialist engineering firm аге required. ЗЗ

Pistons and piston rings - examination and renovation

1 Worn pistons and rings сап usually Ье diagnosed when the symptoms of excessive oil consumptlon and low compression оссш and аге $ometimes, though not always, assocated with worn cylinder bores. Compression testers that screw into the spark plug holes аге ауаНаЫе and these сап indicate where low compres$lon i$ occurring. Wear u$ually accelerate$ the more it 15 left so when the $ymptoms occur, early action сап possibIy save the expense of а геЬоге . 2 Another symptom of piston wear is piston slap - а knocking noise from the crankcase not to Ье confused with connecting rod bearing failure. It сап Ье heard clearly at low engine speed when there 1з по load (idl ing for example) and the engine Is cold . and is much less audibIe when the engine speed in creases. Piston wea r u$ually occurs in the skirt ог lower end of the piston and Is Indicated Ьу vertical

1

Chapter 1 Engine

32 •

s:"eaks in the worn агеа which is always оп the thrust side. 11 сап al50 ье seen where the skirt thickness is different. 3 Piston г1п9 wear сап Ье checked Ьу fit5t removing the rings from the pistons. as described in Section 23 . Then place the rings in the cylinder bores from the top, pushing them down about 1.5 inches (Э8 тт) with the head of а piston Нгот which the rings have Ьееп removed! 50 that they rest sQuare in the cylinder. Then measure the gap the ends of the ring with а feeler gauge. If the gap оп апу of the rings exceeds the dimensions given in the Specifications. they should Ье renewed (Fig. 1.24). 4 The groove in which the rings locate in the piston сап also Ьесоте enlarged due 10 wear. The side clearance between the rings and piston should not exceed the dimensions given in the Specifications, (Fig.

1.251. 5 However. It is

•

f

гаге

that а piston is only worn in the ring groove and the need 10 renew them for this fault alone Is hardly еУег encounlered .

Fig. 1.24 Checking а piston гiпg овр (Sec. 33)

34 Connecting rods and piston pins - examination

апd

renovation

1 Piston pins аге а shrink-fit Into Ihe connecting rods. Neither of these componen ts would normally need renewal unless the pistons were being changed, 1п which case the new pistons would automat ically Ье supplied with new pins. 2 Connect ing rods аге not subject 10 wear but in extreme circum5tances such as engine seizure , they could Ье distorted. Such condilion5 тау Ье visua lly apparent but where doubl exists they shou ld Ье ehanged. The bearing сарэ should al50 Ье examined for indications of filing down which тау have Ьееп altempted in the mistaken idea that bearing slaekness eould Ье remedied 1п this way. If there аге such sign5 then the conneeting rods should Ье renewed .

Fig. 1.25 Cheeking the piston rings side clearance (Sec. 33)

35 Camshaft and camshaft bearings -

ехаmiП8tiоп

and

геПОУ8-

tion 1 The ca mshaft bearing bU5he5 should Ье examined for signs of scoring and pitting. If they need renewal they will have to Ье deall with professionally а5 , although it тау Ье relatively еа5У 10 гетоуе the old bushes , the eorrect fitling of new ones requires special tools. If they аге not fitted evenly and square from the уегу 51art they са п Ье distorted, thus causing localised wear in а уегу short time . See уоиг Ford dealer ог loeat engineering speciali5t for thi5 work. 2 The eamshaft ilself тау show signs of wear оп Ihe bearing jou rna ls. сат lobes ог the skew gear. The main decision 10 take is what degree of wear justifie5 renewal . which Is costly. Апу sign5 of scoring ог damage 10 the bearing journals must Ье rectified and. as under5ize bearing bushes аге not supplied . Ihe ;ournals can not Ье reground. Renewal of the w hole eamshaft i5 the only 50lution. Simi larly, excessive wear оп the skew gear which сап Ье эееп where Ihe distribulor driveshaft teeth mesh . wi ll теап renewal of the whole ca mshaft. 3 The са т lobes themsel ves тау 5how signs of ridging ог pitting оп the high polnt5. If the tidging is light the n it тау Ье possibIe to smooth it ои ! with fine етегу . The еат lobe5 , however, аге эигfасе hardened and опе е this 15 penetraled wear will Ье уегу rapid thereafter. The eams аге also offset and tapered 10 ca use the valve lifters (о rotate thu5 ensuring that wear is еуеп - so do not mi5take thi5 cond ition for wear.

ROD

VALVE СНЕСК

VALVE

vAL У Е SPRING LOCK RING

PLUNGER СНЕСК

RETAINER

Fig . 1.26 Туре 1 hydraulic valve lifter (Sec.

ЗБ)

BALL AND SPRING RETAINER PUSH 000

•

36 Valve lifters -

еХ8miпаtiоп

and renovation

1 The fa ces of the valve Hfters whieh Ьеаг оп the cam5haft shoLJ1d 5how по signs of pitting. scoring ог other forms of wear. They 5hould al50 по! Ье а 1005e fit in their housing. Wear i5 only normally eneounte red at уегу high mileages ог in eases of negleeted engine lubrication. Renew jf necessaгy . 2 A"lthough it is p05sibIe to di5mantle the hydraulie valve lifters Ьу removing the spring еН рэ and tapping out the valve assembly , it is not worthwhile fitting new components to ап old va lve body and the besl poliey is {о renew all the va lve lifters whenever а major engine оуег ­ Ilaul i5 ea rried out.

PLUNGER SPRING

LIFТER

BOD'f

ASSEMBL'f

Fig. 1.27 Туре 2 hvdraulic valve lifter (Sec . 35)

• •

l•

•

Chapter 1 Engine

37 V.tves and vBlve seats - examination

I

,

апd

зз

renovation , the cylinder head(s) should Ье given {о уош Ford dealer ог 'оса' engineerlng works who will Ье аЫе {о remove the old seats and in5t811 new ones.

renov8tion

1 W \th the valves removed from the cy1inder heads examine the heads for signs of cracking, burning away and pitting of the edge where it seats 1 п the рап. The зеаts of the valves in the cylinder head should а ] so Ье examined far the sэmа 51gn5. Usuatly it i5 the valve that deteriora tes fir5t but if а bad valve 15 not rectified the seat wi1l suHer аnd this i5 more difficult to repair. 2 Providing the valve heads and seats аге not cracked ог badly pitt ed. minor Ьиrn marks and bIemishes сап Ье ground out using саг­ boru ndum paste. This тау Ье done Ьу placing а sтезг of carborundum paste ОП the edge of the valve and, using 8 suction-type valve holder. grinding the valve in-situ. Thls is done with а semi-rotary action, twisting the handle of the va lve holder between the hands and lifting ;t occasiona lly to redistrlbute the paste . Use а coarse paste to start wlth and finlsh wlth а flne paste. As soon as а matt gray unbroken line appears оп both the valve and the seat , the valve is 'ground-ln'. АН traces of сагЬоп should also Ье cleaned from the head and the neck of the valve stem. А wire brush mounted in а power drill Is а quick and effective way of doing this. 4 Another form of valve wear сап occur оп the stem where 11 runs 1п the guide in the cylinder head. This сап Ье detec1ed Ьу trying to rock the valve from side-to-side. If 1here Is апу movement at all It Is ап Indication that the valve stem ог guide is worn. Check the stem first wlth а mlcrometer а1 polnts all along and around its leng1h ; if they аге по1 within the specified size, new valves wlll ргоЬаЫу solve the probJem. If the guides аге worn, however, they wlll need reboring for oversize valves ог for Installlng guide inseгts. The valve seats will also need recutt ing {о ensure they аге concentric with the stems. This work should Ье given to уоиг Ford dealer ог local engineering works. 5 When all valve grinding Is completed it Is essential that every trace of grinding paste is removed from the valves and ports in the cylinder head. Thls should Ье done with thorough washing in gasoJine ог kerosene and btowing out with а jet of air. If particles of carborundum paste should work their way into the engine they would cause havoc with bearings ог cylinder walls. 6 The Boss 429 engine is equipped with aluminium cylinder heads and the valve seats аге а shrink-fit in the head. If the seats аге beyond

Э8

Timing chain and .procket. - 8xamination and renovation

1 Examine the sprocket teeth for excessive wear and renew if necessary. 2 Check the timing chain for wear and slackness 1п 1he pins and links. As а guide, temporarily install the chain and sprockets, and rota1e the crankshaft 50 that опе side of the chain Is under 1еП510п. Now check that the maximum possibIe sideways movement of the stack side of the chain does по! exceed t in (12 .5 тт). 3 If апу doubt exists regarding the condition of the chaln the most sensibte policy is 10 renew It.

39 Flywheel (in9

9ваг

- examination and r8novation

1 If the ring gear is badly worn ог ha5 missing teeth it should Ье renewed. The old ring сап Ье removed from 1he flywheel Ьу cutting а notch between two teeth with а hacksaw and then splitt;ng it with а cold chisel. 2 То install а new ring gear requires heating the rlng 10 400°F (204°С). This сап Ье done Ьу poli5hing four equally spaced 5ections of the gea r, laying it оп а suitabIe heat resi5tant suгface (such as fire bricks) and heating It evenly wlth а bIow lam p ог torch until the polished areas turn а light yellow tint. 00 по! overheat ог the hard wearing properties will Ье lost. The 9еаг has а chamfered 1ппег edge which shou ld go against the shou lder when put оп the flywheel. When hot enough place 1he gear in position quickly, tapping i1 home If necessary, and let 11 сооl пашгаllу without quenching in апу way.

40 Oil pump - oV8rhaul

1

1 The oil pump maintains а pressure of around 45-60 Ibf/in 2 • Ап oil pressure gauge is fitted to give earlier warning of falling oil ргеззигез

DISTRIBUTOR INTERMEDIATE DRIVE

SHAFТ

Fig. 1.28 Exploded Vi8W of oil pump (Sec. 40) OIL RELIEF VALVE

r --

ВООУ

IDENTIFICATION MARKS ROTOR AND SHAFT ASSEMBLY

PLATE

Chapter 1 Engine

з4

F•• I.r Goug.

Fig. 1.30 Checking the clearanc8 between the outer rotor and 011 pump housing (Sec. 40)

..... Fig. 1.29 Сhесkiпя the oil ритр inner rotor lobe clesrance (Sec. 40) due to overheating ог general wesf. 2 А! а major engine overhaul 1t 15 аз well to check the pump and exchange 1t for а reconditioned unit 1f necessary. The efficient орега­ t10" of the oil pump depends оп the finely machined tolerances between the moving parts of the rotor and the body, and recondition-

i"g of these 15 generally not within the competence 01 the

Sfrolght Ed,.

"оп­

specialist owner. 3 То dismantle the pump, fir5t гетоуе it from the engine, as described in Section 21. 4 Аеrnоуе the two bolts securing the i"'et tube and filter to the pump body; гетоуе the 1"'et tube and rellef valve components which will Ье released. 5 Аетоуе the four bolts securing the rotor end plate, and 11ft off the plate. 6 The necessary clearances тау now Ье checked using а machined straight-edge (а good steel rule) and а 1eeler gauge. 7 Оп bl-rotor type pumps the critical clearances аге between the 10Ьез 01 the center rotor and сопуех 1aces 01 the outer rotor, between the outer rotor and the pump body, and between both rotors and the end соуег plate. 8 The rotor 10Ье clearances тау Ье checked as shown 1п Flg. 1.29. The clearances should not exceed 0.006 in (0.15 mm). The clearance between the outer rotor and ритр body should not exceed 0.01 О 1п (О.25 mm). 5 •• Fig. 1.30. 9 The end110at clearance сап Ье measured Ьу placlng а steel straight-edge across the end of the pump and measuring the gap between the rotors and the straight-edge. The gap оп either rotor should not exceed 0.005 in (0.13 mm). See Fig. 1.31. 10 If the only excessive clearances аге end110at it is possibIe to reduce them Ьу removing the rotors 1гот the pump body and lapping away the lасе 01 the body оп а 11at bed until the necessary clearances аге obtained. 1I must Ье emphasised, however, that the 1асе 01 the body must remain peгfectly 11at and square 10 the axis 01 the rotor spindle otherw ise the clearances will not Ье equal and the end соуег will not Ье а pressure-tight 1it to the body. It Is worth tryin9 , 01 соигзе, 11 the pump 1з in need 01 renewal anyway, but unless done properly It could seriously jeopardise the rest of ап overhaul. Апу var1at10ns in the other clearances should Ье оуегсоте with ап exchange unit. 11 When reassembIing the ритр and instatling the end соуег, make sше that the interlor Is scrupulously clean and that the pressure rel1e1 valve parts аге assembIed in the correct positlons.

41 Cylinder heads and piston crowns - decarboniz8tion 1 When cylinder heads аге removed either in the course 01 ап оуег­ haul, ог 10г inspection 01 bores ог valve condition when the engine is in the саг , it is normal to гетоуе all сагЬоп deposits from the piston crowns and heads. 2 Thls 15 best done with а cup-shaped wire brush and ап elect ric drill and is 1airly straight10rward when the engine is dismantled and the pistons removed. Sometimes ha rd spots 01 сагЬоп аге not easily removed except Ьу а scraper. When cleaning the pistons wlth а зсгарег take саге not to damage the suгface of the piston in апу way.

F•• I.r

Fig. 1.31 Checking the oil pump rotor endfloat (Э_с. 40) 3 When the engine Is in the саг certain precautions must Ье taken when decarbonizing the pislon crowns, in order to prevent dislodged pieces 01 сагЬоп 1allin9 into the interior 01 the engine which could cause damage to cylinder bores, pistons and rings - or If allowed into the water passages - damage to the water pump. Tuгn the engine, there10re , so that the piston being worked оп Is at the top 01 its stroke and then mask off the adjacent cylinder Ьоге and all surrounding water jacket cha nnels with рарег and adhesive tape. Press grease into the gap all round the piston to keep сагЬоп particles out and then scrape all сагЬоп away Ьу hand care1ully. 00 not use а power drill and wire brush when the engine is in the саг аз it will Ье v irtually impossibIe to keep all the сагЬоп dust clear of the engine. When completed, care1ully clear out the grease Tound the rim 01 the piston with а matchstick ог something similar - bringing апу сагЬоп particles with it. Repeat the process оп the other seven piston crowns.

42 Rock_,

о_вг

- examination and renovation

1 The rocker arms should Ье examined 10г signs of excessive wear and, оп engines equipped with shaft-mounted rockers, the shafts should Ье checked 10г possibIe distortion. 2 Check the shaft 10г straightness Ьу rolling it оп а 11at suгface. It is most unlikely that it will deviate from normal, but 11 it does, then а judicious attempt тау Ье made to straighten it. 11 this is not success1ul purchase а new shaft. The suгface 01 the shaft shoutd Ье 1гее 1гот апу worn ridges caused Ьу the rocker arms. 11 апу wear is evident renew the rocker shaft. Wear is likely to have occurred only i1 the rocker shaft oil holes have Ьесоте bIocked. 3 Check the rocker агтз for wear 01 the rocker bushes, 10г wear at the rocker агт 1асе which Ьеагз оп the valve stem, and 1ог wear 01 the

,

Chapter 1 Engine adfU51 ng ball-ended screws. Wear in the rocker агт bush сап Ье checlted ьу gripping the rocker агт tip and holding the rocker агrn in piace on the shaft, "oti"g if there 15 зпу lateral rocker агт shake. If эпу $hake 15 present, and the дгт i5 10056 оп the shaft, remedial action must ье taken. It i5 recommended that элу worn rocker агт Ье taken 10 the 'осаl Ford dealer ог automobile engineering works to have the old bush drawn out and а new опе installed. 4 Check the tip of the rocker arm where it bears ОП the valve head. foг cracking ог serious wear оп the case-hardening. If попе i5 present the rocker агт may Ье re-installed. Check the pushrods far straightness Ьу rolllng them оп а flat surface.

43 Engin&

г&аааетЫу

- g8"&ral

1 AII components of the engine must Ье clea"ed of оН sludge and old gaskets, and the working areas shoutd also Ье clear and clean. In addltion to the погтаl range of good quallty socket wrenches and general tools which аге essentii.il , the following must Ье availabIe before reassembIy begins: (8) Comp/ete set 01 new g8skets (ь) Supp/y о{ clean f8gS (с) Cfean оН сап (u" о{ new eng;ne 0# (d) Тorque wrench (е) А" new spare P8fts as necess8ГY

44 E"gine

геаазетЫу

I

4 Select the halves of the five main bearing shells that have the 011 slots and grooves and position them into the crankcase bearing housIngs (photo). Ensure that the notches in the ends of the shells аге correctly located in the cut-outs in the housings. 5 Note that the center main bearing shells have flanges, which act аз thrust washers. These аге availabIe in various thicknesses in order 10 Ье аЫе to set the crankshaft endfloat. 6 Push the иррег half of lhe crankshaft 011 seal into the recess at the геаг of the crankcase (photo). For fuгther information оп installing the геаг crankshaft oil зеаl refer to Section 25. 7 Lubricate the crankshaft journals with engine оН and carefully lower the crankshaft inlo position (photo). 8 Place the lower (plain) shells inl0 the main bearing caps (phOl0). 9 Push the lower half of the crankshaft 011 seal Into the recess '" the геаг main bearing сар (photo). 10 Position the геаг and center main bearlng сарз оуег the crankshaft and temporarily tighten the retaining bolts (photos). 11 Check the crankshaft endfloat using feeler gauges (photo). If the endfloat is not within 0.004 to 0.008 in (0.1 to 0.2 тт ) the crankshaft should Ье removed and the center thrust bearings replaced with ones of the песеззагу thickness to achieve this tolerance. 12 When the crankshaft endfloat is correct. in5tall all the main bearing caps and retaining bolts. Note that the bearing caps should Ье marked with а питЬег from 1 to 5 and ап arrow 10 епзше that they аге installed 1п the correct position (photo). 13 Finally, tighten the main bearing сар bolts 10 the specified torque wrench setting (photo). Note: Оп certa;n 80ss-type eng;nes the mа;п bear;ng caps аге secured а diagonal sequence.

- camshaft and crankshaft

the camshaft carefully i"to the bIock, taking саге not to let апу of the сат 10Ьез damage the bearing bushes (photo). 2 Install the camshaft thrust plate and secure it with the two screws. These screws must Ье tightened firmly (photo). 3 Ensure that the crankcase is thoroughly clean and that all oilways аге clea r. А thin twist drill is usefut for clearlng the oilways, or if possibIe they тау Ье bIown out with compressed а1г. Treat the crankshaft in the same fashion, and then inject engine 011 into the oilways. 1

35

Ьу {ouг

bolts 8nd these must

Ье

t;ghtened

;п

Inseгt

45 Engine reassembIy - pistons. connecting rods and oil pump

1 The subsequent paragraph5 оп аззетЫу аззите that all the checks described in Sections ЗЗ and 34 have Ьееп carried out . Also the engine has been paгtially assembIed as described in Section 44. 2 The assembIy 01 new pistons to connecting rods should have Ьееп

1

FLYWНEfL

CLUТCH МAfN

PILOT BUSHING

BEARING

CRANKSHAFТ МAIN

CRANKSHAFТ

КЕУ

BEARING INSfRTS

FRONT

REAR OIL SEAL

I

• DAМPER

PULLEY

I

BEARING CAPS

Fig. 1.32 Exploded view of cr8nkshaft and 8ssociated components ISec. 44)

44.1 In5talling the cam5haft

44.4 Inst811ation of center main bearing shel l

44.2 In5tall1ng the camshaft thrust plate

r 44.6 In5tarlation of

гваг

main bearing and oil

seal

44.9 Oil seal receS5 in

геаг

main bearing

С8Р

44.7 Loweting the crankshaft Into the cylinder

44.8 In5talling

bIock

bearing

44.1 од Instatling the

геаг

main bearing

сар

...

44 . 10В

а

shell bearing into

а

main

сар

.. . followed

Ьу

the center main bearing

сар

44.1 1 Checking the crankshaft endfloat

44.12 Identification mark оп main bearing

сар

44.1 3 Tightening the main bearing

сар

bolts

Chapter 1 Engine INSTALL SEAL WITH LIP TOWA<1QS FRONT

fRONT OF ENGINE )

•

,..

SЕдL НALVE S ТО

PR QTRUDE BEYQНO P"RTINC; F"'CES l'HIS 01;1 ANCE ТО ALLOW FOR САР '10 BLOCK AL!(;HMEIН

I

I

t ..

OF "Ед!! _IN дно CYLINDER BLOCK

RЕд!! FдСЕ

ВЕДRINС; сдР

VIEW LООЮt!G ДТ PA.RTING FA.CE OF SPLIT LIP. TYPE С Rдt!КSНд FТ SEAL

Fig. 1.33 Method of installing crankshaft

геаг

oil seal (Sec . 44)

'ЕАС

Fig. 1.34 Applying se81er to геаг main bearing caps (Sec, 44)

UPPER COMPRESSION RING

lOWER ..._ _--.:COMPRESSION ~ RING

Oll RING ASSEMBlY

37

carried out as detailed in Section 24. The new pistons should

supplied with rings already instal'ed . 3 If new rings аге being instal'ed 10 existing pistons. make sure that each ring groove in the piston i5 completely cleaned of сагЬоп

deposits. This i5 done mast easily Ьу breaking опе of the old rings and using the sharp end as а sсгарег. Ве careful not 10 remove апу metal from the groove Ьу mistake I 4 The end-gap of the new piston rings - three far each piston - must Ье checked in the cylinder bores as described in Section ЗЗ. 5 The minimum gap for аН three rings must Ье within Specifications . If the gap is too small , опе end of the ring mU$t Ье filed to increase the gap. То do this the ring should Ье gripped in а vise between two thin pieces of soft metal in such а way that only the end 'о Ье filed is gripped and $0 that it only protrude$ above the ;aw$ of the vise а very $mall distance. This will eliminate the possibility of bending and breaking the ring while fШпg the end . Use а thin . fine file and proceed in easy stages - checking the gap Ьу replacing the ring in the Ьоге until the necessary minimum gap is correct. This must Ье done with every ring, checking each опе in the Ьоге to which it will eventually Ье fitted. То avoid mistakes it is best to complete опе set of rings at а time, and replace the piston in the cylinder Ьоге before proceeding to the next . 6 То install the rings оп to the pis10ns calls for patience and саге if breakages аге to Ье avoided. The three rings for each piston must all Ье fitted over the crown. so obviously the first опе (о go оп is the slotted oil control ring. Hold the ring over the (ор of the piston and spread the ends just enough to get it around the circumference . Then , with the fingers ease it down, keeping it рагаllеl (о the ring grooves Ьу 'wa lking' the ring ends alternately down the piston . Being wider than the compression rings по difficulty should Ье encountered in getting it over the first two grooves in the piston. 7 The lower compression ring , which goes оп next, must only Ье fitted опе way up. It is marked тор to indicate its upper face. е Start installing this ring Ьу spreading the ends to get it located over the top of the piston . 9 The lower compression ring has 10 Ье guided over the top ring groove and this сап Ье done Ьу using а suitabIy cut piece of tin which сап Ье placed so as to cover the (ор groove under the ends of the ring. 1О Alternatively , а feeler bIade may Ье slid around under the ring to guide it into its groove . 11 The (ор ring тау Ье installed either way up as it is Ьаггеl faced . 12 With the rings installed , the piston!con necting rod assembIy IS ready for installing in the cyl inder. 13 Each connecting rod and bearing сар should have Ьееп marked оп removal , but in апу case the cytinder number is etched lightly оп the end of the сар and connecting rod alongside !photo). 14 The connecting rod and bearing caps аге numbered from 1 to 4 in the right bank of the cylinder bIock and from 5 10 е in the 'еп bank with the lower number commencing at the frOn1 of the bIock. The numbered side 01 the rod and сар must face toward the outside of the cylinder bIock and the notch in the top 01 the piston must face toward

PISTON PlN CONNECТlNG

- -1

NUT_+-

Fig. 1.35 Piston and connecting rod assembIy - typical (Sec. 45)

Ье

45.13 Identification numbers

оп

connecting rod and bearing

сар

1

Chapter 1 Engine

з8 ~ е

front o f the engine. Оп 351 НО engines the aгrQW ОП top of the t)tS:On must face inboard (эее Figs. 1.36 and 1.37 and photo). IMPORTAN T : Опе side о( the bearing сар and connecting rod is chamfered and this must Ье positioned towдrd the crank pin thrust !асе о!

18 Pu sh the pisto n Into the cylinder Ьоге (the correct way round) untll the 011 control rlng abuts the face of the bIock. Then , uslng а piston ring compressor contract the rings and tap the piston Into the cylinder (photo). Take great с аге t o Ье sure that а rlng is not trapped оп the top edge of the cylinder Ьоге and when tapping the piston in do not use апу force. If thls is not done the rlngs could easily Ье broken. 19 When the piston has Ьееп fully located in the Ьоге push It down зо that the end of the connecting rod seats о п the journa l оп the crankshaft. Make зиге the journa l 1з welllubricated w ith engine 011 . 20 Maintalning absolute clean liness all the tlme , Install the other shell bearlng ha lf Into the сар , оп се agaln with the notches 1п the bearing and сар lined ир (photo). lubricate it wlth englne 011 and Insta ll It to the connecti ng rod зо that the holes in the сар fi t to the dowels in the conne cting rod.

the crankshaft 10 allow !ог the sma" radius between the jouгnal

and web (ph010). 15 8efo(8 installing the pistons, posi tion the three rings around each

piston

50

that the gaps

аге

spaced from each othe r as shown in Fig.

1.38. 16 Clean the cyli nder b ores using а cJean piece of lint-free cloth . and lubrjcate the bores with some eng ine oil . 17 In51atl а new shell bearing half into t he first connecting rod ensuring the оН feed hole in the shell tines up with the hole in the conne ct ing rod (photo) .

LEFТ ВАНК

R:IGНT ВАН К

АIGНТ

NOT CH TOWARD F RON T ENGI NE

BANK

LEFT BANK

ARROWS PO INT I

QF ROO а

SlaE OF

А оа

t Fig. 1.36 Correct positionlng of pistons and connecting rods (Sec . 45) Flg. 1.37 Correct posltionlng of pistons and connecting rods used in type 351 НО englnes (Sec . 45)

45 . 14А

Natches in plston crown must face towards the front of the engine .. .

O IL RING 5PACER А

OJl RJNG 5EGMENT

,.

/ '~

OJL RING SEGMENT

\ -

,

/

•

/ 45 . 148 .. . and t he chamfered side of the

\ ,

сопп -

PIN BORE

ect ing rod and bearing сар must face the radiu$ between the cran kshaft journal and web

С PIHON

i

COMPRE5SIQN RING FRONT O F ENG INE

Fig.

45 . 17 In$tal lln9 ./

t

bearin9 $hell

оп а

connecting

rod

С

j COMPRE5SION

а

RING

1 .38 Spacing the piston ring gaps (5.с.45)

I

45.18 Tapping

а

pi$ton into the cyli nder bIock

45.20 Install1n9 Fig . 1.39 Tapping

а

piston l"to the

(5.с.45)

Ьоге

ecting rod

сар

а

shell bearing into

а соп п ­

Chapter 1 Engine 21

Insta .

I 11 pistons and connecting rods in

оо!

а

similar manner and do mistakes locating the correct number piston in the

m l ke апу CQfrect borе . 22 When 811 the connecting rod caps аге correctly installed, tighten the securing nuts to the specified torque wrench setting (photoJ . 23 Before installing the оН pump, prime it Ьу filling the inlet роп with engine oil and rotating the driveshaft to distгibute it. 24 In5tall the hexagonal driveshaft into the pump body noting that the end with the spring washer must Ье furthest away from the pump. 25 Carefully install the driveshaft and pump into the bIock ensuring that the end of the shaft 1з correctly entered into the distributor apeгture {photoJ. 26 Secure the pump in place with the two retaining bolts, and install the f1lter and pipe аззетЫу (photoJ.

46 Enginl 1

геа888тЫу

- timing chain and timing

СОУ8Г

Install the spacer onto the end of the camshaft

ensuгing

that the

з9

510t is correctly located Qver the dowel (photo). 2 Aotate the camshaft 50 that the dowel i5 facing downward and then rot8te the crankshaft 50 that the keyway in the front end of the crankshaft 15 facing upward in line with the camshaft dowel. Note: If

the t8sk is being caгried оut with the engine in the vehicle and the distributor has not Ьееп removed, lift о" the distributor сар and check that the rotoг is pointing toward the No. 1 cylinder spark pfug lead position. If it is not, rotate the camshaft 1800. 3 Lay the camshaft and crankshaft 5prockets оп the bench 50 that

the single dot

ОП

the camshatt sprocket perimeter

i5

directly opposite

mark оп the crankshaft sprocket. Maintain them in this position instatl the timing chain around both sprockets. Carefully install both sprockets and the chain onto the camshaft crankshaft, and tap them onto the dowel and keyway гespectively. 5 Now make а careful check to ensure that the tim ing marks аге still correctly aligned (photo and Fig. 1.40J. 6 Position the fuel pump eccentric оп the camshaft dowel and secuгe it with the washer and bolt , (photoJ. Tighten the bolt to the specified torque wrench setting. the and 4 and

."•

•

I

I

45.22 Тightening the connecting rod nuts

46.1 Installing the camshaft

зрасег

45.25

IпstаШпg

tM

оН

pump and driveShaft

45.26 Installing the oil pump inlet pipe and filter

46.5 Alignment of camshaft and crankshaft sprocket timing marks

T IMING

I

МARKS

Fig. 1.40 Correct alignment of camshaft end crankshaft timing marks (Sec. 46)

46.6 Installing the fuel pump operating tric

ессеп­

46.7 Location of crankshaft oil thrower

1

46.8 In5tallin9 the timin9 cover oil 5eal

46.9 Lowering the timing cover into position

46.1 О Installation of the cra nkshaft damper

REAR

47.3 Correct interlocking of oil gaskets

.

Fig . 1.41 Location of oil рап gaskets and seals - typical (Sec. 47)

рап

seal5 and

47.7 Flywheel in position

оп

the crankshaft

\

47.8 Inslallin9 lhe flywheel retai nin9 bolts

48.2 Inserting the valves in the cyJinder head

УО!'''': Spri"9

Cornpresso •

48. 3 Location of valve stem sea l

48.5 Inslal lin9 lhe valve retainer

Fig .

1 .42

Соmргеssiпg а (50с . 48)

valve

•

SРГlпg

•

<~.- '

•

"

Chapter 1 Engine

I I

7 Place the оВ thrower in position оп the end of the crankshaft (photo). 8 Install д new sea! in the timing соуег apeгture ensuring it i5 the соггес! way round (photo). Тар it fully home using а 11аl bIock of WQod. 9 Se lect the fronl соуег gasket and using а su itabIe sealing соm­ pound position it оп the engine fronl pl8te and offer up the соуег (photo). 10 Place the front соуег bolts in positioll and screw them ир loosely. Then install the crankshaft damper onto the keyway of the crankshaft (photo). See that the boss o f the damper is lubricated where the oil sea l runs. 11 The in5tallation of the crankshaft damper, before tightening the соуег bolts, centralises the seal to the diImper. The bolts holding the соуег тау then Ье tightened 'о the specified torque setting.

47 Engine reassembIy and flywheel

~

I t

геаг

plate. crankshaft damper. oil

рап

48 Engine reassembIy - valve gear. cylinder heads. and intake manifold 1 When the cylind er heads have Ьееп decarbonized and the valves ground in as described in Sections 37 and 41. the cylinder heads тау Ье reassembIed. If the valves have Ьееп removed as described in Sect ion 12 there will Ье по confusion as to which valve bel ongs in which position . 2 Make sure al l traces of саФоп and grind ing paste have Ьееп removed . lubricate the valve stem with engine oi l and place it in the appropriate guide (photo). It will then protrude through the (ор of the cylinder head . 3 Install а new seal cup оуег the valve stem (photo). 4 Pla ce the valve spring оуег the valve "tem . Note that оп some engines а spacer is fitted between the spring and cylinder head .

а

hydrauljc valve lifter into the

5

Instal l the circular retainer оуег the spring w ith the protruding center boss retainer downward (photo). 6 Using а ргорег valve spring compressor tool . compress the spring down the valve stem sufficiently far to епаЫе the two halves of the locks (eol lets) to Ье installed into the groove in the valve stem. If necessary the locks should Ье smeared with grease to keep them in position. The spring compressor тау then Ье released . Watch to ensure that the locks stay together in position аз the retainer comes past them . If the retainer is а little off-center it тау foree опе lock out о' its groove in which case the spring must Ье recompressed and the lock repositioned. When the compressor is finaHy released, tap the head of the valve stem with а soft mallet to make sure the valve assembIy is securely held in position . 7 Stand the engine the right way up оп the bench and install the valve lifters if they have Ьееп removed from the bIock. If these have Ьееп kept in order оп removal, as suggested . it will Ье а simple matter to install them (photo ).

/ nstalling the cy/indeг heads (s tandaгd engines)

1 If the engine гваг plate has Ьееп removed it should now Ье installed . Make sure that both metal faces аге quite clean before installation . No gasket is used. 2 In5tall the bolt and washer which locate the crankshaft damper, bIock the erankshaft with а piece of wuud against the side of the crankcase and tighten the bolt to the specjjled torque setting . 3 Clean аН traces of old gasket which тау remain from the oil рап joint faces and соуег the faces of both the crankcase and рап with jointing compound. The oil рап gasket is in four sections which dovetail together and these should Ье ca refully positioned and the joints interloeked (photoJ. 4 The engine is then ready for the oil рап to Ье installed . 5 Clean the interior of the рап thoroughlY, apply jointing compound to the joint edge and place it in position . 6 Inst atl а" the oil рап bolts and tighten them evenly. 7 The flywheel тау now Ье installed . lv1 ake su re that the mating flanges аге clean and free from burrs, and line up the bolt holes correetly !photoJ. 8 Offer up the spacer (where appl ica bIe / and screw in the six reta in~ ing bol t s. Tighten them evenly to the specified torque wrench setting (photoJ .

48 .7 Inserting bIock

41

48 . 8А

8 Make sure that the cylinder head and bIock faces аге clean and free from grease ог oil , and place the new head gasket in position . То ensure сопесt location the word FRONT is usually marked оп the иррег side of the gasket (photos). 9 Carefully place the cylinder heads in position оп the bIock (photo) . 10 Make sure the cylinder head bolts аге clean and lightly oiled , and install them. Nip them all down lightly and then tighten them in the sequence shown in Fig. 1.1 З . The bolts should Ье tightened down to progressive torque loadings - а" to 50 'Ы ft (6.9 kgf т) then а" to 60 Ibf ft (8.30 kgf mJ , and finally to the specified torque wrench setting. 11 Now install the pushrods into pos;tion , making sure that they аге installed the same way up as they сате out and aeeording to the original valve position. This will not Ье diffieult if they have Ьееп kept in order (photo).

/nstalling the cy/indeг heads (80ss 429 engine) The Boss 429 engines use special seals 8nd g8skets in place 01 the сопуепаопа' cyNnder head gasket and the loflowing procedure must Ье used when installing the cylinder heads. 12 Thoroughly clean the eylinder head and bIock mating suгfaces with а clean pieee of cloth soaked in chlorathane . 13 Coat the upper end of the cylinder head and bIock with а si li cone rubber priтer such as Dow Corning А -4094 . Coat the gasket counterbores in the eylinder head with а qui ck dгying adhesive sealer to ргеуеп! the gasket dropping ou t when the head is lifted into position . 14 Install four of the coтbustion chaтber gaskets in the counterbores ensuring the tabs аге seated down. 15 Install four 01 the t in (6 тт ) gaskets into the cylinder head counterbores with the stepped side fac ing up. 16 In5tall seventeen of the t in ( 12 тт ! gaskets into the cyli nder head counterbore5 with the stepped side facing up. 17 Apply а continuous strip of sealant along the top edge of the cyli nder head . 18 Install а steel rod of suitabIe diameter into опе of the bolt holes in each end o f the cylinder bIock. These will act as guides when lowering the head in to position. ЕП5ше that the rods аге long enough to Ье w ithdrawn after the head is in place . 19 Carefully lower the cylinder head into position оуег the guide pins.

Cylinder head gasket in position

48 .88 The word FRONT ensures corгe ct posit ioning 01 the cylinder head gaskets

1

Chapter 1 Engine

42

COOLANT TEMPERATURE SENOING UNIТ

(

~CARВUREТOR

\\ANIFOLD- TD·BLOCK FRONT SEAL

SPACER

REGULATOR VAlVE VENT HQSE

о 48.9 CyHnder heads positioned

оп

bIock

BOLT _ _ _~

МANIFDLD- ТО·НЕАD

GASKET

MANIFDlD-ТD-8LОСК

REAR SEAl

60LT- " ' / "

48 . 11 Inserting the pushrods

Fig. 1.43 Location of inlet manifold gaskets - typical (Sec. 48)

Make sure that попе of the gaskets drop out 01 the head. 20 Screw in eight 01 the cy1inder head bolts and washers but do

поl

tighten them fully at this stage. 21 Аетоуе the two guide rods and install the remaining two cylinder head bol ts. 22 Тighten the bolts in sequence {о ап initial torque wrench setting of 60 'Ы ft (8 .2 8 kgf т). Next, torque tighten them {о 80 Ibf ft ( , 1.0 kgf т) ; finally, torque tighten them to 90/ 95 Ibf ft (12.4/ 13.1 kgf т ). 23 Rереа! the above procedures with the other cylinder head. 24 Install the pushrods аэ described ,п paragraph 12 of this Section. АII

engines

25

Оп

engines with stud- mounted rockers , position the rocket агтэ over the pushrods and valve stems, and carefully tighten the retaining nuts (bolts оп some engine5) jU5t enough to retain the pU5hrods in their correct positions. 26 In the с аэе 01 shaft-mounted rockers, lubricate the shafts with clean engine oil and rea5sembIe the rockers. springs and pedestals onto the shafts in the correct order (эее Fig. 1.16). 27 Insta ll the rockers and shafts to the cyli nder heads , and tighten down the retaining bolts progre55ively 10 avoid distortion 01 the 5hafts. Тighten lhe bolt5 to а torque wrench setting 01 40/ 45 Ibf ft (5.5/ 6.2 kgf

ml. adjusted either now ог at а later stage аэ described ,п the following Section. 29 То install the inlet manilold, firsl епэиге that the cylinder head • 1асеэ аге clean and then lightly coat them with а suitabIe jointing с отpound. 30 Careful ly stick the ga5ket5 in place ensuring that the smaH 1ront and геаг piec es аге interlocked with the two main gaskets (photo) . 31 lower the intake manifold carefully into place and check that попе of the gaskets ha ve Ьееп pushed out of position (photo ). 32 In5ert the intake manifold securing bolts. Note that some 01 the bolts аге longer than others and саге must Ье taken to епэиге that they аге installed in the соггес! hole . 33 Tighten the intake manifold bolts progressively in the appropriate 5equence shown in Figs. 1.7, 1.8, 1.9, 1.10, 1.11, ог 1.12 . FinaHy tighten them (о the specilied torque wrench setling.

28 The valve clearances

тиэ! Ье

49 Valve lash - adjustment 1 With the exception of ce гtain high-performance versions of the V8 engines which include lhe Boss 302, 351 and 429 series, all slandard engines аге equipped with hydraulic valve lifters. The5e automatically compensate 10г valve gear wear and опсе the initial clearance ha5 Ьееп corгec tly 5et по further adju5tment will Ье required until а соп­ siderabIe mileage has Ьееп covered. 2 The 390, 427 and 428 engines аге fitted with shaft-mounted rocker агтэ which аге поп-аdju5tаbIе. The correct clearance is obtained Ьу in5ta11in9 а IOnger ог shoгter pU5h rod as necessary. These аге availabIe ,п increments 01 0.060 in (1.5 тт) and сап Ье obtained Iгот уоиг Ford dealer. 3 50те of the early 302 си ,п en9ine5 аге equipped with adju5tabIe rocker5 but all later V8 en9ines have positive-stop rocker mounting studs . Оп the 1огтег type the correct valve clearance is obtained Ьу screwing the rocker агт locknut up ог down as necessary , while оп the latter 'уре the nut is screwed right down until it stops. 11 the clearance is then found to Ье outside the specified limits, а longer ог shoгter pushrod must Ье installed , as necessary. These аге obtainable from your Ford dealer. 4 The later positive-stop type rocker stud сап Ье identified Ьу the lact thal the plain section 01 the stud nearest the cylinder head is larger in diameter than the threaded portion . 5 8е1оге commen cing adjustment . ensure that the rocker агт locknuts аге in good condition and the fulcrum spacer slides easily оп the rocker 5tuds . 6 Оп the earlier 302 с и ,п engines with adjustabIe rocker arms , proceed Ьу rotatin9 the crankshaft until No 1 piston is at ТОС (top dead center) of the compression 5troke. Thi5 сап Ье a5certained Ьу removing the spark plug and with а linger placed over the hole. rolatin9 the crankshalt until pressure is lelt. This indicates the piston is rising оп the compre5sion stroke. Continue to rotate the crankshaft until the timing pointer оп the Iront cover is aligned with the ТОС mark оп the crankshaft damper (photo). 7 Push down the No 1 cylinder rocker arms эо that the pushrod 10rces the valve lifter down into the completely collapsed position.

•

Chapter 1 Engine

48.30 Correct positioning of intake manifold gaskets

48.31 Installation of intake manifold

43

49.6 Alignment of pointer and crankshaft damper

ТОС

mark

оп

,

\

1

Fig. 1.44 Checking the valv8 clsarances оп 8ngin8 equipped with hydraulic lifters. Note that thaspecial tool shown i8 not Bssential 1ог this task (Sec . 49) Using feeler gauges, check that the clearance between the rQcker агт and valve st8m i5 within the 11mits given а1 the end of this Section. 9 Adjust the clearances аэ necessary Ьу turning the rocker агт reta ining nut up ог down using а socket wrench (photo). 1О When the No 1 cylinder valve сlеаГ8псеs аге correct, rotate the crankshaft until the next piston i5 at the тое position of the coтpres5ion stroke and adjust the valve clearan ces as descгibed for No 1 cylinder. Continue to adjust the remaining valve clearances following the appropriate firing order sequence given in the engine Specificatlons. 11 Оп later engines with the positive-stop rocker агт studs, the piston must Ье set to the ТОС position аз described previously and then the rocker агm nut must Ье screwed down fully and tightened to а torque wrench setting of 18 to 20 Ibf ft (2.4 to 2.5 kgf т). Push the rocker агт down so that the valve lifter is in the fuHy co llapsed position and check the clea rance between the rocker агт and valve stem using feeler gauges. 12 If the clearance is not within the specified dimensions, the pushrod must Ье replaced with ап oversize ог undersize опе as appropriate. 1 3 The valve clearances оп engines with shaft-mounted rockers аге al50 adju5ted Ьу using undersize ог over5ize pushrod5. Note : When оЫв;n;nу replscement pushrods, always take the old pushrod along to уоuг Ford dealer (о ensure that the new rod is the size required. 14 Solid valve lihers. The valve clearances оп engines equipped with 50lid valve lifters аге adju5ted Ьу means of а 5et screw and locknut оп the pushrod end of the rocker агт. 15 With the exception of the Boss 429 engines, final va lve adju5tment 5hould only Ье carried out with the engine hot. However, for initial 5tart-up purp05es fotlowing ап engine overhaul , the valve clearances сап Ье 5et cold and then re-checked after the engine ha5 Ьееп 5tarted and warmed up. The valve clearances оп the Boss 429

49.9 Setting the valve clearance5 оп earlier engine5 equipped with аdjU5tаЫе stud-mounted rocker агт5

8

ТУРЕ

FEELER GAUGE '"

но J

Fig , 1.45 Adjusting the valve clearances оп engines equipped with solid valve lifters (Sec. 49) should only Ье adju5ted when the engine is cold. 16 Begin Ьу rotating the engine until the No 1 piston is а! ТОС оп the firing stroke as described previously and check the No 1 cytinder valve cleara nces using fee ler gauges. If the clearances аге по! within the specified dimensions given at the end of this Section , slacken the locknut and turn the set screw in ог out to decrease ог increase the gap as required . Tighten the locknut and re-check the clearance. 17 Aotate the cra nkshaft 900 until the next piston is at то е оп the

Chapter 1 Engine ng stroke and adjust the valve clearances as described. Continue 10 ad ust the remaining valve clearances following the appropriate firing order sequence in the engine Specifications. ~.

Va/ve c/earances (hydrau/ic /ifters) Engine (си in)

Minimum

Мах/тит

260 and 289 302

0.082 in (2.08 mт) O.067in(1.70mm}

351

0.083 in (2.10

390, 427and428

O.100in (2.54mm)

0 . 152 ;П 0.167 in 0 . 183 in 0.200 in

429

0.075 in ( 1.90mm)

О.175;п

mт)

(3.86 mт) (4.24 mm) (4.64 mm) (5.08 mm) (4.44 mm)

Va/ve c/earances (so/id /ifters) (си "п) 289НР

Engine

3028055 35180ssandHO 429 Boss 429 SCJ

Intake 0.0 18 in 0.025 in 0.025 in 0.0 13 in 0 .0 19 in

(0.45 mm)

(0.63 mm) (0.63 mm) (0.33 mm) (0.48 тm)

Exhaust 0.0 18 in (0.45 mm) 0.025 in (0.63 mm)

0 .025 "п (0.63 mm) 0.0 13 in ro.ЗЗ mm} 0.0 19 in (0.48 тт)

50 Engine rea55embIy - in5t811ing ancillary component5 , The exhaust manifold5 аге best in5talled before putting the engine back into the с аг а5 they provide very useful hold5 if the engine has 10 Ье manhandled а! all. Note that по gaskets аге u5ed оп the exhaust mani10lds. 2 In$t atl each mani10ld, tighten the bolts evenly and bend over the locking tabs (p hotosJ. 3 The ancillary engine components must Ье installed and the method 01 doing this is detailed in the appropriate Chapter$. Section 9 01 this Chapter gives а list 01 the items involved. When thi$ ha$ Ьееп done the engine is ready to Ье put back in the саг. 4 For details оп how {о in$tall the distributor and the method 01 ignition timing , refer to Chapter 4. 51

Eng ine in5tallation - without trBn5mi55ion

The engine mU5t Ье positioned suitably 50 that the sling used сап Ье easily attached and the lifting tackle hooked оп. Position the engine the righ t way round in 1ront 01 the саг and then raise it 50 that it тау Ье brought into position over the саг, ог 1he саг rotled in10 position underneath it. 2 The tran5mi5sion should Ье jacked up 10 its approximately погта' position. 3 Lower the engine steadily into the engine com partmen t, keeping all ancillaгy wires, pipes and cables well clear 01 the sides. 11 is best 10 have а second person guiding the engine while it is being lowered. 4 The tricky part is finally mating the engine 10 the transmission. ,

which involve5 locating the transmission input shaft into the clutch housing and flywheel . Provided that the clutch friction plate has Ьееп cenlered correctly as described in Chapter 5, there should Ье little difficulty. Grea5e the splines 01 the input shaft 1irst. 1I тау Ье necessary { о rock the engine from side to side in order to get the engine 1utly home. Under по circum$tances let апу strain Ье imparted onto the input shaft. This could occur i1 the shaft was not fully located and the engine was raised ог lowered тоге than the amount required for very 51ight adjustment of position. 5 As soon as the engine i5 1ully up to the clutch housing. instatl the bolts holding the two together. 6 Now finatly lower the engine onto its mounting brackets а1 the 1ront. and in5tall and tighten the nuts, and washers. 7 Rе -с оппес1 аtl elec1tical connection5, the fuellines and carburetor linkages, cooting sy51em hoses and radiator in 1he reverse order 10 Ihat de5cribed in Section 5 . 8 Reconnect the clutch саЫе а5 de5cribed in Chapter 5 , install the exhaust pipes and reconnect them 10 the mani10ld extension5, install the plate covering the lower hal1 01 the clutch housing and remove the supporting jack. 9 Fill the engine with fresh oil and refill the radiator with coolant.

52 Engine in5tallation - with

тапиаl

transmission

1 The transmission should Ье installed in the engine , takin9 the same precautions regarding the input shaft as mentioned in Seclion

50. 2

The general principle5 of lifting the engine/transmission assembly аге the same а5 10г the engine atone but the transmission will 1ill everything to а much steeper аП9lе. Installation will c ertainty requ ire the assistance 01 а second регsоп . 3 Lift the transmission end of the unit into the engine compartment (unless you аге fortunate enough to have а hoist with а very high lift) and then lower and guide the unit down. Опе 01 the first things 10 Ье done is to reconnect the рroреllег shaft 1nto the transmission геаг extension casing 50 someone 5hould Ье ready {о lift and guide the ргореllег shaft into position а5 soon as the tгаП5miS5iоп (5 пеаг enough . This саппо! Ье done after the unit has Ьееп lowered beyond а certain position. 4 If а trolley jack is ava ilable this (5 the time to pla ce it under the transmission 50 that а5 the engine is lowered further Ihe геаг end сап Ье supported and raised as neces5ary - at the same time being аЫе to гоll back as required . Without 5uch а jack, support the геаг in such а way that it сап slide i1 pos5ible. In апу case the transmission will have 10 Ье jacked and held up in position when the unit nears its 1inal posilion. 5 Locate the frOnl mounting brackets оп the locating bolts as described in Section 50.

\

50.2А

Installing the exhaust manifolds

50.2 В

ОО поl

retaining bolts

forget the locking tabs when installing the manifold

I

,

Chapter 1 Engine "яа

6

SOC1tet

те

аnd

speedometer drive

саЫе

with the transmission drive

install the snap-ring and bolt. This must

Ье

done before the

trалsrnlSSЮП suppoгting

7

Jack

ир

the

геаг

tюdyfгаmе.

10 the

crossmember i5 in place. of the transmission and position the crossmember

Then i"5tall and tighten down the two retaining

bolts аnd the center bolt to the transmission extension. 8 l"slall the tгапsmissiоп remote control shift lever and housing as

described in Chapter 6. 9 Reconnect the clutch саЫе and adjust as described in Chapter 5 and reconnect the back-up tight wire. The final connections should

then

Ье

made

аз

described in Section 51 and in addition 10 the engine

lu bricant and coolant, the transmission should also fresh oil.

I

53 Engine - initial star1-up after overhaul

ог

Ье

refilled with

major repair

1 Make sure tha1 the Ьанегу is fully charged and that all lubricants , coolants and fuel аге replenished. 2 If the fue l system has Ьееп dismantled it will reQuire several revolutions of the engine оп the staгter motor to ge1 the fuel up to the

I

45

carburetor. It will help if the spark plugs аге removed and the engine tuгned over оп the starter motor. This will ensure that the carburetor is primed with fuel and also that oil is circulated aTound the engine prior 10 staгting. 3 As soon as the engine fires and runs, keep it going at а fast idle only (по faster~ and bring i1 up 10 погтаl working temperature . 4 As the engine warms up there will Ье odd smells and some smoke from paгts getting hot and burning off 011 deposits. The signs to look for аге leaks of oil ог water which will Ье obvious jf serious. Check also the ctamp connections of the exhaust pipes to the manifolds as these do not always 'find' their exact gas-tight positlon until warmth and vibration have acted оп them and it Is almost certain that they need tightening fuгther. This should Ье done . of cou rse . with the engine stopped . 5 When the running temperature has Ьееп reached adjust the idling speed as described in Chapter З . 6 Stop the engine and wait а few minutes to see if апу lubri cant ог coolant Is dripping out when the engine is stationary, 7 Road test the саг to check that the timing is correct and giving the necessary sm001hness and powef. 00 по! гасе the engine - if new bearings and/ or pistons and rings have Ьееп installed i1 should Ье treated as а new engine and run-in а1 reduced speed for 500 miles

(800 km) ,

I

54 Fault diagnosis - engine Symptom

Reason/ s

Engine will not

\

Engine

tuгns

tuгn

over when starter switch is operated

over normally but fatl s

'о

fire and run

)

Engine

r

•

staгts

but runs uneven ly and misfires

Flat battery Bad battery connections Bad connections at solenoid switch and/ or Staгter motor jammed Oefective solenoid Starter motor defective No spark at plugs No fuel reaching engine Тоо much fuet reaching the engine

staгter

motor

1 (floodi ng ~

Ign it ion and/ or fuel system faults Incorrect vatve clearan ces Burnt out valves Blown cyl inder head gasket Worn piston rings ог cylinder bores

Lack of power

Ign11ion and/o r fuel system faults Incorrect valve clearances Вшп' out valves Blown cylinder head gasket Worn piston rings ог cylinder bores

Excessive oil consumption

Oil teaks from crankshaft геаг oil seal , timing cover gasket and oil seal. rocker cover gasket, oil filter gasket, oil рап gasket . oil рап plug washe r. Worn piston rings ог cytinder bores . resulting in oil being burnt Ьу engine - smoky exhaust is ап indication Worn valve guides and/ or defective valve stem seals - smoke bIowing out from the rocker cover vents is ап indica tion

Excessive mechanical noise from engine

Wrong valve-to-rocker clearances (solid lifters! Worn crankshaft bearings Worn cylind ers (piston slap~ Worn timing cha in and/o r sprocket

-

Note 1 : When investigating starting and uneven running faults do not Ье tempted into snap- diagnosis. Start (гот the beginning о' the check procedure and follow it through. It w ill (аке less time "" the 'опу гиn. Роог peгfoгтance (гот ап engine in terms о' power and есоnоту is not пог­ таНу diagnosed Qu;ckly, '" аnу event the ignition and (иеl systems must Ье checked first before assuming апу further investiga tion needs (о Ье made. Note 2: Оп engines eQuipped with hydraulic valve lifters, а mech8nical tapping noise тау Ье heard оп initial start- up. However, as the engine oil pressure rises, the valve lifters will expand and the noise should cease. If it does not, the valve lifters should Ье checked (ог соггесС operation,

Chapter 2 Cooling system Contents Antifreeze and corrosion inhibitors

.......•. •....

Cooling system - draining ... ... . Cooling system - filling ... . . . . . . Cooling system - flushing .......

. ..... .•.•. . . ..... ... • .•.. .. ......... . . . .•......

2 4 3

Drivebelts - inspection and adjusting .... . ..• .••. •.• • • •.. Drivebelts - гетоуа' and installation .......• .. .......... Fault diagnosis - cooling system ....... • . • . . .. . ......

11 12 16

General description

15

....... .. . . . . . . . . . . . . • . . . . . . . . . .

1

Radiator - removal. inspection, clean ing and installation ...... Temperature gauge and sender unit - гетоуаl and installation Temperature gauge - fault diagnosis .. . . . . . . . . . . . . . . . .. Thermostat - гетоуаl and 1nstallation . . . . . . . . . . . . . . . . . . . Thermostat - test1n9 ......................•.• .. .... Vi scous coolin9 fan - removal and installation .... . . . . . • . . .. Water pump - rem oval and installal10n .. . . . . .••••. . . . . Water pump - overhaul ........ ..... ...... . •••... ...

5 14 13 6 7 1О 8 9

Specifications

System type

. . . . .

. . ... . . . .

. . . . .

... . . .. . . . . . . . . ....

Thermostat Туре

.... . .... .. . Loca tion ........ . Openin9 temperature Fully ореп ....... .

• • •

•

•

•

•

•

•

•

•

•

• • • •

•

·

.. .

•

•

• • • • • • • • • •

•

•

•

•

•

•

• • • • • • •

•

•

• •

•

•

•

• • • • •

•

•

• •

• • • • • • •

· . .. ·.. .

... .. . . . . ... .

Radiator Туре

............. . Pressure с ар settin9 .. '

•

• •

•

•

• •

•

•

... ...... ....•. • .. . Drivebelt tension ........ . .

. •

•

·.. ....... . ... . . · . ..

. . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . .. .. . . . . . . . . . . .

Water pump Туре

•

•

. . . .

. . . . . . . . . . . ........ . . . . . . . . . . .. . ...... . .

Pressurized . assisted

Ьу

pump and fan

Wax-lilled Front of intake manifold 188 0 10 195 0 F (860 to 91 о С ) 212 0 to 2150 F (100 0 10 101 0

С)

Vertical-flow ог cross-flow. dependin9 13 Ibf/in 2 (0.91 kgl/ cm 2 )

оп

model

Centrifugal impeller type Approximalely 0 .5 in (1 3 mm ) 01 movement at midpoint of longesl span of belt

Cooling system capacities 260cuin . . . . . ...... . .... .... .... , . • ...... . ....... 289cu in ... ... .............. . ......•... ........... з02сuiп . . . . . . . . . . . . . . • . . . . . . . . . . . . • . • . . . . . . . . . . . . 351cuin ....• .......•... .• ... ... .• . • .. • . • . ... . ..... 390cuin ....• • ... . ... .. •••.... . ... . • .. • . •.... . ..... 427cuin .... ... .... .• . . ... . ... .. . • .•.......... . 428 си in . . . . . . . . . . . . . . . . . •• •• • • • • • • • • • 429 cu in . . . . , . . . . . . . . . . . • • • • • • • • • • • • • • • • • • • •

15 US quarts (14liters) 15 US quarts ( 14 lilers ) 15 US Quarts (14 lilers) 16 US Quarts ( 15liters) 20.5 US Quarts (19.5 lilers) 20 .5 US Quarts (19.5 11ters) 19 .5 US Quarts (18 .5 liters) 18.5 US Quarts (1 7.5 lilers )

Torque wrench settings

Ibf ft 12 to 20 to 4010 12 to

.

. .

•

•

Fan-to-pulley hub . . . . . . . . . . . . . . . . . . . . . . . . . . .•.. . ...... Water pump bolts .............• • ... . .•• • ...• • • • •. • • ... Alternator pivot bolts ....... ...• .. . . . . . • .• . .•. .• . . •. ... Thermostat housing bolts .... . ............•. •.•..... ....

1

General description

The cooling system оп all models comprises а radiator connected to the engine Ьу top and bottom water hoses. а belt-driven fan and water pump . and а thermostat. Small Ьоге hoses transfer water to the heater and automatic choke control unit. The intake manlfold Is water-heated and оп some models the fan incorporates а temperature-conlrolled fluid cou pling which reduces power absorption and fan noise. The cooling system is pressurized 10 епаЫе а higher operaling temperature to Ье maintained without boilinQ. If lhe waler pressure

18 25 50 15

kgf m 1.6t02.5

2.8 'о 3.5 6.0 to 7.0 1.6102 .1

within the system rises аЬоуе the preset limit of the radiator сар. (see Specifications) the spring -Ioaded valve within the сар opens and allows lhe excess water to pass alon9 ап overflow pipe , thus relieving the pressure. 11 is therefore important to ensure that the сар has the согге с ! pressure setting stamped оп the top and that the spring and sealing washer аге in good condition . In operation , cold water in the bottom of the radiator circulates up the lower radiator hose to the water pump where it is pushed round the water passages in the cylinder bIock, helping to keep the cylinder bores and pistons cool. The water then lravels up 10 the inlake manifold and cylinder heads, and circulates round the combustion spaces and valve seats аЬзогЫпа more heat.

,

Chapter 2 Cooling system Е' ег

depenOing

has

а

а оп

cross-flow ог down-flow radiator тау Ье installed the model and уевг 01 manufacture. The cross-flow type

header tank

оп

through the connecting tubes within the radiator соге. thermosta t

its funct ion is 10

i5

located

гestrict

ОП

the front 01 the intake manifold and

the fl ow 01 water between the radiator and the

engine 10 provide fast warm-up until the is reached.

2

погта'

operating temperature

Cooling system - draining

11 t he engine i5 cold , гетоу е the filler сар from the radiator Ьу tuгning the сар counterclockwi se . If the engine is hot, then turn the filler сар very slightly until pressure (п the system has had time to Ье released. Use а rag оуег the с ар to protect your hand fгom escaping steam. If, with the engine very hot, the са р is released suddenly, the drop (п pressure с ап result in the water boiling . With the pressure released the сар сап Ье removed. 2 If antifreeze is used in the cooling system, drain It into а bowl having а capacity of at least that of the cooling system , for re-use . 3 Ореп the drain plug located at the base of the radiator, о г remove the bottom radlator hose. Also remove the engine drain plugs located оп either side of the cyHnder bIock . If the heater has а water control valve, ореп it to drain the heat exchanger. 4 When the water has finished running, ргоЬе the drain plug orifices with а short piece of wire to dislodge апу particles of rust ог sediment whlch may Ье causi ng а bIockage . 1

I

•

I

Cooling system - flushing

each side 01 the radiator and the water fJows

hontontally between the tWQ tanks. The down-flow type has tanks at the (ар and ЬоНот 01 the radiator, and the water flows vertical ly Тhe

з

47

1 'П time the cooling system will gradually 'оsе its efficiency аs the radiator Ье со теs choked with rust, sca le deposits from the water, and other sediment. ТО clean the system out, remove the radiator filler сар and drain plug and 'еауе а hose runn ing in the filler сар neck for ten to fifteen minutes. '" very bad саsеs the radiator shou ld Ье reverse -flu shed . This са п 2 Ье done with the radiator in position . The cyl inder bIock plug is removed and а hose with а suitabIe 1apered adaptor placed in the drain plug hole. Water under ргеssиге is then forced thгough the radiator and out of the header tank fi!ler сар neck. It Is recommended that some polythene sheeting Is placed оуег the engine to stop water finding i1s way (п10 the electri cal system. 3 The hose shou ld now Ье removed and placed (п the radiator сар filler neck, and the radiator washed out (п 1he usual таппег .

4

Cooling system - filling

1 Install the cylindeг bIock and radiator drain plugs . 2 Fill the system slowly to ensure that по air lock develops. If the heater has а water control valve, che ck that it is ореп (control а1 hot), otheгwise ап airlock тау form (п the heater. The Ьеs! type of water to use ( п the cooling system 15 ra in water, mixed (п the correct proportion with the reco mm ended antifreeze/rust inhibitor solution (sее Section 15). Оп the down-flow type radiator the level of coolant mUS1 Ье t 10 Ч in (20 to 35 mm) below the filler neck, while the cross-flow type radiator must Ье filled to the co/d {ill mark (see Fig. 2.4 ). Oveгfilling will

RADIATQR

2

f DRAINCQCK 11'011

,

Fig . 2 .1 Cylinder bIock drain plug (опе each side) (Sec. 2)

Fig . 2.2 Location of radiator drain tap (Sec. 2)

I I

MAINTAIN RAO IATOR FILL LEVEL

•

,

L3 /4T01-1 / 2

t I NCHES ~LWHEN COLD Fig. 2.3 Coolant

'еуеl

for down-flow type radiators (Sec. 4)

Fig . 2 .4 Coolant 'еуеl for cross-flow type radiators (Sec . 4)

Chapter 2 Cooling system

48

i5 only applicabIe when а shroud i5 installed (photo ). 5 Undo and геrnоуе the four bolts that secure the radiator to the front panel. The гadiator тау now Ье lifted upwards and away from the engine compartment. The fragile matrix must not Ье touched Ьу the fan bIades аз it i5 easily punctured (photo). 6 и" the radiator shroud from over the fan bIades and гетоуе from

the engine 7

Fig. 2.5 Later type radiator overflow reservoir (See. 4) merely result in wastage which is especially to Ье avoided when antifreeze is in use. 3 It Is usually found that air locks develop in the heater radiator so the system shou ld Ье vented during refilling Ьу detach lng the heater supply hose from the elbow connection оп the water outlet housing. 4 Pour coolant into the radlator liller neck whi lst the end of the heater supply hose is held at the elbow connection height. When а constant stream of water flows from the supply hose qu ickly insta ll the hose. If venting is not carried out it is possibIe lог the engine to overheat. Should the engine overheat for по apparent reason then the system should Ье vented before seeking other causes. Оп some models а bIeed nipple 1з incorporated in the coolant hose which runs at the геаг of the engine. 5 After filllng the system run the engine with the filler сар off until nOTmal operating temperature is reached. Check the coolant level and reli ll il necessary. 6 Insta ll the radiator сар and turn it clockwise to lock it in position.

Radiator - remov81, inspeetion, ele8ning and in8t8118tion

1 Drain the cooling system as described in Section 2 . 2 Slacken the two clips which hold the top and bottom rad iator hoses оп the radiator and carefully pull off the two hoses. 3 Where applicabIe , remove radiator upper splash shie ld and disconnect the hose from the automatic transmission oil cooler. Plug the ends of the hoses to prevent fluid loss and ingress of dirt. 4 U ndo and remove the four bolts that зесuге the radiator shroud to the radiator side pane ls and move the shroud over the fan bIades. This

5,4 Removing the radiator cowl securing bolts

With the radiator away from the

саг , апу

leaks

сап Ье

soldered

ог

repaired with а suitabIe proprietary substance. Clean out the inside of the radiator Ьу flushing as described in this Chapter. When the radiator i5 out of the саг it i5 advantageou5 to turn it upside down and reverse flush . Clean the exterior of the radiator Ьу carefu lly using а compressed air jet ог а strong jet of water to clear away апу road dirt, bugs etc. 8 Inspect the radiator hoses for cracks. in ternal ог external perishing, and damage Ьу overtightening of the securing cl ips. Also inspect the over1low pipe. Renew the hoses if suspect. Examine the radiator hose clips and renew them if they аге rusted ог distorted. 9 The drain plug and washer should Ье renewed if there has Ьееп апу leakage . 1О Installation of the radiator is the reverse sequence to remova l. After refilling the system run the engine and check for leaks. 11 If а transmission oi l cooler is installed, check the hoses for leaks and top- up the f luid level, 11 necessary.

CONSTAN T FULL RESERVOIR

5

compaгtment .

6

Thermost8t - removal and inst811ation

1 Partial ly drain the cooling system , as described in Section 2. 2 Slacken the top radiator hose to the thermostat housing and remove the hose . 3 Undo and remove the two bolts and spring washers that secure the thermostat housing to the intake man ifold. 4 Carefully 11ft the thermostat housing away f rom the intake manifold. Recover the joint washer adhering to either the housing ог intake manifold (photo). 5 Withdraw the thermostat. making а note 01 which way round it is litted (photo). 6 Insta ll the thermostat using the reverse procedure to removal. 7 Always ensure that the thermostat housing and intake manifold mating faces аге clean and flat. 11 the thermostat housing is badly corroded instal l а new housing. Always use а new gasket. Tighten the two securing bolts to the specified torque.

7

Thermostat - tB8ting

1 Remove the thermostat, as described in the previous Section. 2 Test the thermostat for correct functioning Ьу suspending it оп а string in а saucepan of cold water together with а thermometer. Heat the water and note the temperature at which the thermostat begins to ореп. This should Ье as given in the Specifications. Continue heating the water until the thermostat is lully ореп. Then 'е! it cool down naturally. 3 If the thermostat does not fully ореп in boiling water, ог does not close down as the water cools, then it must Ье discarded and а new опе installed. Should the thermostat Ье stuck ореп when cold , this will usually Ье apparent when removing it from the housing.

5.5 Lifting out the radiator

6.4 Removing the thermostat housing

! d ,

•

,

•

Chapter 2 Cooling system

49

I

•

I I

6.5 Location of thermostat

I

Fig. 2 .6 Correct location ofthermostat (Sec. 61

I

Water pump -

1

Drain the cooting system , as described in Section 2.

2 3

Aemove the radiator and shroud , as described in Section 5. Loosen the alternator adjusting bolts and гетоуе the drivebelt. If

ап

air-conditioning pump is installed the alternator and mounting

bracket will have to

I

гетоувl

8

Ье

and installation

removed completely .

4 Ает оуе the fan and pulley from the pump. 5 Unscrew and remove the bolts and washers that secure the water pump assembIy. Note t he location of the bolts as they зге of different

•

length s.

i

I [

6 lift away the water pump assembIy. Rе соуег the gasket if not stuck to the casting. If песеээагу also remove the thermostat houslng from the water pump. 7 Before Installing the water pump аээетЫу, remove all traces of the old gasket and sealing compound from the front cover аП9 water pump assembIy. 8 Carefully apply а sealer to both sides of а new gasket and accurately position оп the water pump. 9 Hold the water pump in position and screw in two bolts and washers, so retaining it to the fгont cover. 1О Remove all gasket material from the thermostat housing mating faces. Apply а sealer to both sides of the new gasket and position it оп the water pump. Secure in posltion with the two bolts and washers. 11 Install all remaining securing bolts and wзs hегs ensuring they аге located in their original positions. Tighten 1п а diagonal and progressive mаппег to the correct torque wrench sеttlпgs (see Specifications). 12 Install the 1ап , drivebelt(s) and radlator ; then refill the сооliпg system .

9

~

I

11 Drivebelts -

Fig. 2.7 Viscous drive cooling fan (Sec. 10)

iпsресtiоп апd

adjusti"g

The пumЬег of drlvebelts оп the саг will depend оп whlch extras аге installed, ie air-conditionlng compressot, powet steering ритр and thermactor pump (photo). 2 Periodically the belts should Ье checked for coггect tenslon and weat. Use а flashli9ht and examine the inside surface of the belts for cracks and If in evidence renew the belt(s} . 3 The alternator belt tension is adjusted Ьу slackenlng the two lower pivot bolts апd top slide bolt , and moving the alternator in the requlred direction (photo). 4 Power steering and thermactor pump drivebelts аге adjusted Ьу slackening the slot bolts and screwing the adjusting bolts in ог out to achieve the required belt te"sion. The slol bolts аге lhen lightened (see Fig. 2.9). Note: Оп some e8rlier models the power steering and thermactor рuтр drivebelts аге adjusled Ьу slackening lhe mounting bolts оп the рumр brackel and carefully levering the рumр away (гот the engine (see Fig. 2.1 О snd photoJ. 5 When ап air-conditioning ритр is installed the drivebelt tension Is controlled Ьу ап idler риНеу ; this has а sin91e pivot bolt and ап adjust Ing bolt located behlnd the pulley. 6 То get the belts adjusted correctly the саг should Ье taken 10 а Ford dealer who will have а speclal belt tensioning tool . However the home mechanic сап obtaln approximately the сопес! tension Ьу adjusting the belt(s) until there is about t in ( 13 тт) of movemenl midway between the pulleys (see Fig . 2.12) . ,

Water pump - overhaul

Water pump fai lure will Ье iпdiсаtеd Ьу coolant leakage. по isу оре гаti оп апd/ог excess movement of the ф1уе splndle. If апу of these faults аге ргеsепt а repla ce ment pump must Ье obtained from а Ford dealer as 1! 1э ПОl pract ical ог even economical to attempt гераiг i пg а worn-ou t unit.

1 О V15cous 1

сооliпg 18П - remov81 8пd iП5t8118t1оп

Ает оуе

the radlator, as described in Section 5. 2 Slacken the fan belt and remove the bolts securing the fan drive clut ch to the water pump hub . 3 Аетоуе the fan drive clutch and fа п as а complete assembIy. 4 А етоуе the retaining bolts and separate the drive clutch from the fап .

5

The viscous clutch assembIy is not repairabIe and if faulty should Ье replaced with а new clutch u п it. 6 Install the fan and clutch using the reverse of the гетоуаl р госеdure.

11 . 1 Layout of engine driven accessories and drivebelts - lypical

2

Chapte,2 Cooling system

50

PIVQT BOLT

PULLEYS

11.3 Alternator tap pivot mounting

ADJUSТlNG

11.4 Earlier type power steering ритр mounting bracket

DRIVE 8ELT

BOLT

Fig. 2.8 Pivot bolt and slide adjustment - typical

(Зее.

11)

ADJUSTING BOL Т PIVOT BOLT BEHIND PULLEY

,

" ...

,,

ORIVE BELT , ,

,{

,

. .'

,11,

1, ,\

" •" • ).. '

о

,,),

..

.. ,

"

"

1",

" I

I .

дDJUSТ\NG

BOLT

\

PULLEY ARM SLOT

Fig. 2.9 Power steering ритр adjustment -18ter models (See. 11)

Fig.2.11 Air-conditioning purnp idler pulley adjustment - typical IS"c, 11)

RULER _ _":'

BELT DEFLECTIQN

STRAIGHT fDGE

,

•

Fig. 2.1 О Power steering

ритр

adjustment -

вагliвг

models

IS"c,11)

, 2 Drivebelts - remov81 a"d inst81latio" 1 ТО remove а drivebelt, slacken the relevant accessory pivot and . adjusting bolts and move it in towards the engine as far as possibIe . Remove the belt Ьу lifting it over the pulley , rotat;n9 the pulley а! the эате time. Note: If air conditioning and/or power steering pumps аге

Fig. 2.12 Method of checking drivebelt adjustment (See. 111

installed these drivebelts will have to Ье removed prior to the гетоуа' of the alternator/ fan belt . 2 Install the drivebelt ls) using the reverse sequence to removal. If а new belt is installed the engine should Ье run for 1О minutes then switched off and the belt tension re-checked . 3 Оп some engines the fan is driven Ьу twin belts and these should always Ье renewed as а pair.

•

Chapter 2 Cooling system

13 Temperature 1

явияв

below freezlng it i5 e55ent1al that 50me of the water 15 drained and ап adequate amount of ethylene glycot antifreeze i5 added to the coollng sy5tem. If antifreeze 15 not u5ed, it i5 eS5ential to use а cott05ion inhibitor in the cooling 5ystem in the proportion recommended Ьу the inhibitor manufacturer. 2 Апу antifreeze of good quality сап Ье used. Never use ап antifreeze with ап alcohol Ьа5е а5 evaporation i5 too high. 3 M05t antifreeze with ап anti-corr05ion additive сап Ье left in the cooling 5Y5tem for up to two уеаГ5, but after six month5 it i5 advi5abIe to have the specific gravity of the coolant checked at your local repair 5tat1on and thereafter опсв every three months. 4 The tabIe below gives the proportion of antifreeze and degree of protection:

- fault diagnosis

11 the temperature gauge fails 10 work, 81ther the gauge, the

sender unit. the wiring

ог

the connections аге

аl

fault.

2 11 15 П Оl possibIe 10 repair the gauge ог the sender unit and they must Ье replaced Ьу new units if а! fauJt. 3 First check that the wiring connections аге sound. Check the w iring for breaks using ап ohmmeter. The sender unit and gauge

should

Ье

tested

Ьу

14 TemperBture 1

Information

substitution.

о_иов

оп

and sender unit - removaland installation

the removal of the gauge will

Ье

found in Chapter

2 The sender unit i5 screwed l"to the left-hand side 01 the cylinder bIock. ТО remove the unit, disconnect the wire connector апd unscrew the unit with а suitabIe wrench. 3 In5tall the 5ender unit u5ing the revet5e procedure to removal .

1

'П

Commences to freeze

Antifreeze

10.

15 Antifreeze and corrosion

51

ос

% 25 33t

-13 - 19 -36

50

0F 9 -2 -33

Frozen solid ос

0F

-26 -36 -48

-15 -33 -53

inhiЫtors

circumstance5 where it Is likety that the temperature will drop

Note: Never use antifreeze ;п the w;ndscreen washer will cause damage to the pa;ntwork.

reservoiг

as ;t

16 Fault diagnosis - cooling system Symptom

Reason/ s

Overheating

Insufficient water in cooling system Fan belt slipping (accompanied Ьу а shrieking noise оп rapid engine acce[eration) Radiator соге bIocked ог radiator 9гillе re5tricted Bottom water hose collapsed, impeding flow Thermostat not opening properly 19n1tion advance and retard incorrectly set (accompanied Ьу loss of power, and perhaps misflring) Carburetor incorrectly adjusted (mixture too lean) Exhaust system partially bIocked Oillevel in oil рап too low Blown cylinder head gasket (water/ 5team being forced down the radiator overflow рlре under pressure) Engine nat yet broken-in Brakes binding

Underheating

Thermostat jammed ореп Incorrect thermostat instalted allowlng premature opening of valve Thermostat misslng

loss of cool ing water

loose clips оп water hoses Тор , bottom ог by-pass water hoses perished and leaking Radiator саге leaking Thermostat gasket leaking Radiator pressure сар spring woгn ог seal ineffective Blown cylinder head gasketls (pressure in system forcing water/ steam down overflow pipe) Cylinder wall ог head cracked

•

2

•

Chapter 3 Fuel, exhaust and emission control systems Contents Air cteaner and duct systems - general description . ......... Air cleaner and filter eleme"t - гвтоуаl and instal lation ....•. . Air cleaner duct and valve assembIy - testing ... .... ....... Autolite and Motorcraft 21 00 carburetors - adjustments ...... Autolite and Motorcraft 4300 carburetors - adjustments . ..... Carburetion - warning ......... .... ....... ...... .... Carburetor adjustments - general ...... ..... ....... . .. . Carburetor - general description .. ...... ...... ..... .... Carburetor (Hol ley 4150С ) - dismantling and reassembIy ..... Carburetor - removal and installation . .. ..... .... ...... . . Carburetor (Rochester Quadrajet 4MV) - dismantling and reassembIy .... ........... .. . . . . . . . . . . . . . . . . . . . . . Carburetor - servicing (genera!) . .. .... ...... ....... .... Carburetor (type 2100) - dismantling and reassembIy ....... . Carb uretor (type 4300) - dismantling and reassembIy ..... ... Curb idle speed and fuel mixture - adjustment .... ........ . Oownshift linkage (automatic transmission) - adjustment .....

з

5 4 15 ,6 1О 12 11 23 19 24 20 21 22 13 27

Emission control systems - general descrlption .. .•.... •.. . . Emission control system - maintenance 8nd testing ....•... . Exhaust system - description and renew8! .... . ....... • ... Fast idle speed - adjustment .......... .... . .... . ...... Fault diagnosis - emission control system .... . ..••.. • .... Fault diagnosis - fuel system ...... ..... .. . • . •• •• .•.... Fuel filter - renewal ....................•...•.. •. ... Fuel pump-descriptlon .............•. • .•........... Fuel pump - гетоуаl and installation . ...•.•.•......•.... Fuel pump - testing ...... ...... ... .•• • .. •.• •• . • . ... Fuel tank - cleaning and repair ..... .. .• • ••..•...... .. . Fuel tank - гетоуаl and installation .. . . . .... о General description .................•.. ......... . .. Ноllеу 41 БОС carburetor - adjustments ........ . ......... Aochester Quadrajet 4MV carburetor - adJu,tments о...... .. Us Federal Aegulations - emission control ....... . •.. . .... •

•

•

•

•

•

•

•

•

••

Specific8tions

Fuel pump Mechanical, 5ingle-action Oe l i v e гy

pressure: 1965 thru 69 ...........•. .• .• .....• . . .•....... ... 1970thru 73 . .. ........•.......... о With 429 Boss engine .....•........ ....•.•..... ..... •

•

••••••••••••

Fuel tank capacity

4.5 10 5.5 Ibffon' 10.31 - 0 .38 kgf/cm'l 5 .5106 .5 Ibffo n' 10.38 - 0 .45 kgf/cm'l 6 10 8 Ibf/ in' 10.42 - 0 .56 kgf/cm'l

US gol

1965 thru 68 .. . .. .. . .. ..•.•. 1969 .... .. ... ... ...... • • •. 19 7 О . . . . . . . . . . • • • . . . . . • • • • 1971 ........ ... . .. .. ..•. о 1972thru73 . ... .... ........ •

. .......... •.• . • • . • . • . .. .. . • • . ... • • •• .. . • • • • • . .. •• . •• .. . . . ••••. •. . . .. . . . ••

•••••

••

•••••

•

••••

•••••

. . ..... .... ....•...... ..

litr. 60.56 75.7 83.27 75.7 73.6

16 20 22 20 19.5

Fuel filter ..... ... . . . . . ... . . .. . .... . ... .... ... . ... .

In-Ilne, di5posabIe

Air cleaner ..... . ...... . ................ . ... . ..... .

OisposabIe element

Carburetors 2 - Ьаггеl

type

4 - Ьаггеl 'уре

А utolite

• • • • •

•

•

•

••

• • • •

•

•

•

• •

•

•

•

• • • • •

•

•

•

•

•

•

•

•

•

• • • •

.. ... .... .. ..... ..... .......• . • . •. . ... ...

2100 carbuгetors

(811

Auto1ite 2100, Autolite 21000 ог Motorcraft 21 000 Autolite 4300, Autotite 43000, Motorcraft 4ЗООD, Holley 4150С ог Aochester Quadrajet 4MV

dimensions in inches)

C8rburetor No 9510 Throttle Ьоге diameter ..........•. •.•. .......•.•.•. . . ... Venturi diameter ....... . .... ..• . •. ....... • . •.•...•• • • . Fuelleve l (wet) ± Ji ....... ..... . . .... . . . . . . . . . ........ . Float 5etting ( dгy) ± 9 ........................ .... . . ... . Mainjet . . .. , . . ......... ..... .•.•...... ... . • .•...... Power valve identification ....... • .. . • ...... ....• . • . •. ... Pump rod P05ition ......... . ..• . . .. • .• . . . .. • . •. ... • • •.

C8AF - BD 1.56 1.08

C9AF-A 1.56 1.08

C9ZF-B 1.68 , .23

C9ZF-A 1.68 1.23

t t

t t

t 1\

t

48F Green No 3

48F Green N02

54F Green N03

I

54F Plein N03

29 30 28 14 32 31

9 6 7

8 26 25 1 17

18 2

•

Chapter 3 Fuel. exhaust and emission control systems C9AF-A

C9ZF-B

C9ZF-A

Bi·metal ident ification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

C8AF-BD TN

ТО

тw

тw

Сар

2 - rich

Index

2 - rich

0.130 0 .11 О

0 .120 0.11 О

0 .120 0.11 О

1 - rich 0 .150 0.130

т

т

650 1400

550 1600

550 1600

650 1300

DOAF-C

DOAF-D

DOAF-E

DOAF-F

Transm ission .... .. ... . ........... .. .... . ..... . .... . .

Manual

Auto

Manual

Auto

Throttle Ьоге diameter . . . . . . . . . . ... . . . • . • . . . . . ... . ... ... V enturi diameter . . . . . . . . .. • . . . . . ....• . • ... , . . .. . . . . . . . Fuel level (wet) + Float setting ( dгy ) Main jet . .. . . . . . . . ... . ... .. .. .. . . . • . . . ... . ... . . , ' , , , Power valve ident ifi cation ... . , . . .. , . . . ... .. . , . . . . . . . . ' ., Pump rod posi tion . " " ... . . , . . . . . , . •... .•. . . . . . . . . " , Choke system : · meta I'd ' .lOn .. . , . . . . . . . , , , ... . . , , . , . . . . . . , , I entl'f Icat В IСар setting .. " " " , ." , .... " " ' •. . " , . . . . . . . , ,, Pulld own setting (+ 0 .0 1О ) ." ...... , . • . • . , ..... . , . . . , Fast idle cam clearan ce ' . , , , . , ... ' . ' , . . . . , , , , ... , . . . , Dashpot adj ustme nt (+ ~ ) , , , . , . , , ' . . . . . . . . . . . .. , , , , , , .. . Idle speed : Curb id le гр т , . . . , , , , .. , , , ...... , , , ..... , , , . ' .... , Fast idle гр т - kickdown step " , . .... " , ... " " . , . . . . .

1.56 1.08

1.56 1.08

1.68 1.23

1.68 1.23

~ ~

~,

~ ~

s

е

system : setting

... . . . . . ... . . . . .. . . . . . . . . .... . .. .. . .. .

Pulldown setting (+ 0 .010) ...... . . . .. . ... . ......... . .

Fast idle

с ат

clearance ....... . ... . . ... .. . .......... .

DashpoI adjustment (+ Ь ' Idle speed:

......... . .................... .

Cu rb idle rpm . . . ... ... . . . . . . . . . .. . . . . . . . . ... . .. .. . Fast id le грт - kickdown step . . . . . . . ... .. . . . . . . . . . . . . .

!I

53

,

,

1.

I

А utolite 21 OOD carburetors (а" Carburetor No 951 О

,

I

dimensions ,"п inches)

»... .. ...... ....... ......... ...... .. . +» ....... ........ ..... ............. .

i

,

t I

~

54F

~

48F

48F

Plain

Green

Red

Red

No 3

No2

No 3

No4

TN

тw

тw

тw

1 - ri ch

1 - rich

2 -Iean

0 .150 0.130

0.150 0 .130

2 -Iean 0.230 0.190

575

1 400

1500

0.200 0.170

t

t 800/ 500*

55F

700/ 500' 1300

575 1600

*Higher idle sp eed with throttle solenoid energized/fower idle speed with throttle solenoid de-energized i

Carbur8tor No 9510 Transm ission . . . . "

. " , .. "

, .. . ' . ' "

.. "

"

.• . . ' . ' . ' "

Thrott le Ьо г е dia meter . , , . . . . • ' • . . . . •.• . . . . . , .• . .. . . . . . , Ven turi di am eter ... , .. , ... , • ... . . . . . . . . . , . , , . .. .. .• .. , Fuel level (wet) + Fl oat sett ing (d гy ) + Й ' , , , , .. , , , , . . . . . ' , , .... , , , .. : . . ' . , Main jet . .. , , , , . . . . . , , ... , .• . • . . . . . , ... . ..•.• ... ... , Power valve ide ntification " . . ,., . . . . • . .. ' . . . , . • .• ... . .. , Pu mp rod position . . . . , ' ... " , . . . . . . . " . . . . . . , . . . . . . . , Choke system: Bi-m etal identificat ion , , . . . . , , •.•. • ' , , . . . . . , , , , . .•. . . Сар setting " , . . . . " . . . . ,' • . •. . .. " ... " . • ' • .. . . . Pu lldown setting (+ 0,010) ." , .. • ... . . . . . . . , . . . .. . .. . Fast idle с ат clearance . , ' . . ' . . , .. . ... , , , .. , , , , . ' . . . . Idle speed: Curb idle rpm* . . . . .. . " ... " " " ... , . . . . . . . " " , . . Fa st idle rpm - kickdown step . . " " " .. " " . . . " " " "

n.... , , , .. , , , , ..... , , , , .. . , , , , ..... . '

I

D1AF-DA

D10F-PA

D1ZF-SA

D10F-RA

Auto

Manual

Auto

Auto (California only)

1.56 1.08

1.68 1.23

1.68 1.23

1.68 1.23

~ ~

~ ~

~, 54F

~54F

Plain

Green

Red

Red

No 3

No 3

No3

No3

ТВ5

ТВ5

ТВ4

ТВ4

1 - rich 0.170 0. 150

Index

1 - rich

0.230 0.190

1 - rich 0.200 0.170

0.200 0.170

600/ 500 1400

700/ 500 1500

600/ 500 1500

600/500 1500

D2ZF-LA

D20F-UB

47F

61F

~

*Higher idle speed with throttle solenoid energized / lower idle speed with throttle solenoid de -energized Carburetor No 9510 ..

Т ransmlSSIOn

. . . . , . . . . . . " ' ... ' " . . . . . .. " , ... " " , , , Throttle Ь ог е diameter , .. . , , , ' . .. ' , , , ' .. . ' . , ' , .. , ' , , , , , . Venturi diameter .. , , ... . . . ' , . . . . , , .... . ' . , . . . . . . . , .• . ' Fuel leve l (wet ) + " ' , , , . . . . ... . .. , , , . .... . , . , . . . .. , . , . . Float setting ( dгy ) Main jet , , , . . . . . . , . , . . . . , , , , .. , , , , .. . ' , , , , .. , , , , , , , , Power valve ident ifi cation . . " , ... " " ' .. . '. " , .. " " " , , Pump rod position . ' " . . . . . , . . . . " ,' . . . . " , . . . . . " , ' ., Choke system : 8i- metal ide ntifi cation ... , . . . . . ..•. . . . . . .. , . . . , . , . , . . Сар setting ... " . , .. . " . ... , . . " . . ' " " . " " , ' . ', Pulldown setting (+ 0 .010) , . . . . , . " , . • ' ., . . . . " " " . , Fast idle cam clearance ... , . . . . , , ' , , , . .. , , , .. , , , , , , , , Idle СО (%) , , . . . . . . .. , . .. , , , ... , . , .. . . . . . .. . , . , . , ... . Dashpot adjustment (± Idle speed: Curb idle rpm* .. " " . ... , . . . . . . " " .. " , . . . . . " " , Fast idle rpm - kickdown step , ... .. " " .. " , .. . " " " ,

±" ...... ...... ,...... ... ........ .,.,

i.J ' , , .. . . , . .... , . . ... . ' ..... ' .. . '

D20F-KA.

D2AF-HA.

-КВ

-НВ.-НС

Manual

Auto

Manual

Auto

1.56

1.56

1 . 0В

1.0В

1.68 1.21

1.68 1.21

~ ~

~ ~

~

~ ~

~

48F

48F

61F

Yellow

G reen

Green

Green

2А

2А

3А

3А

ТУ

ТХ

ТХ

ТХ

1 - rich

1 - rich 0.150 0.130 0.19

1 - rich

1 - rich 0.190 0.160 0.5

0 .140 0 .130 0 .5

-

800/ 500 1400

0.240 0.210 0 .5

54F

t

-

-

600/ 500**

750/ 500 1400

575/ 500···

1400

*Higher idle speed with throttle solenoid energized / lower idle speed with throttle solenoid de-energized. **Without solenoid: 575 ***California: 625/500

•

,

1500

•

Chapter 3 Fuel. exhaust and emission control systems

Mororcraft 21000

carbuгetoгs (а" dimensions

in inchesJ

C.rburetor No 9510 т

• • ransmlSSIOn ....................................... .

Тhrottle Ьоге

diameter ......•.•..........•.•............

Venturi diameter . . . . . . . . . . • . . . . . . . . . . . . • . . ..........•. Fuelle",el (wet) +,1 ......................... . . .. .... . . . Float setting (dry) + Mainjet . . . . . . . . . . . . . . . . . . • . . . . . . . . . . • . • . . . . . . . . . . . . Power va lve identification . . . • . . . . . . . . . . . . • . • . . . . . . . . . . . . Pump rod position ......... ..• • •.... . •.• ..• • • ...•.. ...

rs ............ . ....... .. ........... .

D3GF-BB 1.56 1.08

D30F-EA Auto 1.56 1.08

D3AF-DC Auto 1.68 1.21

D3AF-PA Auto 1.68 1.21

~

~

~

~

55F Black

3 2N864

Manual

4

47F

4

4

Brown

49F Black

2д

2д

54F Black 3

2N884

2N884

2N864

3 - rich

3 - rich

1250 0.2 0.5

Refer to engine decal 1400 1500 0.2 0.2 0.5 0.5

4

Electric choke system: 8i-metal identification . . . . . . . . . . . . . . . . • . . . . . . . . . . . . . . Сар setting ..... " .....•. " .... " ' •. . .•. " , , , ... , Pulldown setting .. , .. , , , .•. , , , , , . , , , •.•. . . . , ... ... , Fast idle cam clearance .. , .•. , . , , , ... , •... . •. , .•. , .. . Idle speed: Curb idle грт ......... , ..... , , .. . ..•.•.•.... , . , .. . Fast idle грт - kickdown . , ..... , , ..... , .•.•..... , .... Idle СО (%) - CaHfornia ." ..... " .... " , • . . ...... " .. - Other ' , .. , , , ... , , , , ... , , , ........ • • . ..

3 - rich Refer to text Refer 10 text

3 - rich

1500

Holley 4150С carburetors (811 dimensions "п inches) Carburetor No 951 О Transmission .... , .... "." ...... ,' • . . . . . . . . . . . . . . . . . Throttle Ьоге diameter - Primaгy .... , ...•.• ' ............ . . - Secondaгy .. , . ..•.•. .• .........•.. Venturi diameter - Primaгy ......... . ..•.• ..•... ......... - Secondary ...... . ...•.•.......... , .... Fuellevel .......... , ........ .. ......•............ , .. Огу float setting ....................•.•.•• . ... . .. ' • • •. Main jet - Primary ........• • • ......• • . .•.•.. . ... " .•. _ - Secondary .... , ...... , ....•.•............•.. Choke system: 8i-metal identification .. , ..........•.•..... , , , ...... . Choke se1ting . . . . . . . . . . . . . . . . . . . • . • . . . . . . . . . . . . •. . Pulldown setting ......... ..... _ •••..•. . . . . , . ..•.• . . Fast idle cam setting ....••. . . .• _ ••• . .•... , . , , ..•.•.. .. Р итр сат pos,t,on . . . . . . . . . . . . . . . . • . • . . . . . . . . . . . . . . • . . Ритр override clearance ..............• ' ......... I • • • • • , Dashpot adjustment .............•.•.• ' ... ..... _ ..••• . , Idle speed : СигЬ idle rpm ........ , . . . . . . . . . . . . . . . . . . . , ....... . Fast idle грт .. , ...... " . . . . . . . . . . . . . . . . . . . . . . . . . .

C9AF-M Manual 1.69 1.69 1.38 1.44

66 79

C9AF-N Auto 1.69 1.69 1.38 1.44 Lower edge 01 sight plug Parallel with floa1 bowl 1100г (bowl 66 79

GТI

2 - rich 0.30 0.060 No 2 0.015 0.100

GTA 1 - rich 0.30 0.080 No2 0.015 0.100

700 1350"

650 1550**

DOOF-S Manual 1.69 1.69 1.38 1.34 inverted) 64 82 Manual

No2 0.015

700/500· 2:200*·*

**K'-ckdown ог second step 01 свm *"Highest stop 01 С8m *Higher idle speed with throttle solenoid energized / lower idle speed with throttle solenoid de-energized Carburetor No 9510 Transmission ... , ..... " .... , ....•.•..... " .......•. . Throttle Ьоге diameter - Primary ... ...•.•..........•.•... _ - Secondary ... . •...•• . ....•.• . •..•. Venturi diameter - Primary ..........• . .• _ • . . . . _ •.•.•.•.. - Secondary ........•.•..........•.•.•.. Fuel teve l .......................•.•..........•.•.•.. Огу float setting ................•............•.•.•. . .. Main jet - Primaгy ......•.... . ..• . •. . •.... . ..• . • .•..•. - Secondaгy ....•..... • • • • •..• .... . . _ • . •.• .• .. Choke syslem ................•.•.• '. . .. ........•.•.•.. Ритр сат posi1ion . . . . . . . . . . . . . . . . ..•... ........ ...•.. Pump override clearance ..........•.•.•..........•.• , •.. Dashpot adjustment ...............•.•. , •.. . ....•••. .. . Idle speed : Cuгb idle грт . . . . . . . . . . . . . . . . . . , . . . . . . . . . . . . . . . . . . Fast idle грт - highest step 01 сат . . . . . . . . . . . . . . . . . . . . . .

DOZF-AA Manual 1.69 1.69 1.38 1.34

66 79 Manual No2 0.015 0.140 725

DOZF-AC DOZF-AB DOZF-AD Auto Manual Auto 1.69 1.69 1.69 1.69 1.69 1.69 1.38 1.38 1.38 1.34 1.34 1.34 Lower edge 01 sight plug Parallel with I10at bowl 1100г (bowl inverted) 66 66 66 79 79 79 Manual Manual Manual No 2 No2 No 2 0.015 0.015 0 .0 15 0.200 675

1900 2100 *Higher idle speed With throttle solenoid energized / lower speed with throttle solenoid de-energized Carburetor No 951 О Transmission . . . . . . . . . . . . . . . . . . . . . • . . . . . . . . . . . . . . . . • . Throttle Ьоге diameter - Primaгy .........•. . ............•. - Secondary .....•.• . .... , . . . . ....•. Venturi diameter - Primary .........•.• • ••.• , ... . . . . . ..•. - Secondary ........ .• . •. .............•. Fuet level . . . . . . . . . . . . . . . . . . . . . . . . . . • . . . , ..........•. Огу float setting .......... , ..... ...•.•.•........... • •. Main jet - Primary ..... . •• • • • •.... , • .• ••• • ..........•. - Secondary ....•............•. .. .. , ......... .

D1ZF-VA Manual 1.69 1.69 1.38 1.44

71 82

725/500· 1900

D1ZF-YA Manual 1.69 1.69 1.38 1.44 Lower edge 01 sight plug Рагаtlеl with floal bowl floor (bowl 71 83

675/500· 2100

D1ZF-XA Auto 1.69 1.69 1.38 1.44 inverted) 70 83

•

•

Chapter 3 Fuel. exhaust and emission control systems D1ZF-VA Cholte system .......... ...•. . . ..• . .... . .. . . ....• . . . •. Bt-metal identification ..... . .. . . . .. , . ..•.. ....... .....•. Сар

set1ing

. . . . . . . . . . . . . . . .... .... . . . . . . . . . . . .... . . .

Fast idJe сат clea rance .......... ... . . . . . . . . . . . . . . . . . .. . .. Р ump сат posltlon . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... . •... Pump override clearance .... . ... . ... . •.• . . . . . .. . ..•.•.•. Dashpot adjustment .......... .... . . . . . . . . . . . . . . . . . . . . . Idle speed: ешь idle rpm .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Idle

Manua l

No 2 0.015

55

D1ZF- YA Auto

D1ZF-XA Auto

GТI

GТA

2 - rich

2 - rich

Й

Й No 2 0.0 15

No 2 0.015

t

L

"

825

700

Fast idle - highest step of сат . . . . . . . . . . . . . . . . . . . . . . . . .

2100

2200

СО (%) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.5

0.3

650/ 500' 2400 0.2

*Higher idle speed with throttle sofenoid energized / lower idle speed w'-th throttle soJenoid de-energ'-zed А utolite 4300 caгbuгetors (а" dimensions in inches) Carburetor No 9510 Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Throttle Ьоге diameter - Primaгy ....... . .. ..• .•.. . ... . .... - Seco ndaгy .... .. . . . . . . . . . . . . . . . . . . Venturi diameter - Primary ....... ... ...•.•.... ... ... ... . Float setting (+ Ы ......... ........................... . Supplemental valve setting (+ в':4) . . . . . . . . . . . ... ..... . . . . . . . .. . Гlтaгy ......... .. ..... . . . .. . . . •.... . . . .... М aln Jet - Secondary ............ . . . ..• . .•. •........... Pump lever position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Choke SY5tem : Bi-metal identification . . . . . . . . . . . . . . . . . . . • . . . . . . . . . .. Сар settin9 ....... .......... . . .. . . .. . • , ... . . . . . . . Pulldown settin9 (+ 0.01 О ) .. ........ .... . . . . . . . . . . . . . Fast idle сат settin9 + 0.0101 ............ . . . . . . . . . . . . . Dashpot adjustment ...... ... ........... • ... . .......... Idle 5peed : Curb idle грт ........ . . . . ... . ... . . . .... . •.. . . . . . .. Fast idle грт ....... ..• ..... .. ....... . . .... ....... р

I

I

Carburetor No 9510 Transmission . . . . . . . . . . . . . . . ..... . . . . . .... . ..... . . . . . Throttle Ьоге diameter - Primaгy ......... •...•.... ........ Secondary ........ .. . . . . . . . . . . . . . . Venturi diameter - Primary . . . . . . . . . . . . . • . . . . . .. ...... . .. Float setting (+ Ы ................. . .... .. .. . . ...... . . . Supplementa l valve setting (± ~) . . . . . . . . . . . . .. . . . . . . . . . . . . M ain iet - Primary ....... ... ......... . . . . . . . ......... . - Secondary . . . . . . . . . . . . . . . . . . .•. . ............ Pump lever position ..... .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Choke system: Bi-metal identification ....... . . . . . ... . . .. •........... Сар settin9 . . . . . . . . . . . . . . . . . . . . . ....• .. ......... . Pulldown setting . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . Fast idle с ат setting .... . ..•......... . . .. .. . . . . . . . .. Dashpot adiustment ....... .. . . . ... . . . •.. ... . ..... . . . .. Idle speed : Curb idle грт ... ....... ............ . . • . . . . . . . . . . . . Fast idle грт . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . Idle СО (%) . . . . . . . . . . . . . . . . . . . ... . . . . . . . . . . . . . . . . . . . .

C9ZF-D Auto 1.437 1.562 1.00

C9ZF-F Auto 1.562 1.687 1.250

C9ZF-C Manual 1.437 1.562 1.00

C9ZF- E Manual 1.562 1.687 1.250

~ ~

Ii,

Ii,

Ii,

49F "0.120

63F "0.128

No3

No 2

No 3

ЕУ

ЕУ

ЕО8

1 -I ean

2 - Iean 0.170 0.130

Index 0.230 0.21 О

~

t

1400

550 1400

675 1250

700 1300

DOOF-Z-AB Manual 1.56 1.6 9 1.25

DOOF-Y-AC Auto 1.56 1.69 1.25

DIOF-EA Manual 1.56 1.69 1.25

DIOF-AAA Auto 1.56 1.69 1.25

~ ~

Ii

~ ~

~,

48F 0.120 No2 ЕХ

1-

'еап

0.160 0.100

575

62F "0.128

0.2 50 0.230

~

"0.62F116

61F 0 .128 No2

62F 0.128 No 2

61F 0 .116 No2

4ТУ

4ТХ

4ТУ

4Т Х

Index 0.180 0 .160

Index 0.200 0.180 0.080

Index 0.180 0.160

Index 0.200 0.180

800/ 500' 1250

600 1400

825/ 500' 1250

No2

-

1. 1

625/ 500 1400 0.5

*Higher '-dJе speed with throttJe solenoid energized / lower ;dle speed with throttle solenoid de-energized Autolite 43000 caгbuгetoгs (811 dimensions in inches)

t

Carburetor No 591 О Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . Throttle Ьоге diameter - Primaгy ........ . •.•.•............ - Secondary .........•. • . . . . . . . . . . . . Venturi diameter ....... . . . . . . . . . . . . . . . . ..•. ... ........ Float setting (+ ЗЪ) ............. . ........ . . . . .. ........ . Supplemental valve 5etti ng (+ i.J ........ . ... . . .. . .... .... . ' Ма ',п'Je t - Р г,та гу .. . .. .... . . . . . . . . . . . . . . . ... . . . . . . . . . Seco ndary metering rod identification ....... . . ... .. . .. ... .. . Pump 'еуег posit ion .... .... . . . . . . . . . . . . . . . . . . • . . . . . . . . Choke system: Bi- metal identification .... . . . . ..... . . . • .• ... . ..... . •. Сар 5etting . .......... .. •...• . . . .. . .•. ....... . .. . Pu lldown 5etting . . . . . . . . . . . . . . . . . . . . . . . .•.. . . . . . . .. Fast idle сат 5etting ... . •............ ... ... . . . .•.... Idle speed: Curb idle грт* ......... ... . ..• . •.... .. .• ...• . . .• . . Fa5t idle грт .... . . . ...... . •.•.........• .... .. ... .

D2ZF-GA Manual 1.56 1.96 1.25

D2ZF-AA Manual 1.56 1.96 1.25

D2ZF-8B Auto 1.56 1.96 1.25

D2ZF-DA Auto 1.56 1.96 1.25

~

0.030 61F 4 ring No 1

~

0. 030 61F 3 rin9 No 1

Ii

0.030 61F 3 rin9 No 1

~

0.030 61F 3 rin9 No 1

4ТУ

4ТУ

4Т Х

4ТХ

Index 0.200 0.180

Index 0.200 0.180

Index 0.200 0.200

Index 0.200 0 .200

1000/ 500 1200

1000/ 500 1200

700/500 1200

800/ 500 1200

а

Chapter 3 Fuel, exhaust and emission control systams

56

D2ZF-GA

D2ZF-AA 0.5

D2ZF-BB 0.5

deCOI%) .... ........ .. ... ... ...... .. ............. . · Higher И/е speed with throttle solenoid energized / loweг idle speed with throttle solenoid de-energized Motoгcгaft 4ЗООD caгbuгetoгs (аll dimens;ons

D2ZF- DA 0.5

in inchesJ

Carburetor No 9510 .. Т ransm lS510n ... . . . . . . . . . . . . . . ... ....... .......... .. . Throttle Ьоге diameter - Primaгy .. .....• .•............•.•. - Secondaгy . ..• . • .......... . . • .•. • . Venturi diameter . ... . . . . . . . . . . . . . ••••• •.• . . . • .•. •. ••• . Float 5etting (+ g) . . ............... . . .. . . . . . . . . . . ... .. . Supplemental valve 5etting (+~) . . . . . . . . . • . . . . . . . . . . . . . . . . Metering jet - Primaгy/Secon daгy ........• . •..... .... .... . Secondary meterlng rod identification ...... • . •..... ......... Pump lever p05ition .......... .... ..•.• . •. .• . . . . . . . . . .. Electric choke sY5tem: Bi-metal ide ntilicat ion . . . . . . . . . . . . . . • . • . • . . . . . . . . . . . . Сар 5etting ..................................... . Pul ldown 5etting ........• .• ....... • . • . • . . ..•....... Fa5t idle са т settl ng .... . • . •. • .. , .... • , .. . • , • , • , .. . , Idle 5peed : Curb idle грт .. . , , ... .. ........ , , .... • . • .......... Fast idle грт - kickdown .. , ..•.. , , , , , ...• , • ........ , , Idle СО (%) - California . " , .. " " , . . . . . . . . . . . . . . . . . . . . . . - Other . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rochesteг Quadгajet 4MV caгbuгetoгs (а" dimensions in inches) Carburetor No 9510 Transmis5ion .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Throttle Ьоге diameter - Primaгy ........... • .•..•...•.. . .. - Se con daгy .......• , ••.•.• . • . •.. . .. Venturi diameter . . . . . . . . . . . . . . . . . . . . . . .• .•. . . . ........ Adju5tment5: Float level ... ... ..... • .•............ •. •.......... Pump rod locat ion ....... .. . ..........•. , ..••.•• . . . Air valve da5hpot .......... .• • • • • , . . .. • .• .. ..•.•. •. Pulldown vacuum break .....•..........•. •. •.•.•.... Сат clea rance (choke rod) ....•.•..........•.•.•.•.... Unloader (dechoke) ......... . . . ........ • . • . • . • . • . .• . Air vatve lockout .... ... . ..... .• . • • . . .. • • • • •.• ....•. Curb idle грт . .... ..... . . . . . . . . . . . . . . . . . . .... . ...... . Fast idle rpm (second 5tep 01 сат) . . . . . . . . . . . . . . . . . . . . . . . . .

DЗZF-АС

DЗZF-ВС

DЗZF-DС

DЗZF-LA

DЗZF-МА

Manual 1.56 1.96 1.2 5

Auto 1.56 1.96 1.25

Мапиа l

1.56 1.96 1.25

Manual 1.56 1.96 1.25

Auto 1.56 1.96 1.25

~

~

~

~

~

0.030 62F 1 ring No 1

0 .030 60F 3 ring5 No 1

0 .030

1 ring No 1

0.030 62F 1 ring No 1

4ТОВ

4ТО

4ТН

4АР

4АР

Index 0.180 0. 180

1NR 0.170 0.170

Index 0.180 0.180

Index 0.170 0.170

Index 0.180 0.180

to engine decal 2000 1300 0.2 0.2 0.6 0.6

1300 0.2 0.6

0.030 6ЗF

6ЗF

3 rings No 1

Аеlег

1750 0.2 0.5

1750 0.2 0.6

DOOF- A Manual

DOOF-E Auto

Ч

Ч

2t 11>

2t 11>

I!

I!

Outboard 0.030 0.140 0.1 за 0.300 0 .015 700 1800 0.3

Outboard 0.030 0.190 0.166 0.300 0.015

650/ 500· 2000 0.3

"Higher idle speed with throttle solenoid energized /Iower idle speed with throttle solenoid de-energized 1

General description

The ca rburetors litted to Mustang V8 engine5 аге 01 the downdraft two- о г four-barrel type , which аге сараЫе 01 5upplying the correct аlг­ / fuel mixture under all operating conditiOn5. 80th the prima гy and secondaгy ve nturi5 аге provided with throttle valve5. The luel sY5tem compri5e5 а luel tank at the геаг 01 the саг, ап inliпе di5p05abIe fuel li1ter and а mechanically-operated luel ритр mounted оп the left 5ide 01 the cylinder lront cover. The ритр draw5 ga50line lгот the tank and deliver5 It to the carburetor. The gasoli ne level in the carburetor i5 controtled Ьу а Il0at-operated needte valve. Gasoline I1oW5 pa5t the need le valve until the I10at rises to а predetermined level and closes the needle valve. The luel риmр then freewheel5 under slight back ргеЗ5иге until the ga50line 'е уеl drops in the carburetor 11оа! chamber and the needle va lve opens. Variou5 arrangement5 of the emi5sion control sy5tem5 аге u5ed to control the amount 01 air pollution caused Ьу the emi5sion 01 сагЬоп monoxide, hydro-carbons and oxides of nitrogen produced Ьу the engine . Three type'5 01 emis5ion control 5Y5tem5 аге u5ed (thoug h not оп а ll models) ; these аге crankcase emiS5ion control, exhaust emission control and luel evaporation control. Further inlormation wil l Ье 10und in the relevant Section5 of this Chapter. Note: Before starting аnу

work оп the 'ие/ system refer to Section 2. 2

US Federal Regulations - emission control

The fuel 5Y5tem has Ьееп modified (accord ing to уевг and m ode l) 50 that the саг w ill compty with the US Federal Regulation5 covering em i5sion 01 hydrocarbons and с агЬоп m onox ide , То achieve this the

ign1t10n system must Ье accurately 5et using special equipment (зее Chapter 4 ) before апу attempt is made to adjust the carburetor ог it5 controls. Thereafter the fuel system тау Ье reset but оп ев again special equipment must Ье used. The information contained in this Chapter is given to assist the reader to clean andloverhaul the various co mponents but, when completed, the саг must Ье taken to the local Ford dealer 10г final adju5tment5 to Ье made. Failure to do this will ргоЬаЫу теап that the саг does по! comply with the regu lations.

э

Air cleener and duct systems - general description

тemperature-operated

type

The t emperature-operated 5y5tem has а thermostat ically control led valve plate within the duct. When the engine i5 cold the therm05tat maintain5 the valve plate in the raised position and air is drawn 1nto the air cleaner via а shroud tube. This en5ures тоге efficient fuel atomi5ation а5 the engine warm5 up. When the engine hes reached it5 normal operating temperature the therm05tat closes the plate valve and cool air is drawn into the air cleaner (see Fig 3.1).

Vacuum-operated type Оп the vacuum-operated 5Y5tem the plate valve i5 controlled Ьу

the inlet manilold vacuum. When the engine i5 cold, heated air 15 du cted Ьу the heat 5tove tube into the air cleaner, but а5 the engine warm5 up cold air i5 progres5ively m ixed with this warm air to maintain а carburetor air temperature of 105 to 130 0 F (40. 5 to 76.ВОС). At high ambient temperature5 t he hot air intake i5 Cl05Bd off completely. The mixing 01 air i5 regulated Ьу е vacuu m -operated motor оп the ai r cleaner inlet duct, which is controlted Ьу а bi-metal temperature 5еП50Г.

•

•

,---------------------------------------------------------------------57

I

I CLEAN ER

CLEANER

I

А"

•

,

НЕ"'Т ОН

Н ОТ

r

не",т

AIR

.,...,.. .,...,..

OFF

НОТ

AIR

Fig. 3.1 Temperature-operated duct and valve 8ssembly - operation (Sec. З)

I I I

AUXILIARY AIR

INlEТ

VAlVE

дно

VACUUМMOTOR ASSEмeLY

, I ,1 ," I I'

~ :' ~, ""

," ,'' ,.е

I

~

Fig. 3 .2 Air cleaner with 8uxiliary air inlet valve

MOTQR НООО

апd

V8cuum motors (Sec. 3)

НО(Ю. TQ.AIR

CLEANEJ< SEAl

DUCT

HOSE

ТО

IN TД KE МдNIFUШ

Fig. З . З 428 Cobra Jet r8m air сlsапеr assembIy (Sec . 31

дно

VAL У Е

-

Chapter 3 Fuel. exhaust and emission control systems Cobta Jet гат aiг intake Т'he гат

air system allows outside air to Ье forced through the fu.nctional hood scoop and Into the air cleaner during ареп throttle conditions. During погта' engine operation, air enters the air cleaner through the conventional duct and valve аssетЫу. When the intake manifold vacuum drops to 4 'П (101 тт) Hg (ореп throttle ог heavy load ) the vacuum motor орепз the гвт air valve. allowing air to Ье forced directly into the air cleaner from the hood air scoop. (Fig. 3.3)

BI·MEТAL SWITCH

VACUUM OFF

Оп аll

modets it 15 important that the air cleaner duct апd valve system operates correctly аз It affects the exhaust emission control system and тау result 'п the failure of the саг to meet Federal emission геgulэtiОП5.

4

Air cleaner duct and valve

а88етЫу

- tB8ting

Temperatuгe-operated (уре

VACUUМ он

1 With а cold engine and under-hood temperature 01 'е55 than 100 0 F (37.В О С) , the vatve plate should Ье in theHeat Оп p05ition (sее

ТО VACUUM SOURCE

MOTOR

Fig. З. 11. 2 11 the plate is not in the Heat Оп position check 10г sticking ог binding 01 the valve plate, and correct il песе55агу. 3 То check the therm05tat, remove the duct a5sembIy and immerse 11 in water 50 that the thermostat capsule 15 covered wlth water. Rai5e the water temperature to 1000 F (37.В О С) and check that the valve plate is in the Heat Оп position. 4 Rai5e the water temperature to 135°F (57.2 0 С) and check that the valve plate is 1п the Heat О" position. 5 11 the valve plale doe5 по! operate as specilied, the duct and va lve a55embIy must Ье renewed .

Vacuum-operated

ТО DUCT VALVE

Fig. 3.4 Vacuum-operated duct and valve assembIy

(Эее.

4)

(уре

6 Check that the duct valve is ореп when the engine 15 5witched off. Start the engine and check thal the valve closes when idling (except where the engine i5 hot). 11 Ihi5 lails to happen check 10г d15connected ог leaking vacuum lines and 10г соггес! operation 01 the bj-metal sensor (see Fig. 3.4). 7 Ореп and close the throttle rapidly. The valve should ореп during throttle opening. 11 this doe5 not happen check the va lve 10г binding. в The bi-metal switch сап Ье checked Ьу subjecting It to heated air (eg а halr dryer) ог removing it and immer5ing it in water heated to BO° F ( 26.7 0 С) . Only 51ight movement 01 the bl-metal i5 nece5sary to Un5eat the bteed valve. 9 То check the vacuum motor, 5tart the englne and check that the va cuum motor plate i5 lully cl05ed. Oi5connect the vacuum hose and check that the plate i5 in the lully ореп p05ition . 11 thi5 does not happen check 10г binding 01 the plate and motor rod , and lог vacuum lгот the motor. 11 there i5 по binding and there 15 по vacuum lrom the motor the vacuum motor 15 1aulty and mU5t Ье renewed.

5.3 Air cleaner with top

соуег

removed

engine. and is operated Ьу ап eccentric оп the front 01 the camshaft. 2 The pump i5 а sealed unit and cannot Ье repaired. 11 it develop5 1ault it must Ье discarded and а new pump in5talled.

а

R ат air intake 1О Check that the valve i5 ореп with the engine switched off ог the va cuum h05e di5connected. With the engine idling the ram air valve 5hould Ье cl05ed. 11 this does not happen check 10г valve binding, va cuum leak5 ог а disconnected vacuum 11пе . end rectify а5 nece5sary. 11 the sY5tem still does not lunction correctly renew the vacuum motor.

5

Air cle8ner 8nd filter 818ment -

гвmоvаlапd iП8t8118tiоп

7

Fuel pump -

Disconnect the vacuum h05e 1гот the vacuum motor (where аррli с аЫе ). and the crankca5e ventilation h05e from the air cleaner. 2 Remove the wingnut attaching the air cleaner to the carburetor and lift off the air cleaner and duct assembIy. 3 Aemove the air cleaner top соуег and take out the liller element

(8)

(photo l. 4 Inslallal10n i5 the геуеГ5е of the гетоуа' proceduгe , using new gaskets as necessary. Оп ram air 5Y5tem5 check the hood-Io-air cleaner seal 10г AII -round contact.

(с)

Fuel pump - description

1

The 1uel pump i5 located

(ь)

8 оп

the left 5ide 01 the lront

соуег

01 the

and instellation

1 Aemove the inlet and outlet pipes at the pump and plug the end5 10 5top luellos5, ог dirt 1inding its way into the 5ystem (photo). 2 Undo and гетоуе the two bolts and 5pring wa5hers that secuгe the pump to the lront соуег. 3 Lift away the luel pump and ga5ket. 4 In5tallation 01 the 1uel pump i5 the reverse 5equence to removal but there аге 5everal additional points that 5hould Ье noted:

1

6

гетОУ81

Пghtеn

the рuтр securing bolt$ to the spec'-!'-ed torque. 8efore reconnecting the Р'-ре !гот the !иеl tank (о the ритр , '-nlet, тОУ8 the end to 8 pO$it"on lower than the !иеl tank $0 that !иеl сап $yphon out. Quickly connect the pipe to the ритр inlet. O;sconnect the pipe В! the carburetor and шrn the engine оуег иntil gasoline '-s$ue$ !гот the ореn end. Quickly connect the pipe to the carburetor un;оn. This last oper8t'-on will help to рг"те the ритр.

Fuel pump - te.ting A5suming that the 1uel line5 and union5

аге

in good conditlon and

,

•

Chapter 3 Fuel. exhaust and emission control systems

I

59

11 Carburetor - generel description

The following two- and 'оиг-Ьаггеl carburetors аге used оп Mustangs with V8 engines. 80th types аге 01 downdralt design with automatic choke:

Two-barre/ type Autolite21002-V Autolite 21000 2-V Motorcгah 21000 2-V

Four-barre/ type Autolite 4300 4-V А utolite 43000 4- V Motorcraft 43000 4-V Ho//,y4150C4-V

Rochester Quadrajet 4MV

7.1 Disconnecting the fuellines 8t the fuel

ритр

, that there аге по leaks anywhere, check the performance of the fuel purnp in the following manner. Disconnect the fuel pipe at the саг­ buretor inlet union, and the high tension lead to the coi! and , with а suitabIe container ог large rag in position to catch the ejected fuel, turn the engine оуег. Д good Spurt of gasoline should emerge from the end of the pipe еуегу second revolution. CAUTION: 00 паС С8ГГУ оиС this

I

test when the engine is hot.

9

Fuel filter - renewal

1

Initia lly remove the carburetor air cleanet.

2

Loosen the fuel line clips at the filter,

риН

off the fuel lines and

discard the clips. Оп later models, unscrew the filter from the саг­ buretor, In5tall the new f11ter using new еНР5 , 5tart the eng1ne and eheek for 3 fuel leak5 Note: If the new Ijlter shows the direction 01 'иеl f/ow, take саге

4

that it is installed the correct way round. In5tall the air cleaner.

1 О Carburet10n - warning

,

,

1 Before making апу adjustment ог alterat10n to the carburetor ог emi5sion control sY5tem5 the owner i5 advised to make him5elf aware of апу Federa l, 5tate ог Prov1ncial laws which тау Ье contravened Ьу making апу 5uch adju5tment ог 8lterat10n. 2 5etting dimen5ion5 and 5pecifieat10n5 аге given in thi5 Chapter where relevant to adju5tment procedure5, Where the5e differ from th05e given оп the engine tune-up decal (if 50 equipped), the decal information should Ье a5sumed to Ье correct. 3 Where the use of 5pecial te5t equipment 15 called up (eg, exhau5t ga5 СО analyzer, etc), and this equipment i5 not availabIe, апу setting ог calibrat10n 5hould Ье regarded а5 а temporary теа5ше only and should Ье rechecked Ьу а suitabIy equipped Ford dealer ог саг­ buretion/ emi55ion con trol 5pecialist at the earHest opportunity. 4 Before attempting апу ea rburetor adjustment5, fif5t asceгtain that the following items аге 5eгv1ceaЫe ог correctly 5et: (а) (Ы (с)

(d)

А"

vacuum hoses and connections Ignition system Spark plugs Ignition jnitial advance

5 If sat1sfactory adjustment cannot p01nt5: (.) с arburetor fuellevel

,

(Ы (с)

(d) (,)

Ье

Crankcase ventilation system Va/ve clearances Engine compression Idle mixture.

obtained check the follow1ng

Туре 2100 carburetor (Autolite and Motorcraftl The carburetor has two main assembIies; these аге the air horn and the та1п body, The а1г hoгn assembly contain5 the ehoke plate and the internal vent5 for the fuel bowl. The throttle plate, the accelerating pump assembIy, the power valve aS5embIy and the fuel bowl аге in the main body ; the automat1c choke hou5ing 15 attached to the main body, Ea ch Ьоге eontains а main and а bo05ter ven turi , main fuel d1scharge, accelerating pump diseharge, idle fuel di5charge and а throttle plate, The Autolite 21000 2-V has а two-piece fast idle 'еуег and the crankca5e em1ssion h05B eonnection 15 incorporated in the та!п body. The Motorcraft 21000 ha5 ап electric choke 5Y5tem eonsisting of а choke сар, thermostatic spri ng, а bl-metal temperature 5en5ing 5witch and а ceramie heater, The choke i5 powered from the center tap of the alternator (see Fig . 3.1 О). А! temperature5 below 60°F (1 5.6 0 С) the switch i5 ореп; at аЬоуе 60°F the sw1tch closes and current is 5upplied to the ceramic heater. As the heater warms, It caU5e5 the thermostat spring to pufl the choke plates open within 1t minute5. Туре 4300 (Autolite and Motorcraft) The carburetor has three main assembIies ; these аге the air horn, main body and throttle body. The main (primary) fuel 5Y5tem ha5 bo05ter-type venturis ca5t integral with the air horn and the main venturis аге ca5t 1ntegral with the main body. The secondary throttle plates аге mechanically operated from the primary linkage, The secondary а1г valve plates аге located аЬоуе the 5eeondary Ьоге, Secondary fuel supply 15 controlled Ьу metering rods which аге at1aehed to the а1г valve plates, А slngle fuel bowl 5upplie5 both the primary and secondary system5. The accelerating pump i5 located in the fuel bowl. The automatic choke 5Y5tem 15 а bj-metal thermo5tatic type whieh operates when the under-hood temperature i5 below 60 ° F (15.6 0 С). The Motorcraft 43000 carburetor has an electric choke sY5tem which i5 the 5ате as that оп the Motorcraft 23000 carburetor described previou5ly. Туре 4150С (Holley) The fuel inlet SY5tem contain5 ап external fuel distribution tube whieh passe5 fue l from the primary fuel inlet to the secondary fuel inlet. The рг1тагу fuel bowl is vented duгing euгb and off-idle engine operation through а vent valve, actuated Ьу а 'еуег оп the throttle shaft, The primary 5tage of the earburetor contains а fuel bowl , fuel bowl vent, тetering bIock and ап aeeelerating pump, The pгimary power valve i5 located in the primary metering bIock. The primary bores each contain а primary and bo05ter ventuгi , main fuel discharge nozzle, throttle plate and ап idle fuel pa5sage, The choke plate, mounted оп the air horn, i5 controlled Ьу ап automatic ehoke mechani5m, The secondary 5tage contain5 the secondary fuel bowl, metering bIock and throttle operating diaphragm aS5embIie5. The 5econdary bores each contain а primary and booster venturi, а transfer system, а main secondary fuel di5eharge nozzle and а throttle plate.

Rochester Quadrajet 4MV The Quadrajet carburetor ha5 two stages of operation, The pгimary side ha5 а triple venturi set-up equipped with plain tube nozzles,

3

-

60 FUEL BOWL THERMOSTATIC SPRING HOUSING

СНОКЕ

NG

MAIN СНОКЕ

ВООУ

HOUSING

SHIELO

/

FUEL BOWL VENT VALVE ТНRОТТLЕ

LEVER SHAF T

ANTI - STALL DASHPUT

АССЕ

TING PUMP ASSEMB L У

IDLE

MITER

Fig . 3.5 Autolite 2100 carburetor - 18ft ftont

,

СНОКЕ

д'"

i

VACUUM

FAST IDLE СНО КЕ

МAIN ВООУ

view (Sec. 101

д'"

CLEAN

TU.'

СНОКЕ НЕд ТЕО

AIR INlET ТНRОПlЕ

'"D

LEVER SPRING

/ VACUUМ PISTON HOUSING DISТRIBUTQR

VACUUM

•

'P[JII',R VALVE PICK-UP LIMITER

....." ""'Т VAL УЕ ROO

, Fig . З . 6 Autolite 21 00 carburetor - bottom view (Sec. 1 О)

•

61 INTERNAL BOWL С НОКЕ PLдТE

I

AUTOMATIC

СНОКЕ

СНОКЕ

DIAPHRAGM

LINK

•

I

FUEL INLET

•

l...-. _

_

_

MAIN ВООУ

//

I

ACCELERAТlNG

THROnLE LEVER

PUMP ASSEMBLY

I Fig. Э.7 Autolite 21 ооо carburetor -18ft front

1 view (S"C. 1 01

СНОКЕ

DIAPHRAGM STOP

DIAPHRAGM VACUUM AIR

FASTIDLE ADJUSTING СНОКЕ НЕАТ

TUBE

! THROnLE

_ _ FAST IDLE САМ

I

THROnLE _

"'"

PLдTES

-

IDLE

IDLE

LIMIТER

STOP АССЕ

NG PUMP ASSEMBL У

Fig. 3.8 Autolite 21 OOD carbur8tor - bottom view ISec. 1 О)

62 С НО К Е P lA ТE

ACCELERATOR P UМ?

l EVER

\

CURB

ЮLЕ

ADJUSТI N G

Fig. 3.9 Motorcraft 21000 carburetor -Ieft front

t

view (5ес. 10)

ELEC TA IC С Н О"'Е еде

•

CENTEATAP OF _______________ ALТEANATOR

t8LACK IОЕNТIFI С АТЮN AING I

Fig. 3.1 О Electric choke wiring connections

SPEED SCREW

(58С.

1 О)

•

~-----------------------------------------------------------------63

ACCElERATING

СНОКЕ

F'\JМP !Т'"

ACCELERД TING PUМP

THERМOSTA ТlC

LEVER

I

AIR

I

VДLVЕ

.00

FUEL

IDlE

ТНRОТТLЕ SНAFT

-

АНО

DISTRIBUTOR PICK·UP ТUBe

Fig. З , 11 AutoJite 4300 carburetor -Ieft front

t

lEVER

viвw (Sec . 1 О)

i ACCELERATING PUМP

FAST IDLE СНОКЕ

I

САМ

SCREW

сноке

DASHPQT

3 СНОКЕ

THERMOSTAТlC

SPRING

I

I

I

lDlE ADJUST1HG SCREW

LEVER

СQNNЕСТЮN

-

• AIR VALVE tDLE C(»,\PEH5ATOR

QASHPQT

Fig.

З.,

2 Autolite 4300 carburetor - top view (Sec. 1 о!

Chapter 3 Fuel. exhaust and emission control systems Орвг;)ноп

is similar to mast carburetors using the venturi principle. ~ rip le venturi stack~up, plus the smaH primary bores, result in тоге S'. able and finer fue! control during idle and part-throttle operation.

Ouring off-idle and part-throttle, fuel metering is achieved with tapered m etering rods operating in specially designed jets, positioned

Ьу а

manifold-vacu um-responsive piston.

The secondary side has two bores. These, added to the primary, •

supply enough air to meet engine requirements. The air valve is used in the secondary side for metering control and supplements the primary bores to meet air and fuel requirements of the engine.

The secondary air valve mechanically operates tapered metering rods, which move in oriflce plates , so that fuel flow from the secondary nozzles Is controlled in direct proportion to air flowing through the secondary bores. The primaгy side of the ca rburetor has six operating systems; these аге float, idle, main metering, power, pump and choke. The secondary side has опе main metering system. AII metering systems receive fuel from the опе floa1 bowl.

Solenoid throttle positioner А

solenoid throttle positioner assembIy is incorporated оп certain versions of the different types of carburetor to prevent dieseling (running-on) after the ignition has Ьееп switched off, Ьу allowing the throttle DJates to close b~yond the point required for idling.

12 Carburetor adjustments - general The method of adjusting the two- and fоuг-ЬаггеJ carburetors is basically the same for both types. То identify the location of the adjusting screws and components for each type of carburetor reference should Ье made to the appropriate illustrations which accompanies the text. Aher adjustments have Ьееп carried out, the саг must Ье taken to а Ford service station for final checking to ensure that the exhaust emission is within the limits specified Ьу Federal Aegulations. 13

СшЬ

idle speed and fuel mixture - adjustment

1 Apply the parking brake and chock the road wheels. 2 Check the choke and throttle linkage for freedom of movement and adju$t if necessary. 3 То епаЫе the carburetor to Ье $et correctly it will Ье necessary to attach а tachometer unless the саг i$ already зо equipped. 4 Where applicabIe set the air conditioning to Off. 5 5et the automatic transmission to P8rk, ог manual transmi$$ion in Neutra/, then run the engine at normal operating temperature. Check that the choke plates аге in the fully ореп position.

СНОКЕ

THERMOSTA ТIС SPRING HOUSING

THROHLE SOLENOID

SOLENOID ADJ USrING SCREW

SCREW KICKDOWN LINКAGE

ADJUSTING SCREW AIR

DISTRIBU ТlON

TUNNELS

ТНRОТТLЕ sтop

SCREW

Fig. 3.1 3 Motorcraft 4300О carburetor (Sec. 1 О)

~-----------------------------------------------------------~ PLATE

FUEL BOWL

PRIМARY

I •

yE NТ

дно SНAFT

ROO

,до,

FUE L BOWL SECONDARY FUEL

FUEL INLET

INLEТ

NEEDLE

•

METERING BLOCK

SНAFT

IN LET PRIМARY

LE

SHAFT ASSEMBLY

Fig . 3 .14 Holley

P R1МARY

4150С

THR OHLE ASSEMBL У

IDLE AD JUSTMENT SCREW

carburetor - Ieft side view (Sec. 1 О)

PRlМARY SТAGE

FUEL

PLATES POWER VALVE VACUUМ

I

3

I I

I f I

SPEED AOJUSTMENT SCREW

SECONDARY

SECONDAR'r THRDH LE sтop SCREW

SТAGE

ТНRDТТLЕ PLдTES

SECONDARY FUEL BOttL

Fig. 3 .' 5 Holley

4150С

carburetor - bottom view (Sec. 10)

~----------------------------------------------------------~

SECONDAAY METEAING

СНОКЕ

AIA

PLATE

SECONDAAY AIA VALVE LEVEA

АОО

СНОКЕ

CONTAOL

•

FUEL INLET

ВАЕАК

CONTAOL LEVEA

FAST

САМ

DLE FOLLOWEA

САМ

Fig. 3.16 Rochester Quadrajet 4MV carburetor - right rear view

PLAТE

(Эве.

1 О)

SECONDARY METERING ROO

AI.

VACUUM

IDLE

ТНRОТТLЕ

SНAH АНО

FUEL. _ _ __ FILTER

"'--LEVER

:U.B IDLE

ADJUSTING SCREW IDLE SOLEHOID POSITIONER

Fig. 3.17 Rochester Quadrajet 4MV carburetor -18п front view (See. 101

•

Chapter 3 Fuel. exhaust and emission control systems 6

Оп сзгs

with automatic transmission place the selector

'еуег ёп

ОПvе pos itioл .

7 дdjust the curb idle screw in ог out 10 obtain the specified curb idle speed. If il is not possibIe 10 adjust the idle speed with the air Cl eaner ё п position . гетоуе it, make the adjustment, then install the аёг сlв а лег again and recheck the idle speed . 8 Where а throttle solenoid i5 fitted, tuгл the solenoid adjusting •

screw , located in the solenoid mоuпtiпg bracket. 10 obtain the specified curb idle speed. Disconnect the solenoid wire at the соп ­ nector пеаг the wiring harness then adjust the curb idle SCf8W 10

obta in the specified idle speed. Connect the solenoid wire and

ореп

the throttle slightly Ьу hand. The solenoid plunger will remain in the extended p05ition а5 IOn9 а5 the ignition 15 Оп and the 50lenoid i5 energized. 9 Тшп the idle mixture 5creW5 within the range of the limiting саР5 to obtain the 5moothe5t idle p055ibIe. Where the idle mixture i5 too rich , indicated Ьу а 500ty exhau5t 5moke and the engine hunting,

67

rotate the 5creW5 clockwi5e. Where the mixture i5 too lean , indicated Ьу the engine 5peed tending to increase then decrease, and p055ibIy а 'hollow' exhau5t note, rotate the 5creW5 counterclockwise. , О Reset the idJe speed after the mixture i5 sati5factorily adjusted . , 1 If the idle mixture cannot Ье set sati5factorily within the гапое of the limiting сарз , pull off the сарз and adju5t the mixture scr8W5 but re-in5tall the caps afterward5, In сазе it is not possibIe to obtain а satisfactory s8tting, rotate each screw in turn , counting the exact number of turn5 to jU5t зеаl It, then back off the same number of turns . Thi5 will give а datum point from which adju5tment сап соттепсе. 80th 5creW5 сап Ье expected to Ье the 5ате number of turns from the 5eat when correctly 5et, after which the limitin9 сар must Ье ге­ in5talled. 12 Оп completion of вnу idle тixture adju5tment, ensure that the setting is checked Ьу а Ford dealer ог carburetor/ emission control specialist at the earlie5t opportunity.

llМlТERS

IDLE SPEED ADJUSTING SCREW

Fig. 3.18 Idle fuel mixture adjusting limiters - 2100D carburetor (Soc. 1 З)

Fig. 3.19 Curb idle speed adju5ting screw - 2100D cerburetor (Soc. 1 З)

FLOAT ADJUSTMENT IDLE

3

XTURE

l

I CURB IDLE SPEED

Fig . 3 .20 Idle fuel mixture adjusting limiters - 4300D carburetor (Sec. , 31

IDLE SPEED

ADJUSТI

SCREW

о

о ACCELERATING PUMP OVERRIDE SPRING DASHPOT

Fig. 3.21 Curb idle speed adjusting screw4300D carburetor (Sec. 131

Fig. 3.22 Holley 4150С carburetor adjustments (Sec. 131

•

Chapter 3

68

Fuвl,

exhaust and emission control systems 2 Loosen the thermostatic spring housing clamp securing screws. 3 5et the spring housing to the specified index mark, (эее Specifica· tion5 at the beginning of this Chapter). Turning the housing clockwise will give а leaner mixture (Fig. 3.26). 4 Install the heater hose and mounting bracket. and the air cleaner 8ssembIy.

Anri-sra// dashpor (if insra//ed) •

ACCELERATING PUMP SOLENOID

:=- CURB IDLE ADJUSTING SCREW

ТНRОТТLЕ

POSITIONER

5

With the engine at normal operating temperature, and the idle

speed and mixture properly adjusted , 1005en the dashpot lосkпut. 6 Hold the throttle in the closed position and depress the plunger with а screwdriver. then measure the clearance between the throttle lever and the plunger (Fig. 3.27). 7 Turn the dashpot in the direction required to obtain the зрееifiеd elearanee between the tip of the plunger and the throttle lever. 8 Tighten the loeknut and then reeheek the adjustment.

Acce/eraring рumр srroke serring IDLE FUEL MIXTURE LIMIТER Fig. 3.23 Rochester Quadrajet 4MV carburetor (See. 13)

14 Fast idle speed - adjustment

The fast idle speed adjusting screw contacts оnе edge о' the fast idle сат. The сат permits а faster engine idle speed 'ог smoother running when the engine is cold during choke орегаиоn. 1 Cheek that the eurb idte speed and mixture аге adjusted to speeification before 5etting the fa5t id le 5peed (see Section 13). 2 Run the engine to погтаl operating temperature and remove the а1г cleaner. 3 Connect а tachometer. if necessary. 4 Manually rotate the fast idle сат until the fa5t idle adju5ting screw rests оп the 5pecified step of the сат. 5 Turn the fa5t idle adjusting screw inward ог outward. а5 required, to obtain the specifled fast idle 5peed. 6 Switch off the engine, dlsconnect the tachometer (where applicаЫе) and re-lnstall the а1г eleaner.

15 Autolite and Motoreraft 21 00 earburetors - adjustments

9 The aecelerating pump stroke should not Ье altered from the specified settlng. If i1 has Ьееп altered. ог after repair. S8t the stroke аз follows. 1 О The primary throttle shaft lever (overtravel lever! has 4 holes and the accelerating pump link has 2 holes (5ее Fig. 3.28) to control the pump stroke. 11 Release the operatlng rod from the retalning clip Ьу ргезsiпg the tab end of the сliр toward the rod. and at the same time pres5 the rod away from the cl ip. 12 Position the clip over the specified hole in the overtravel lever. Press the ends of the clip together and insert the operating rod through the elip and the overtravellever. Release the elip to engage the rod.

Choke р/асе pu//down -Aurolire

сагЬuгесог

13 Remove the а1г cleaner. 14 With the engine at normal орегаНпя temperature, 100sen the choke therm05tatic 5pring houslng securing screw and set the housing 900 in the rieh direction (counterclockwise!. 15 Disconnect the heater hose from the choke houslng. 16 Turn the fast idle adju5ting serew outward опе fuB tuгn. 17 Start the engine, then eheck for the specified clearance Ьу insertIng а drill, of the appropriate diameter, between the lower edge of the ehoke plate and the air horn wall, (see Fig . 3.29). 18 Adjust the cleara nce, If neeessary, Ьу turning the diaphragm 5topscrew, clockwise to decrease ог countercloekwise to increase the elearance. 19 Reconnect the heater hose and set the choke thermostatlc spring hou5ing to specification. Adjust the fa5t idle speed (see Section 14).

Auromaric choke rhermosraric spring housing 1 Remove the air cleaner aS5embly, and the heater hose and mounting bracket (where applicable) from the carburetor. FДSТ IDLE СДМ ДDJUSТING SCR E\I/

FДSТ

HOUS\NG

'НDЕХ МARK

IDL E

САМ

-

HOUSIНG FдST

IDLE

СДМ

FДSТ

IOLE SPEED ДDJUSТING SCRE\I/

Fig. 3.24 Fast idle speed adjustment 2100D carburetor ISec. 14) Fig. 3 .25 Fast idle sp6ed adjustment 4ЗООD carburetor (See. 14)

INDEX W.RK

Fig. 3.26 Automatic choke thermo8tBtie spring housing adjustment {21 00 earburetor! (Sec. 15)

~-----------------------------------------------------------~

ADJUSTTO $PECIFIED C LEARANCE

PLUNGER

I

•

Fig. 3.27 Anti-stall dashpot adjustment (2100 carburetor) (Sec. 15)

PUMP

___---NO 1

_ _-No2 '--No3

t )

No 4

, •

I

OPERATING АОО

Fig. 3.28 Accelerator pump stroke adjustment (2100 carburetor) (Sec. 151 ОАI

LL ОА GAUGE OF SPECIFIED CLEARANCE

I

l

3

•

FAST IDLE

САМ

ADJUSТlNG

SCREW

I I

•

С НОКЕ НЕАТ

, DIAPHRAGM STOP SCR

FASTIDLE ADJUSTING SCREW

TUBE CONNECTION

I I

Fig. 3.29 Checking the choke plate pulldown clearance (2100 carburetor) (Sec. 151

Chapter 3 Fuel. exhaust and emission control systems

70 .п .о

.-, fuel meter, по specific clearance is indicated far pulldown ustment. If there is ап indication of lean mixture during cold start-

1!"Ig. ",а -

decrease the clearance between the choke plate and the air horn Ьу

0.02 in (0.5 mm) Ьу turning the diaphragm stop screw clockwise. 22 If ап overrich condition is indicated during cold starting, increase те puJldown clearance Ьу 0.02 in (0.5 тт) Ьу tuгning the diaphragm

IDLE 'JlJS.TI~II' SCREW

stop screw counterclockwisв. •

23 If further adjustment is necessary always тake the adjustments in steps of 0.02 in (0.5 mm). If the original putldown adjustment i5 1051, set the clearance between the choke plate and the air horn 10 0.16 in (4.0 mm); then adjust as required in steps 010.02 in (0.5 тт). 24 Саггу out the procedures described in paragraph 19.

Fast idle

саm

CONVENTIONAL ONE • PIECE

саm

IDLE LEVER

clearance -Autolite carburetors

25 Loosen the choke thermostatic spring housing securing screws and set the housing 900 in the rich direction. 26 Position the fast idle speed screw at the kickdown step of the fast idle сат. The kickdown step is identified Ьу а 'V' stamped оп the сат (5ее Fig. 3.301 . 27 Оп Э51-С and 400 engines, а two-piece fast idle is used to provide clearance between the lever and manifold , and а tang оп the top 'еуег will align with the V-mark оп the сат. 28 Check for the specilied clearance between the lower edge 01 the choke plate and the air horn wall, using а drill 01 appropriate diameter to determine the clearance. 29 ТО adjust. turn the fast idle сат clearance adjusting screw clockwise to increase and counterclockwise to decrease the clearance. 30 5et the choke thermostatic spring housing to specifications. adjust the dashpot (where applicabIe). and the idle speed and fuel mixture.

Fast idle

FASТ

сд м

TWO·

clearance - Motorcraft carbuгetor

31 Rotate the choke thermostatic spring housing 900 in the rich direction. 32 Position the last idle speed screw ог lever оп the high step of the сащ then depress the choke pulldown diaphragm against the diaphragm 5tOP screw {о place the choke in the pulldown position . 33 While holding the choke pulldown diaphragm depressed. ореп the throttle slightly and allow the fa5t idle сат to lall. then close the throttle and check the position of the last id le сат ог lever. The screw should contact the сат at the V-ma rk оп the сат. Adjust the fast idle сат adjusting screw {о obtain the correct setting. 34 Reset the choke thermostatic spring hou5ing {о specilications.

РIЕСЕ

FAST IDLE LEVER FOR ЗS1·С ENGINE

Fig. 3.30 Fest idle levers - Autolite 21000 cerburetor (Sec. 15)

,•

\:.':11

Fuellevel float adjustment - dry This is а preliminary adjustment made after repair ог overhaul with the carburetor off the engine. Ппаl adjustment (set) is made after the carburetor is installed оп the engine. 35 With the air horn removed , the 11оа! raised and the fuel inlet needle seated. check the distance between the top suгface of the main body casting and the top 01 the float. Depress the float {аЬ to seat the lиеl inlet needle. Take the mea5urement пеаг the center 01 the I10at at the point t in lгот the Iгее end 01 the Il0at. 36 11 а I10at level gauge is used. place the gauge in the согпег of the enlarged end section 01 the fuel bowl (see Fig. 3.31 ). The gauge should touch the float пеаг the end , but not оп the end radius. 37 Adjust. if necessary, Ьу bending the tab оп the I10at to obta in the specified setting.

TOUCH

Дт

THtS POtNi

Fig.3.31 Fuellevel I10at adjustment (dгy) (Sec. 15) •

Fuellevel f/08t 8djustment - wet 38 With the саг оп level ground and the engine at normal operating temperature. remove the afr cleaner assembIy and anchor screw. 39 Remove the air horn securing screW5 and the carburetor identification tag . Leave the air horn and gasket in position. 40 Staгt the engine and let It idle for а few minutes, then rotate the air horn out of the way and геmоуе the gasket to provide access to the I10at аssеmЫу. 41 While the engine is idling, use а depth gauge to measure the distance lгот the top machined suгface of the carburetor body to the level 01 the luel in the fuel bowl. The measurement must Ье made at least 1- in away from апу veгtica l suгface (see Fig. 3 .32). 42 Before mak ing апу adjustment, stop the engine for safety reasons. То adjust the luellevel. bend the I10at tab upwards to raise the level ог downwards to lower it. 43 When checking the level after each adjustment, allow the engine to idle 10г а few minutes to stabilize the luellevel. Check the fuel level

Fig. 3.32 Fuellevel I10et adjustment (wet) (Sec. 15)

,

Chapter 3 Fuel. exhaust and emission control systems

thread) оп the choke plate shaft and ргу the link away from the tapered

efter each adjustment until the specified level is obtained.

44

nstall the air horn and identification ta9 using

I nsu П

а

new gasket.

, ----------------------------16 Autolite end Motorcraft 4300 carburetor5 - adjustment5 А utomatic

choke thermostatic spring housing

1

The procedure i5 the 5ame ( 5ее 5ection 15).

l

а5

described for 21 OO-type carburetors

Anti-sta// dashpot (if insta//ed) 2

The procedure is the same as described for 21 OO-type carburetors ( 5ее Section 15).

Accelerating рumр stroke setting 3 The procedure i5 the same а5 de5cribed for 21 OO-type carburetors

•

(5ее

5ection 15).

Choke plate pu//down 4 Remove the air cleaner and the choke thermostati c spring hou5ing. 5 Bend а wire gauge of 0.036 in diameter at а 90 0 angle approximately t in from опе end. 810ck the throttle about half ореп 50 that the fast idle сет does not contact the fa5t idle adju5tment screw, then insert the bent end 01 the wire gauge between the lower edge of the piston slot and the upper edge of the right-hand slot in the choke housing ( 5ее Fig. 3.33). 6 Pull the choke piston 'еуег counterclockwi5e until the gauge Is 5nug in the pi5ton 510t. Check the choke plate cleara nce (pulldown) between the lower edge 01 the choke plate and the waB of the air horn. 7 То adju5t , if necessary, loosen the hexagon-head 5crew (Ieft-hand

,

СНОКЕ

shaft. 8

the air cleaner anchor screw.

45 Check the idle speed and fuel mixture adjustment, and al50 the dashpot setting (where applicable) , 46 1"$1all the air cleaner assembIy.

,

71

Insert

а

drill, 0.01 О in less than the specified clearance, between

the lower edge of the choke plate and the wall of the air horn . Hold the plate against the drill and with the choke piston snug against the 0.036 in wire gauge tighten the hexagon ~ head screw in the choke plate shaft. The 0.0 1О in drill is used to allow for toleranC6S in the linkage. Use а drill of diameter equal to the specified clearance for final checking . 9 Install the choke thermostatic spring housing and the air cleaner.

Fast idle

саm

clearance adiustment

1 О Rotate the spring housing counterclockwise 90 0 past the index mark alignment point. 11 P05ition the fa5t idle 5peed adju5ting screw оп the kickdown (center) step of the fast idle cam and check the clearance between tne lower edge of the choke plate and the air horn wall. Тшп the fast idle cam adjust ing screw inward to increase. ог outward to decrease . the clearance (see Fig . 3.33). 12 5et the thermostatic choke housing to the specified index mark and tighten the 5ecuring 5crews. 13 Check the idle 5peed . fuel mixture and da5hpot (where аррliсаЫе) adju5tments.

Fuellevel float and auxiliaгy (supplementa!) valve setting 14 Fabricate

а

floa t gauge and bending 1001, to the dimensions as shown in Fig. 3.34. for checking the рага1lеl setting of the dual роп ­ toons. 15 Adjust the gauge to the specified height and fit it оп the air horn as shown in Fig. 3.35. 16 Check the alignment and clearance 01 the pontoons to the gauge. 80th pontoons should just touch the gauge. Align the pontoons, if necessaгy Ьу slightly twisting them. 17 Float clearance is adjusted Ьу bending the primary needle tab. downward to raise the I10at and upward to lower it. using the bending tool.

DRILL GAUGE OF SPECI F I ЕО CLEARANCE SIZE

PLATE

ТАРЕА-

LOCK

SCREW

3

СНОКЕ SHAFT HAND ТНАЕАО}

,

FAST IDLE САМ USTING САМ

0.036 inch

i

...\.-_ WIRE GAUGE ,

I APPLY FAST IDLE SCREW

I

ТО СНОКЕ

PRESSURE LEVER

Fig . З.ЗЗ Choke plate pulldown and 1a5t idle сат adjustment (4300 carburetorl (Sec. 16)

-

•

DRI LL ТWO 3116" HOlES 6"

CENT ERS

•

н о.

12· 32

~

н о.

12 NUT S (6 REQ ' O.)

2" SCREWS (2 REQ'O.)

В ОТ Н N UТS Т О F LOдT

НЕIGНТ SP E C I FICд T IONS

1/8" TOOl - 1/ 16" Dl дМЕ ТЕ R SPRING STEEL WIRE OR WELDING Roo, 8" LONG

-

Fig. 3 .34 Float

оаиов

and bending tool (Sec . 16)

ВЕН О ТА 8 Т О

F LOд TS SHOULD

СО НТ ДСТ

3/' "

OR LONER FLOAT

GAUGE

SET ТО SPECIF ICA Т toNS

INSTALL FR O'!I TH IS

Р1Н 5 IDЕ

Fig . 3 .35 Float setting (4300 carburetorllSec. 16)

•

AUXILIARY VALVE CLEARANCE

Fig. 3.36 Checking the 8uxiliary valve clearance (4300 carburotor) (Sec. 16)

Fig. 3 .37 Adjusting the accelerating ритр override cl8srance (Holley 41 БОС carburetorl (Sec . 17)

•

Chapter 3 Fuel. exhaust and emission control systems

73

18 Ch eck the auxiliary valve clearance (see Fig. 3.36). If necessary, adjust ьу bending the auxiliary valve and float tab, as required, with the

bending tooll Fig. 3.34). 17 Holley 4150С carburetor - adjustments

Automatic choke thermostatic spring housing 1 The procedure i5 the . buretor (see Section 15).

З8те

as described for the Autolite 2100

саг-

58те

as described for the Autolite 2100

саг­

Anti-sta/l dashpot 2

The procedure i5 the

buretor (see Section 1 5). Acce/eГ8ting рumр oveгride cleaгance

3 With the primaгy throttle plates in the wide ареп position, use а feeler gauge to check that the clearance between the pump operating lеуег adjusting screw head and the pump агт , when the pump аrт 15 fuBy depressed manuatly, i5 to specification (see Fig. 3.37). 4 Adjust , if necessary, Ьу turning the adjusting screw in to increase, ог out to decrease, the clearance. Опе half turn of the adjusting screw is equal to 0.015 in.

Choke plate clearance and fast idle

саm

adjustment

Remove the choke thermostatic housing сар. 6 Hold the choke plate fully closed and measure the distance between the flat of the fast idle cam and the choke housing mounting post (see Fig. 3 .38). If necessaгy straighten ог bend the choke rod to obtain the specified clearance. 7 Bend а 0 . ОЗ6 in wire at а 90 0 angle approximately Й in from опе end. Insert the bent end between the lower edge of the piston slot and the upper edge of the slot in the choke housing (Fig. 3.39). Ореп the throttle lever to about t throttle and rotate the choke lever counterclockwise so that the bent end of the wire is held in the housing slot Ьу the piston 510t with light pressure applied to the choke lever. Measure the clea rance between the air horn and the lower edge of the choke plate. Adjust, if necessaгy , Ьу bending the adju5ting tзЬ оп the choke lever to obtain the specified clearance. 8 In5tall the choke therm05tatic hou5ing сар and set the сар notch to 5pecification. 9 Соппес, а tachometer to the engine and. with the engine at погтаl operating temperature, set the fast idle 5crew оп the kickdown ог second high step of the fast idle сат. 10 In5tatl the choke therm05tatic hou5ing сар.

5

Fig.

З . 38

Fast idle

сат

adjustment (Holley 4150С carburetor) (5"с.

171

Fuellevel ПОдt adjustment - dry 11 As а preliminaгy adjustment, after repair ог overhaul , adjust the float зо that the center of the float is ап equal distan ce from the top and bottom of the fuel bowl (зее Fig . 3.40). 110LD

I

Fuellevel Поаt adjustment - wet

I

12 With the саг оп а level suгface and the engine а! normal operating temperatu re , check the fuellevel in e8ch fuel bowl separately. Rem ove the air cleaner. 13 Place а suita bIe container below the luel level sight plug to collect апу spillage of fuel. Remove the fuellevel sight plug and check that the fuel level is within" in of the lower edge 01 the sight plug opening. 14 If the level 1з too high it should first Ье lowered below specification and then raised to the correct level. If the level is too low ra ise it to the specified levet. 15 То lower the fuellevel proceed as f ollows: (а) Wich che engine stopped, !oosen the /ock screw оп сор о{ the 'ие/ bow! just enough to allow turning о{ the adjusting nи С underneath fFig. 3.41). CAUТlON : Оо nоС attempt СО adjust the 'иеl 'еуеl w ith the sight plug removed 8nd the eng;ne runn;ng 8S the pressure in the Нnе will SPf8Y 'иеl оuс and present а {iгe hazard. (Ь) Тит the adjusting пиС approximate/y t Сит ;п со lower the fuelleve! Со below specification (с) Tighten the lock screw and install the (иеl level sight р/иу. Start the engine. After the (ие/ 'еуе/ has stabilized stop the engine and check the fuellevel аС the sight р!иу opening. If it is аЬоуе the specified limit гвреаС the previaus steps, turning the adjusting пиС sufficient ta lawer the (ие! be/a w rhe specified /еуе/

Fig. 3.39 Choke plate pulldown adjustment (Holley 4150С carburetor) (Sec, 17)

TUAN ADJUSTING NUT UNTIL CENTER OF FLOAT 15 AN EQUAL DISTANCE FROM тор AND ваттом OF BOWL WITH FUEl BOWL INVЕfПЕD

Fig. 3.40 Float adjustment -

dгy

(5"с.171

•

(Holley 4150С carburetor)

•

Chapter 3 Fuel. exhaust and emission control systems

74 fd}

Loosen the 'оск $crew and (urп the adjusting лиt out in ;псге­ ments о{ 1/6 Сит ог less uпtil the carreet (uеl 'еуе/ ;5 obtained. Aher each adjustment, tighten the /ос/( screw, ins tall the sight plug and start the engine. Run the engine uncil the ас

(е)

16

Secondaгy

{uеl

сапу

out the procedure in paragraph 15 (8),

throttle plates

17 Hold the secondary plates closed. 18 Turn the secondary thrott[e shaft lever adjusting screw (stop

the sight plug opening. /nsta/l the s;ght plug and gasket.

Check the idle speed and Section 13).

raise the fuellevel

Idl and 1.1.

is stвЬШzеd and then recheck the fuelleve!

(uеl /еуе/

То

m;xture adjustment, (see

screw) out until the secondary throttle plates stick in the throttle

Ьогез

IFig.3.421 .

•

САМ

fOLLOWER ON HIGH SТEP Of FAST САМ

' - - LOCK SCA EW

ADJUSТING

NUT AFТER

FUEL LEVEL SIGHT PLUG

Fig. 3.41 Fuel

SCREW

МAI(E5

ON LEVER, ======::...._ ~C:ONTACT 5CREW (2)

PRIМARY ТНRОТТLЕ

TURNS

VALVE CLOSED

ТО

AOJU5T

Fig. 3.43 Pre-5etting the f85t idle 5cr8W (Roche5ter Quadrajet 4MV carburator) 15.с. 181

'еувl

fl08t 8djustment - wet (Ноllву 4150С carburetor) (Sec . 17)

acТWEEN

LQWER EOGE Of VALVE AND AIR HOItN WALL

'ОО то

ADJ~U:ST~~~~,-____~

PLдCE CAM~:C: SECOND SТEP OF FAST IDLE САМ AND НОШ AGAINST HtGHEST SТEP

Fig . 3.42 Adjusting the secondary throttle plate (Holley 4150С carburetor) (Sec. 17) HOLD DOWN ON LEVER TOWARDS СНОКЕ

PRESEТ

IDLE SCREW

Fig. 3.44 Choke rod 8djustment (Rochester Quadrajet 4MV c_rbur.tor) 158С. 181 GAUGE 8EТWEEN AIR HORN WALL AND LOWER EDGE OF СНОКЕ VALVE

8END TANG то ADJUST VACUUM DIAPHRAGM SEAТED­ ия OUTSIDE VACUUМ SOURCE

PLдCE САМ

FOLLOWER ON H!GHEST STEP OF fASТ IDLE САМ

HOLD LEVER WITH PLIERS ТО PREVENT DISTORТlON WHEN 8END1NG TANG

Fig. 3.45 Vacuum break adjustment (Rochester Quadrajet 4MV carburetor) (Sec. 18)

Chapter 3 Fuel. exhaust and emission control systems

75

, 9 ут the screw in (clockwise ) until the screw just contacts the 11 c:ondary lever. then turn il а further t turn clockwis8. "'" V" LVE

cot.O P"\. EТE L У

CLOSf: D

18 Rochester Quedrajet 4MV carburetor - adjustments

Choke гod adjustment Place the fast idle сат follower оп the highest step of the 1азt idle сат (Fig. З.4З). Back-out the lазl idle screw until the primaгy throttle plates аге closed and the сат follower i5 away from the highest step of the сат. Now turn the fазt idle screw inward until the сет follower just contacts the highest step of the сащ then from this poi nt turn the screw two more complete turns. This presets the fазt idle screw 50 that the following choke s8tting5 сап Ье made accurately. 2 With the fasl idle adjustment made, place the сат follower оп the second step of the fast idle сат and against the rise to the highe5t 5tep (Fig. 3.44) . Aotate the choke plate towards the closed choke p05ition Ьу pushing counterclockwise оп the vacuum break 'еуег. 3 Check the clearance between the lower edge of the choke plate, at the choke [еуег end , and the аЁг hoгn wall using а dгШ of 5uitable diameter. AdjU5t, if песеээагу, Ьу bending the choke rod 8t the point shown in Fig. 3 .44, to obtain the 5pecifred clea ran ce. 1

•

I

Vacuum 4

bгeak

Seat the

BEND НЕАЕ F(Ж SPECIFIED CLEAR""'CE ВПWНN АOD "ND (ND DF SLOT

V ACUUM SDUACE

Fig . 3 .46 Adjusting the аЁг valve dashpot (Rochester Quadrajet 4MV carburetor) (Sec. 18)

adjustment

уасиит

break diaphragm using

ап

outside vacuum

HOtO flRМLY

зоигсв.

5

Pla ce the

сат

follower

оп

the highest step of the fast idle

сат

6 Aotate the vacuum break 'вувг counterclockwi5e toward the closed choke until the уасииm break tang contacts the offset in the уасиит break da5hpot rod. 7 With the choke rod in the bottom of the $Iot Ёп the choke 'еуег, check that the clearance between the lower edge of the choke plate and the air horn wall 1э to speci1ication. Adjust i1 песе5$агу Ьу bending the уасиит break tang. Aiг

valve dashpot adjustment

8

Seat the vacuum break diaphragm using

RП"'INER

'N

P~CE

GAUGE FROМ '01' OF CASflNG ТО ТОР Of FLOAT .." ТОЕ

(Fig. 3.451.

I

UЗ Е OUТSIDE

'"'"

"'GA'NSY NHDLE FLO"'T иР О. DOWN ТО ..,DJUST

ап

out5ide

У8сиит

50игсе.

9 With the air valve completely closed and the dlaphragm 5eated, check the clearance between the аЁг valve da5hpot rod and the air valve 'еуег. 1О Adju5t, i1 nece5saгy. Ьу bending the гod at the air valve end (Fig.

Fig. 3.47 Adjustin9 the float 'еувl (Rochester Quadrajet 4MV carburetor) (Sec. 18)

3.461. Unloadeг

,

adjustment

11 Use а гиЬЬег band ог 5pring to hold the choke plate Ёп the closed position. then ореп the primaгy throttle plate$ fully. 12 Check the clearance between the lower edge 01 the choke plates and the аlг horn wall, u5ing а drilt of the 5pecified diameter а5 а gauge. The choke rod should Ье Ёп the bottom of the 510t when checking the 5ettlng . 13 AdjU5t, i1 песе55агу, Ьу bending the tang оп the fa5t idle 'еуег to the геаг to increa5e. and to the front to decrease the clearance. 14 Aecheck the clearance after the carburetor 1$ installed оп the engine.

Fuellevel f/oat adjustment 15

I

, 1

АеmОУе

the air horn a5sembIy. 16 Measure the di5tance from the top of the 110at bowl ca5ting to the top of the 110at at the toe (" in back from the toe оп the float эигfасе). When checking the adju5tment, make sure that the float hlnge pin is 1irmly seated and the 110at агт i5 held down against the float needle 50 that it 15 seated . 17 Adju5t, if necessaгy . Ьу bending the float pontoon ир ог down at the point shown in Fig . 3.47. 18 Install the air horn a$sembIy using а new gasket.

19 Carburetor -

гетоуеl

19.4 Carburetor throttle linkage - Ieft-hand $ide

8nd in5t8118tion

5

1 Remove the air cleaner as de5cribed in Section 5. 2 Disconnect the fuel feed line from the carburetor. 3 Di5connect the electrical wiring and уасиит h05e5 fгom the buretor. 4 Di5connect the controllinkage from the carburetor (photo).

саг-

Partially drain the cooling system and disconnect the hoses from the choke housing. 6 Using 5uitably cranked ring/50cket wrenches, remove the сагburetor mounting nuts. Lift оН the carbu retor. 7 Installation of the carburetor 1$ the геуеГ5а' of the removal ргосеdure. AlwaY5 use а new flange gasket.

3

•

.....

cn

01APНAAGМ LINK

~

•

•

SDLENOID •

800sТER DIApН RAC;М'

A$SEM6L У

_ _.....

.!.

~

AIR

VEN TURI SC REW

DIST RIBUТlOO PL AТE.

PLATE

~ ~"r, .., ......~.. SOlENOID ВАА(КЕ Т

ACCELERATING PUMP

QISCHARGE BALL OiECK

дlА HOAH _._ _ _~,

PLAТE

i

NQZZLE ВДА дно BOOSТER_.-.~ УЕНТИАI ASSE MB l У -,

$HAFT

NUT ( Н ОКЕ PLAТE

MAIN 6ООУ

LEVER

АЕТИАН

(НОКЕ

(LEAN AIR

..

FlOA Т SHAFT

'ii'

GдSKET

,

SPRIN ВАА(К Е Т

АССНЕАА TING РИМР DIAPHR AGМ REТAINER

дССНЕАА ТlNG РИМР

(НОКЕ PLД ТЕ АОО

OOSТ SHIE LD ......... FLQA Т МAIN

MAIN

,

ВООУ

FUELINLET NEEDLE SEA Т

r .. SCREE FILTER N

A(CElERATING

AOJUSТlNG

SPRING

SP RING

.

-

FAST COLO ENGINE SCRE W

(А М

FАП

IOLE

LEVER

IOlE

M IXТU RE

(А М Аоа

-

HaJ SING

т

TH ERМOSTATIC

/

AQJUSТlNG

CAPS

ADJ II$TING SCREW

САМ

FAH IDLE

~~

РИ МР сау

PUMP ROO

FAST IDlE

Э

,

LEVER

Е

SCREW

IDLE

J'

SCREW -_ _"

(НОТ ENGIN E)

СН О КЕ

OVER·TR AVEL LEVER

RETAINER

JE

IDLE~

SPEED

I

$HAFr

•

SPRING HOUSIN G

GASKET

~_ _ _ " CLAМP

~

POWER VALVE ЕЪ0.

GA S KEТ

COVER

& ,

2.PIECE f AST IOLE AOJUSTING LEVER _ С ENGINE

ОА$НРОТ

F,

~

Fig. 3.48 Exploded view

о,

Autolite 21 OOD carburetor (Sec. 21)

THROHlE SHAFТ АНО lEVE R ASSEM Bl У

•

ТНRDТТLЕ

PlA TES • ACCELERATING PUMP OVER·TRAVEL SPRIN G

Chapter 3 Fuel, e"haust and emission control systems

77

20 C• .rburetor - servicing (general) As wear takes place in the carburetor ап increase in fuel consu mp100 аnd а falling-off in performance will Ье evident. When а carburetor requires major repair it is recommended that ап exchange unit is purchased. 8ecause of the high degree of precision involved and the necesslty 10 renew the casing when wear takes place round spindles . аnd "ther moving parts, this is опе time when it is better 10 buy а replacemвn t campanent rather than 10 rebuild the old опе. 2 Repair kits аге availabIe for servicing carburetors and providing саге is taken the ca rburetor сап Ье seгviced Ьу following the instruc1

t ions in Section 21 , 22, 23 and 24 , in сопjuпсtiоп with the exploded views in Fig. 3.48, 3.52, 3.54 and 3.57. 3 Efficient carburetion depends оп careful cleaning to а great extent, therefore саге must Ье taken to exclude аll diгt, gum ог water from the carburetor during servicing. Always make зиге to have а clean агеа for dismantl ing and 'ау parts out separately to avoid similar-Iooking рагtз from getting mixed-up. 4 Never ргоЬе jets, fuel passages, ог air bIeeds with а wire , ог similar, to clean them . Always bIow them out with compressed afr ог air from а саг tire ритр. Use gasoline when cleaning the dismantled рагtз. Always use wrenches and screwdrfvers of the correct size when dismantling the carburetor {о avoid damage 10 jets and screws.

21 Carburetor (type 21 00) - dismantling and

, I I

, ,

I

, •

I

Refer

(о

~~'~'_ _ _ _ _ _ SPRING

гваззвтЫу

Fig. 3.48.

1 Aemove the afr cleaner anchor screw . 2 Aemove the automatic choke control rod retainer. 3 Undo the air horn securing screws and remove the carburetor identificati on 1ag. air horn and gasket. 4 Loosen the securing screw and remove the choke contTol rod from the afr horn . Slide the plastic dust seal ои! of the afr horn. 5 Aem ove the choke diaphragm assembIy (Fig. 3.49) . 6 If it is necessary to remove the choke plate relieve the staking оп the attaching screws, undo the screws and slide the plate off the shaft and out from the top о' the air horn . Slide the shaft ои! of the air horn . 7 Aemove the fast idle сат retainer. . 8 Undo the thermostatic choke spring housing securing screws and remove the clamp, housing and gasket. 9 Aemove the choke housing assembIy retaining screws and lift off the choke housing and gasket; then remove the fast idle сат and rod fгom the fast idle са т lever. 1 О Undo the choke lever retaining screw and remove the choke lever and fast idle сат lever from the choke housing. 11 Use а screwdriver {о ргу the float shaft retainer from the fuel inlet seat ( Fig. 3.50) and lift out the float, float shaft retainer and fuel inlet needle assembIy; then remove the retainer and float shaft from the float lever. 12 Remove the fuel inlet needle, seat , filter screen, and the main jets with а jet wrench. 13 Remove the booster venturi screw, air distribution ptate, booster venturi and gasket. Inveгt the main body and collect the accelerating ритр discha rge weig ht and ball. 14 Remove the acce lerating pump operating rod and retainer. 15 U ndo the attaching screws and remove the acceleratfng pump cover. diaphragm assembIy and spring (Fig . 3.51). If it is necessary to remo ve the elastomer valve, grasp it firmly and pull it out. If the valve is removed i1 must Ье discarded and а new valve fitted. 16 Remove the power valve cover and gasket. then using а ЬОХ ог socket wrench unscrew the power valve. Discard the power valve gasket. 17 Re move the idle fuel mixture adjusting screws and the springs, and then the limiters from the adjusting screws. 18 Undo the securfng пи! and remove the fast idte adjusting lever from the throttle shaft. 19 Rem ove the anti-stall dashpot ог solenoid (if installed). 20 If it is necessary to remove the throttle plates, lightly scrfbe the throttle plates alon9 the throttle shaft, and mark each plate and its corresponding Ьоге with ап identification mark. so that they сап Ье reassembIed in theiг original posi1ions. Slide the throttle shaft out of the main body . 21 ReassembIy is the reverse of the dismantling procedure. Use all the items in the repair kit . If the elastomer valve was removed,

Fig. 3.49 Removing the choke diaphragm carburetor) (Sec. 21 I

аззетЫу

(21000

3

Fig. 3.50 Using

а

screwdriver to гетоуе the float shaft retainer (21000 carburetor) (Sec. 21) PUMP CQVER

LEVER

RETURN.SPRING

ELASTOМER

VALVE DIAPHRAGМ

Fig. 3.51

Removing the 8ccelerating pump 8ззеmЫу (21000 carburetor) (Sec. 21)

lubricate the tip of а new valve and inseгt the tip into the accelerator pump cavity center hole . Using а pair of needte-nosed pliers, grip the valve tip and pull the valve in unti l it seats in the ритр cavity then cut off the tip forward of the retaining shoulder. Ве sure to remove the cut off tip from the fuel bowl. 22 When insta lling the idle mixture adjusting screws, turn them in

~----------------------------------------------------------------~

ACCfLfRATOR

PUMP CONTROl ROO REТAINER

AIR VALVE DAMPENER LEYY:'~R:~~_ _ PlrP'

~ ___ У

SCREW (2 REQUIRED)

HQTIDIE

CQМPENSATQR-

"~'- - SCREW (2 REQUlREO) риТЕ

... .........

GASKET

'

[_;~

---- ----- ----- -

SCR(.1 ~ . :?

LINK

AIR VALVE SHAFT

- - - (10 REQUIREDj

_FLOA1 lEVER

А1О УА"

СНОКе риТЕ SНAFT

PLATE L.H.

А

IR HORN

ВООУ

SHAFT-~

~~""

PUМP СНЕСК

VALVE 01$(

RETAINER РIПON ASSEмaLY

POWER VALVE

SCREW (4 REQUIREDj _ - SPRING

AIR VALVE PISTQN

дно

_ _ _ ACCELERATING

FlOAT

GASKEТ

SPRIH(.

-~Г

дно

PUMP PISTQN CUP

LEVER ASSEMBlY

PQWER VALVE

ACCELERATING PUMP DISCHARGE VAlVE SCREW

puмp

RЕТдlNЕR

PUМP PISТON

1JiIJ"'---АССЕlЕRАТING BO('tY

SPRING

FUEL INLET VALVE.c-· дно SE AТ

ROO

AUXILIARY (SU PPLEMENTAL)VALVE ASSEMBLY

МAIN

puмp

c:as •

REQU1RED )

Q&.

....,

BALL СНЕСК RETAINER

k

-~

2

-ACCELERATING PUMP

tNLEТ

BALL

СНЕСК

·МAIN JET

РR1МдRУ ТНRОТТLЕ SНAFT

AND LEVER ASSEM8l У

- - - - МA.lN

ваоу AUX1LlARY LEVER

""@..,.....-SCREW CQNTROL RQO RETA1NER

SECQNDARY

(2 REQU1REDj

1 SCREW lD LE САМ

РR1МдRУ PLдTE

CONTROL ROO RETA1NER (2 REQU1REDj

IDLE

СНОКЕ COНTROL

ROO

LIMIrER САР IDLE fUEL MIXTURE ADJUSTING SCREW IDLE fUEL MIXTURE ADJUSTING SPRING

"

AND LEVER ASSEMBLY THROHLE

HOUSING GASKEТ THERMQSTAT HOUSING THERMOSTATIC HOUSING

PL..д ТЕ

SЕСDf'ЮА RУ ТНО' SНAfT

AND LEV ER

PRIМARY

REТA1NER

SPR ING

SCREW (3 REQUIRED j

SЕСОЮдRУ ТНО' ПL'

RE TURN S PR ING

LEVER ТО А HACH1NG SCREW THROHLE

ВООУ

ANO

HO USI NG

Fig. 3.52 Exploded view of Autolite 4300 carburetor (Sec. 22)

SНAFT

•

Chapter 3 Fuel, exhaust and emission control systems уМ ·

they а ге jU S1 seated then back them оН 1

t

turns for ап initial fuel

"" Х1 У 'е ad ustment _ 23 Duпr"g assembty саrгу out the settings and adjustments desctibed I П Sес tюn

79

15.

ACCELERATOR PUМP D1SCНARGE NEEDLE

.-.

МдIN

JETS

",.-'

22 Carburetor (type 4300) - dism8ntling and гваззетЫу •

Referto Fig. 3.52 1 Аетоуе the choke control rod retainer from the automatic choke lever and separate the rod fгom the lever.

2

Аетоуе

the accelerator

риrnр

spring and washer, then separate

the purnp rod from the lever.

3

I

,l

I

Aemove the air cleaner anchor stud and the air horn securing

screws. Lift off the air horn . 4 Pull cut the flot pin pivot and lifl out the I10а1 assembIy . 5 Аетоуе the ma;" and auxiliary (supplemental~ fuel inlet valve seats and gaskets . 6 Aemove the secondary air valve lever pivot pin and the rod from the dampener piston assembIy and air valve plate . then remove the air valve dampener piston rod and spring . 7 If it is necessary to remove the secondary air valve plates ог shaft . remove the attaching screws. liп out the plates and then slide the shaft out of the air horn. 8 Aelieve the staking оп the choke plate securing screws, гетоуе the screws, lift out the choke plate , then sHde the shaft out of the air horn. 9 Turn the main body upside down and collect the accelerating pump discharge needle (Fig. 3.53 ). 1 О Using а socket wrench unscrew the power valve fr om the fuel bowl . 11 Аетоуе the main metering jets from the fuel bow l. 12 Using long-nosed pliers, remove the accelerating pump inlet check ball retainer, then turn the body оуег and collect the check ball . 13 Аето уе the throttle body-to-main body attaching screws and separate the two castings. Note: 00 ПО! remove the idle mixture limiter caps ог rhe mixture screW$, 14 Ает оуе the choke housing соуег screws, соУег, gasket and thermostatic spring (photo). 15 Undo the choke piston lеУе г retaining screw and rem ove the pisfon assembIy. 16 Aemove the secondary throttle lever-to-primary throttle connecting link reta iners then lift away the link . 17 Ae lieve the staking оп the throttle plate attaching screws , undo the screws and remove the plates. 18 Undo the nut from the secondary throttle shaft, then remove the lockout lever and slide the shaft and return spring out of the throttle body . 19 Undo the securing screw оп the primary throttle shaft and remove the fast idle lever and adjusting screw. Slide the primary throttle shaft and 'еуег assembIy ou t of the throttle body. 20 Аетоуе the retainer and slide the 'еуег and springs off the primary thrott le sha ft . 21 AeassembIy is the reverse of the dismantling procedure. Use all the items in the repair kit. During assembIy carry out the settings and adjustments described in Section 16.

I

23 Carburetor (Holley 4150С) - dismапtliпg and геаззетЫу

i

Refer

(о

puмp

BALL RETAINER

Fig. 3.53 Main body valves and jets (4300 carburetor) (Sec. 22)

3

22 . 14А Aemoving t he choke housing соуе г and spring

Fig. 3.54

Primary (uе/ bow/ and metering block

I

1 Disconnect the interconnecting fuel line а! the primary and secondary fuel bowls. Undo the retaining screws and remove the primary fuel bowl and metering bIock. Discard the gaskets. Аетоуе the baffle . 2 Aemove the idJe fuel mixtute limiters and the idle adjusting screws . Unscrew and remove the main jets (Fig. 3.55). 3 4 Unscrew the power valve with а socket wrench. 5 Aemove the fuellevel adjustment lock screw. Tutn the adjustment nut counterclockwise and remove the locknut and gasket. Aem ove the fuel inlet needle and seat assembIy, do not dismantle them as they аге matched and are renewed аз ап assembIy.

СНЕС К

22.146 Choke housing with gasket removed

,

,

r

~ AIR ClEANER SCREW

дно

.

DIAPHRAGM SPP ING

l

WASHER

~ ..

•

fUEL LE VEL ADJUSTING NUT

( ИQКЕ ТиЕRМOSТдТ

HOUSING

дно

~.

INLEТ

\f

ACCELt.RAТlNG PUМP D ISС ИАRGЕ NOZZLE

.........

SECONDARY 8ALL СНЕСI(

SPRING

CLAMP ........

АНО

WA SHER

,

-ji

WASHER

дно

SfAT

GASKEТ

NEEDLf

PLAT E

SCRE~

С НОК Е !.НAFT

NEEOLE

ACCE LERA TING PUMP rDISC НARGE

SECONDARY HOUSING SCREW

•

SCREW

GASKE1"

............

~ LOC!( SCREW

SCREW

GAS KEТ

"

SECOНDARY Ol"PHRAGМ

АНС НОО

SCRE w

...

...........

СД$КЕТ

FUE L 015 TR НЮТ 101'1 TU8E F 'ТТ

( НОК Е THERMOSTAT " .. LE VE R LINK дно PISTON

DARY MEТERING ВООУ

' GдSKEТ

L-МAINBOOY PRIМARY MEТERING

RQO SEAL

8LOCK

HOUSING

SНAFT дно

LEvER

GдSKEТ

SCREW

FUEL IftLEТ NEEDLE

,,Ано ,,

S IGИJ

О ,

,, I I

SCREW

GдSKEТ

~FLDдT ',,",но FLOдT

PIN

THROHLE ВООУ"

11

DARY

'СОЕО---/

($ НAFJ)

,

ACCELERATING puмp QPERAТlНG L~VERDISTRIaUТlOН

TUВE FIТТlNG

FUEL

ВOWL

4 SLEEVENuт .............

WASHER TНROHLf sн.,FТ

SCREW .......... ,

GASKEТ

08APНRAGМ SPRING

~J

_

FUEL

IHLEТ ДНО FILTER

PRIМARY

THROHLf - . . SCRfW

OtAPНR ....GМ ASSEМOL у

SCRfW

•

PRIМARY

THROTTLf SНдFТ ~SSfwtLY

Fig. 3.54 Exploded view of Holley 4150С carburetor (Sec. 23)

,

PLATES

REТAINER

~

SCREW

ТНRОТТLЕ

AC(fLERAТlHG Pt..IМPCДM

Chapter 3 Fuel. exhaust and emission control systems

)

PRIMARY MEТERING

•

81

20 Aemove the secondary throttle connecting rod reta 1ners and the connect1ng rod. Undo the securing screws and remove the secondary diaphragm lever and the last idle сат levet. 21 Match- mark the throttle plates (see Fig . 3.56) then undo the retaining screws and remove the throttle plates. 22 Aemove the primary throttle shaft return spring. Slide the primary throttle lever and shaft assembIy out 01 the throttle body. 23 Slide the secondary throttle shaft out and remove the bushi ngs lгот the shaft . 24 AeassembIy is the reverse of the dismantling procedure. Use all the items in the repair kit. Ouring assembIy сагry out the settings and adjustments described ,п Section 17.

24 Carburetor (Rochester Quadrajet 4MV) - dismantling and reassembIy J.t

MAIN JETS

Refer (О Fig. 3.57

Fig. 3.55 Removing the main jets (Holley 4150С carburetor) (50с.231

,

Air horn 1 Aemove the retaining clips and disconnect the choke rod, pump rod and vacuum break rod . 2 Undo the attaching screw and 11ft the secondaгy metering rod holder and rods straight upward out of the air horn . then slide the secondary rods out 01 the holder. 3 Aemove the nine securing screws (two аге inside the air horn Ьоге) and lift off the air horn. 4 Undo the 8ttaching screws and remove the choke valve and shaft. 5 Aemove the pump lever rol l pin and pump lever. 6 Using а smaH diameter drift, drive the retaining roll pin out and remove the air valve lockout lever. 7 Undo the tock screw and remove the air valve spring lulcrum pin and then the air valve. 8 Undo the attaching screws and remove the four air valves from the shalt. Slide the air valve shaft out 01 the air horn. then remove the plastic metering rod сат.

I

~

Throttle body Fig. 3.56 Match merk the throttle plates (Sec. 23)

1

6 Undo the attaching screws and гетоуе the f loat asembIy, then slide the shaft out of the float assembIy and collect the spring. 7 Аетоуе the fuel 'еуе' sight plug , fue ! inlet fitting gasket and filter

screen. 8 Аетоуе the accelerator purnp соуег, diaphragm and spring . 9 Undo the retaining screw and гетоуе the plug , spring and bracket from the уеп! rod .

Secondary (uеl bowl and metering bIock 1 о Remove the fuel bowl . metering bIock and gaskets. Dismantle the assembIy Ьу following the procedures described in paragraph 3 through 7.

Main body

,

r

11 Аетоуе the air cleaner anchor stud and the secondary diaphragm operating rod- to-Hnk retainer. 12 Aemove the throttle body retaining screws and 11ft off the throttle body . 13 Aemove the choke rod retainer, the thermostatic spring housing and then the choke housing. 14 Undo the choke housing shaft nut. then remove the lock washer . spacer, shaft , fast idle cam. and the choke piston and lever sssembIy . 15 Aemove the choke. rod and seal from the main body. 16 Aelieve the stsking оп the secuгing screws and remove the choke plate , then s1ide the choke shaft and lever out 01 the air horn. 17 Aemove the secondary d1aphragm housing assembIy and then the diaphragm housing cover ; collect the spring . d1aphragm and vacuum check ball from the housing. 18 Undo the attaching screw and 11ft the accelerating pump discharge nozzle out of the ЬоОу . Invert the body and collect the pump discharge needle .

Throttle body 19 Aemove the accelerator pump operating lever retainer .

9 Unscrew the pump rod from the primary throttle levet. 10 Remove the two idle 11miters, and the 1dle mixture screws and springs . 11 Undo the attaching screw in the end 01 the primaгy thTottle shaft and pull off the fast idle lever and last 1dle сат follower lever.

Float bowl 12 Lift the pump plunger out 01 the pump well and remove the pump return spring. 13 Remove the plastic fil ler bIock over the 1108t valve (Fig. 3.58). 14 Remove the power piston and the primary metering rods as ап assembIy Ьу pushing down against spring tension and allow1ng the piston 10 snap back against the retainer until 1t pops out 01 the casting. 15 Oisconnect the tension spring loops from the top of each primary metering rod then unscrew the rods lroт the hanger. Take саге not to distort the tension spr1ngs ог rods. 16 Lift the power piston spring out 01 the power piston cavity. 17 Pu ll upward оп the hinge pin and remove the 110at аззетЫу. The float needJe and seat аге а matched assembIy and must Ье renewed as а set . 18 Remove the primary main metering jets. 00 not remove the secondsry metering discs ; normal cleaning is all that is necessaгy . 19 Remove the pump discharge check ball retainer and steel check ball. 20 Lift the baffle pJate from the secondaгy bores . , 21 Remove the retaining screw and lift the choke bracket assembIy from the 110at bowl . 22 Slide the last idte сат off the bushing оп the choke bracket. 23 Spread the retain ing ears оп the bracket пех! to the vacuum diaphragm. then slide the vacuum diaphragm assembIy out of the bracket. 24 АеаssетЫу is the reverse of the dismantling procedure. Use all the items in the repair kit. During аsзетЫу саггу out the settings and adjustments described in Sect10n 18. When installing the 1dle m1xture needles and springs , turn them in until they аге just seated and then back them off 1-! turns for ап init1sl setting . Tighten the air horn sесиг­ ing screws in the sequence shown in Fig. 3 .59.

3 ---

~ ----------------------------------------------------------~

•

SECONDARY METEItI NG _ _ као HOLDER ДНО SCREW

SCREW - ..,111

SCREW -

(НОКЕ

Pl.ATE

(Z!

СНОКЕ Pt.AТE

CLIP -

СНОКЕ кор

puмp ACTUAТlNG

LEVER -

ASSEМ8LY

(НОКЕ SНдfТ

AND LEVER

ROLL РаН - AIR VALVE LOCKOUT LEVER

REТURN

- PUMP

LEVER - AIR VALVE LOCKOUТ MEТERlNG

HINGE PlN -

- AIR HQRN

SPRlNG -

НО"'Т

PRIМARY MEТERING

КОО REТAINER

FLOAT

8AFFLE - SECONOARY 8ORE5 СНОКЕ

GASKEТ

ROO - SECONDARY

MEТERING

ROD (2)

ROO

INSERT - FlOAT 80WL

SCREW - IDLE COМPENSA,TOR СОУЕК (2)


PI5TON

~ REТAINEIt· PUМP ~ DISСНд,RGЕ

'D'

n

8AlL

NEEOLE AND SEAT

~

(11)_

2

"'ВALL

- PUMP

OISCНARGE

- PQWER '15TON

ROD -

МAIN MEТERING JEТ

SCREW yACиuм

PRIМARY

BREAK

80WL

САМ

SCREW - IDLE

LEVER - SECONDARY LOCKOUТ

ADJUSТlNG

SPRI NG - IDLE AOJ USTI NG SCREW

LEVER HOSE - yДCиuм 8REAK

5CREW -

GA5KET -

THROHLE САМ

PRIМAltY THROТYLE

ВОDУ ТО

80WL

ВОDУ

FOLLOWER LEVER

~"'.o-

,-

____

CLIP- PUMPROD

FAST IDLE LEVER ---PUМPROD

SCREW - САМ AND FAST IDLE LEVER AHACHING--- -.....'o;!f' SPRING - FASТ IDLE SCREW-;----.:.......~~

~

SCREW FAST IDLE САМ

lEVER

AHACHING

VACUUM OlAPHRAGM

SPRING·

(2)

8REAK CONTROL

НОДТ

FAST IDLE

-

AND FAST IDH LEVER

ADJUSТlNG

IDLE MIXTURE NEEOLE (2)

IQ.....

SCREW • THROHLE 800У ТО 80WL AHACHING NG - IDLE MIXTURE NEDDLE (2) IDLE MIXTURE LIMIТER САР

Fig. 3.57 Exploded view 01 Rochester Quadrajet 4MV carburetor ISec. 24)

,

Chapter 3 Fuel. exhaust and emission control systems

83

Р!"

•

PUMP

REТURN

I

I

, IМдRY

FUEL

DISCНARGE

NOZZLES

I

BAFFLE

PLAТE

LOCA ТlNG O(7t{LS

Fig. 3.58 Dismantling the fl08t bowl (Rochester Quadrajet 4MV carburetor) (Sec. 241

I

5

I

5 VOL Т SUPPL У

FROМ

1.'1. :. -....-

3

J

BIMETAL I

2

STRIP

АНО

•

,

FUEL GAUGE

i

VARIABLE RESISTOR

Fig. 3.59 Tightening sequence of air horn securing screws (Rochester Quadrajet 4MV carburetor) (Sec. 24)

25 Fuel tank - removal and installation

,

Disconnect the

ЬаНегу

FUEL SENDER UNIr

terminals.

Chock the front wheels, jack- up the геаг of the саг and support it ОП jack stands. 3 Ает оуе the fuel tank drain plug and drain the fuel into а suitabIe container. 4 Disconnect the fuel gauge sender unit wiring from the sender unit . then loosen the hose clamp, slide the clamp forward and disconnect the fuel line from the sender unit. 5 Disconnect the fuel tank уеп! hose and the fuel evaporation em ission controlline (if instaHed) . 6 Rem ove the spare tire from the luggage companment to gain access to the fuel tank. 7 Remove the fuel tank filler neck securing screws, loosen the filler neck-to-hose clamps and remove the filler neck. gasket and hose. 2

!

\

Fig. 3.60 Fuellevel indic8ting svstem - schematic (Sec. 25)

,

~

•

5/ 8" fR(J,4 SURFACE Of ЕНО OF S T UDW IТH SHORТEST Ttfl EAO

M~

L

IFOLD FLANGE

HUTS AL TERNATEl DRAW FlANGE EVENL У EXHAUST MANIF OLD

ТlGНТEH

Т О ВЕ

ТО

INТOМANIFOLD

ТО

25 _35

У

FТ-L B

GASKE T

.,

.., -

СRDS 5МЕ М ВЕ R

13/ 16"

1'-0,:::\

fr" ~" '--

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1

SECTION А А,Т REAR ЕОСЕ SUPPORT 35 1 -2 У

"1..1

•

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~\•

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•

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~ ~.

./

P IPE

/~ '

~

"

VIEW Z

FOR 302 DNL У VIEW U "'НО V

."

' ф-

SECTION "'Т АЕАА ЕОСЕ

д

CROS~H(BER

OF SUPPORT 351 - 2У

"UTO. TR"'NS .

INLET PIPf

FRСtП Е НО

OF STUD _IТH

stЮRТЕ SТ ТНАЕдD

LE NGTH ТО ВЕ 1НАЕАDШ 'НТО MANIF OLD

LOWER

VIEWY

DRAW FLANGf EVENLY

T01eXHAUST

25- 35

МANIFOLO

FТ-LB

1М ТЕ RМEDIATE

PIPE

25_35

fТ -LB

VIEW S

ylEW 11'1 CIRCLE

Х

Fig . З . 61 Single exhaust system (Sec. 28)

•

FLOOR

CAOSSМEMВEA HUТS ALТERNAТELY

ТО

u

PIPE

1М L8

•

Chapter 3 Fuel, exhaust and emission control systems 8 Ае тоуе the fuel tank retaining screws and remove the fuel tank . late r m odels аге secured Ьу two support straps. 9 If 11 15 n ecessaгy 10 гетоуе the sender unit, this сап Ье unscrewed from th e tank using the appropriate Ford 1001. Alternatively а suitabIe C-wrench ог drift сап ргоЬаЫу Ье used, but great саге should Ье taken that t he fla"ge 15 not damaged and that there is по danger from sparks i1 а hammer is used. • 1О Installation is the геуегsе of the removal procedure. Use а new sea ! when instal1ing the sender unit.

• 26 Fuel tank - cleaning and repair 1 With time it is likely that sediment will cotlect in the bottom of the fuet tank. Condensation. resulting in rust and other impurities. will usually Ье found in the fuel tank of апу саг more than three ог four уеагз old. 2 When lhe lank is removed il should Ье vigorously flushed out with hol waler and delergent and. if facilities аге availabIe. steam cleaned . 3 Never weld . solder ог bring а naked light close 10 ап empty fuel tank, unless it has Ьееп cleaned аз described in the previous paragraph. for at least two hours.

I

27 Downshift linkage (automatic transmission) - adjustment 1 Disconnect the throttle and downshift return springs. 2 Hold the carburetor throttle lever wide-open againsl the stop , wilh the transmission in full downshift against the stop. 3 Тшп the adjustment screw оп the carburetor kickdown lever to oblain а gap of 0 .040 10 0.080 in (1 102 mm) between the carburetor lever and the adjusting screw. 4 Aelease lhe lransmission and сагЬшеlог 10 the normal free position . Insla ll lhe throttle and downshift relurn springs.

I

I

28 Exhaust system - description and renewal SingJe and dual exhaust systems аге used оп the different models. The single system сап consist 01 а sing!e muff!er exhaust syst~m with ог w/thout а resonatOf, ог а dual muffJer exhaust system. without resonator. The dual exhaust system has two separate exhaust systems without resonators (Figs. 3.61 and 3 .62). 1 The 1гопl pipes аге secured 10 lhe manifold Ьу means of flanges while lhe front and геаг pipe sections аге attached 10 the muffler and! or resonators Ьу U-bolts and clamps. The complete system is attached to the underbody Ьу brackels bolted 10 insulaled hangers. 2 ТО conform to the currenl emission cont rol regulations. later models аге equipped with а catalytic converter Jocated between the front pipe(s) and the muffler(s) . 3 О п а " models а periodic check should Ье made оп the exhaust system for excessive corrosion and leaks. Апу faults should Ье rectified at оп с е 10 avoid contravening the Emission Control laws. ог enabIing сагЬоп m onoxide fumes to enter the саг . 4 A lthough the different exhaust system sections сап Ье renewed separate ly il will usually Ье found that i1 опе section is badly сопоdеd the rest о' the system will Ье approaching the same condition . Therefore the most sensibIe and safest policy is 10 renew the complete system . 5 When refitting а flange 'уре joint always use а new gasket. 6 Models equipped with catalytic converter(s) аге fitted with а heat shieJd which will have to Ье unbolted and removed prior 10 refitting the exhaust system .

1

I •

i

I

29 Emission control svstems - general description То

conform to the anti-pollution laws the Mustang гаnуе 01 models аге equipped with various emission control devices. The specific controJs installed оп each саг will depend оп which State the саг is so!d "n; the emission coпrгo! inlormation lог individual cars is shown оп а data plate inside the engine compartment. This Section describes the various emission controls that mау Ье insta//ed. WAA N I NG: 8efore commencing аnу maintenance ог testing 01 emission control systems the owner is advised (о read Section 2 01 this Chapter to avoid contravening the emission control regulat/ons

85

Improved combustion IIМСО) system 1 The main featuгes о' this syslem аге covered Ьу the design of the engine and carburetor. and therelore require по special information. However. ап electrically assisted choke heater is used as ап aid to 1аз! choke release for ЬеНег emission characteristics during engine watmир.

2 The choke heater is а constant temperature. positive temperatuгe coefficient (РТС) unit. energized from the alternator field (IND) terminal, and is energized when the engine is running . 3 Incorporated with the unit is а fast idle сат latch, which holds the сат оп the high position ипНI the choke heats up and the bi - metat latch backs off (о atlow the latch pin and fast idle сат to rotate to the погта1 run position . 4 дп overcentre spring assists in closing the choke plate {ог initial starting of а cold engine in high amblent temperatures. This spring has по effect after initial choke pull -down occurs.

Positive crankcase ventilation (PCV) system 5 The PCV system operates Ьу drawing in afr and mixing it with the vapors which have escaped past the piston rings (bIow-Ьу vapors) . This mixture is then drawn into the combustion chamber lhrough ап oil separator and PCV valve (Fig. 3.63).

Evaporative emission

сопсго/

6 This system 1з designed to limit lhe emission of fuel vapors 10 lhe atmosphere. It comprises the fuel tank. pressure and vacuum sensitive luel liller сар. а restrictor bIeed orifice. а charcoal canister and the associated connecting lines (Fig. 3.64) . 7 When the fuel tank 1s 1i11ed. vapors аге discharged 10 the atmosphere through the fШег tube. and а зрасе between the 1ппег filler tube and the outer neck. When fue l соуегз the filler controJ tube. уарогз сап по longer езсаре and а vapor lock is created Ьу the orifice ; therefore there сап Ье по flow to the vapor cha rcoal canister. 8 When thermal expansion оссшз in the fuel tank. vapor 1s forced through the orifice 10 the canister. where il is stored when the eng ine is not running and is drawn into the carbuгetor inlake system as зооп аз lhe engine is started .

Exhaust gas recirculation (EGR) system 9 This system 1s designed (о reintroduce small amounts о' exhaust gas into the combustion cycle to reduce the generation 01 oxides 01 nitrogen (NOX). The amount 01 gas re introduced is governed Ьу engine vacuum and temperature. 10 The EGR valve is mounted оп а spacer bIock between the сагburetor and mani10ld. А venturi vacuum amplifier (VVA) is used to change the relatively weak vacuum signal in the carburetor throat to а strong signal for operation of the EGR valve (Fig . 3.65). 11 А rel1ef valve is also used to mod1fy the output EGR signal whenever venturi vacuum 1s equal to, ог greater than, manifold vacuum . This altows the EGA valve to close аl ог пеаг . wide ореп throttle. when maximum engine power is required. 12 The EGA!CSC (cold start cycle) regulates the disttibutor spark advance and EGA valve operation according to the engine coolant temperature . Ьу sequentially switching the vacuum signals. When the coolant temperature is below 82 ° F (27.8 0 С). the EGR ported vacuum swftch (PVS) admils carburetor EGA рог! vacuum twhich оссuгз at approximately 2500 грт ) directly 10 the distributor advance d1aphragm through the one-way check valve. Аl the зате time the PVS ShulS off the carburetor vacuum 10 the EGA valve. 13 When the engine coolant 1s 95°F (35 ° С) ог above. the EGA!PVS directs carburetor vacuum to the EGA vaJve. 14 At temperatures belween 82 and 95 ° F (27 .8 and 35 ° С) . the EGA/ PVS тау Ье closed. ореп ог in the mid- position . 15 А spark delay valve (SDV) 1з incorporated in the system to delay the carburetor spark vacuum to lhe distributor diaphragm unit for а predetermined time. During acceleration . little ог по vacuum is admitted 10 the distributor diaphragm unit until acceleration 1з сот­ pleled because 01 the time delay 01 the SDV and the re-routing of the EGR port vacuum at temperatures above 95°F (32 ° С). The check valve bIocks the vacuum signal from the SDV 10 the EGR! PVS . зо that carburetor spa rk vacuum wШ по! Ье dfssipated at temperatures above

95'F 132 ' CIIFi9. 3.661. 16 The 235° F (113 ° С) PVS is not strictly part 01 the EGR system , but is connected to the distributor vacuum advance unit (о prevent overheating while idling with а hot eng ine . Аl idle speeds. по vacuum is generated at e1ther of the carburetor ports and the engine timing is

Э

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351· 4У

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-

VIEWU&V

SCRE W

-

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• •

ф ЕNDОF ИUDWIТН 5HORH ST TtlREAD lENGTH ТО ВЕ TtlREADED 'НТО MANIFOlD

фТIGНТЕN NUТS

AlIER NA ТEl У

EVENL У

ТО

12 FT·L B ВRЛСКЕТ ЖО Cl AМ P ~

ТО MAINTAIN

TORClUE ДНО Т О DRA W fLANGE

МUИ ВЕ ' Н МАСН

I ONL У

EX HAUST MAN IFOLD VIEW 5

Fig. 3.62 Dual exhaust system (Sec. 28)

,

-

SCREW

vER TICAL

LINE WITH

CL

/ MUFFLER

DF PIPE

vERТlCAl

4..

Of P IPE

•

. Chapter 3 Fuel. exhaust and ami •• ion control systams

87 PVS VALVE

СА "8иАЕТОА

•

,

,.----r=-------'- l

.

I

,

I

ТО IG NIТl ON SWITCH

I

I I

I I

I I

I

FROtH Of V{HI CL E

... .6.PORS WHEN ENGINE 15 A UNNI NG

I

FUEL VAPORS 8иАНЕD

ТО АIА

CLEAN ER

ТО

I

I I L_______ _

810

FUEL VAPOR5 FROM AIA

C LEANER WHEN EHOINE 15 НОТ RUNN'NG (нот

OPTIONAL MOOULATOR OEVICE UИО он $ОМЕ ENGINES

I

WHEN EHGINE 15 AUNNING

fUEL VAPQRS FROМ FU EL TANK WHEN EHGIHE IS НОТ AUNNING IH01 SOAK )

I I

SOLENOID VA LVE

I

Fig . 3 .63 Positive crankc8s8 ventilation (PCV) ,y.t8m - typlc.t 1500. 29) FLOW Of FRESH А 1 А ТО PURGE STQRED fUEL

I

~

~

Flg.

I

З.66

Exhau8t

нае

recirculation

(ЕОА)

I I

ELECTA ON IC

-

__A~=

J

I

eystem (Sec. 29)

SQAK)

fOAM BAFfLE

"A•• ~;;'"''

а

- - - -- _.

[--

, I

I

I

fully retarded. However, when the coolant temperatuгe t88che. 235 Q F (11 З ОС) the PVS is 8ctueted to admit intake manifold v8cuum to the distributor adv8nce diaphragm. The engine timing is thus adv8nced. idling speed is correspondingly increased and the engine temperature Is lowered due to increased f8n speed and coolant flow.

Catalytic сопуегсег 17 Оп 5Оте models а cBtalytic conveгter is incoГPOT8ted upstream of the exhaust front muffler. The conveгter comprlses а ceramic honeycomb-like соге housed in а stainless steel pipe . The соге is coated with а platinum and palladium catalyst which сопvеrtз unburned сагЬоп monoxide and hydrocaгbons into са гЬоп dioxide and water Ьу а chem ical re8ction. 18 No special mаiпtепапсе of the conveгter is requlred , but It сап Ье damaged Ьу the use of leaded fuels, engine mlsflrlng, excessive richness of the carburetor mixture, incorrect operation of the Thermactor system ог running out of g8sol1ne. aiг Сеmрегасиге гegulation

19 Inlet air temperature regulation is accomplished Ьу the use of thermostatic air cleaner and duct system (see Section 3).

I .011_1_'....

-.-",,,

Fig. 3.64 Crols-8ection view of carbon canist.r (Sec. 29)

в

Теmрегасиге activated уасииm system (TAVj 20 дп additional feature incorporated оп зоте models 1з the temperature actuated vacuum (TAV) system. This is designed to select

DlCAY

УАСУ

........ . . ~ (I;W" .......... 0

ACTIVATEO CAABON -F UEL VA POAS STORED WHEN ENGINE н от AUNNING

Inlet

I

L __ ____ Flg. 3.88

I

SO,'~О'ОуА'у.

5р.",

__

---~

d.l.y v.lve .ystom (500 . 29)

either carburetor spark роп vacuum ог camuretor EGR роп vacuum as а fuпсtiоп of ambient air temperature. The selected vacuum source is used to сопtгоl the distributor dlaphragm unit (Fig. З . 67) . 21 The sY8tem comprises ап amblent temperature switch , а threeway solenoid valve, ап external vacuum bIeed апd а latching relay. 22 The temperature switch activates the $olenoid. which i$ open at temperatures below 49°F (9.5 0 С) and is cl08ed abov8 60°F (15.6 0 С).­ Wlthin this temperature range the so[enoid va[ve may Ье ореп ог closed . 23 8elow 49°F (9.5 0 С) the system is inoperative and the distributor diaphragm receives carburetor spark роп vacuum while the EGR valve receives EGR роп vacuum. 24 When the temperature switch closes (аЬоуе 60 0 F! 15.6°C) the three-way solenoid valve is energized from the ig"ition switch and the carburetor EGR poгt vacuum is detivered to the distributor advance diaphragm as well аз to the EGR valve. The latching relay is also energized Ьу the temperature switch clo$ing, and will remain energized until the ignltio" i8 switched off, regardless of the temperature switch being ореп ог closed.

•

88

Chapter 3 Fuel. exhaust and emission control systems Theгmactor

""'" "'''

25 This system 15 designed to reduce the hydrocarbon and сагЬоп monoxide content of the ехhэust gases Ьу continuing the oxidation of unburnt gases after they leave the combustion chambet. This is achieved Ьу using ап engine driven air pump to inject fresh air into the hot exhaust stream after it leaves the combustion chamber. This air mixes with the hot exhaust gases and promotes further oxidation , thus converting some of them into сагЬоп dioxide and water. 26 The air ритр draws in air through ап impeller-type, centrifugal fan and exhausts it from the exhaust manifold through а vacuum соп­ trolled air bypass valve and check valve. Under погта l conditions Thermactor air раззеэ straight through the Ьураэз valve, but during deceleration, when there is а high level of intake manifold vacuum, the diaphragm check valve operates to shut off the Thermactor air to the air supply check valve and exhausts it to atmosphere. The air supply check valve is а non-return valve which will allow Thermactor air to pass to the exhaust manifold but wШ not allow exhaust gases to flow in the reverse direction.

...... ... fV R.

-"с"

---

0'''.'.'''0.

..

exhaust contгol system

v.~uUМ

Ov,,~" '

Transmission regulated spark (TRS) system

Fig. З.67 Temperature activated vacuum (TДV) system (Sec. 29)

27 The TRS system is designed to eliminate vacuum (раг! throttle) spark advance in first and second gear for either manual ог automatic transmission сагэ. 28 Д transmission sensor determines when the transmission i5 in first ог second gear. When the transmission is in опе of the lower gears, the solenoid vacuum valve is closed preventing part-throttle spark vacuum fгom reaching the distributor diaphragm so that по part-throttle spark advance results. 29 This system results in insufficient spark advance at low ambient temperatures. То overcome this, ап amblent temperature switch is installed in the sY5tem which overrides the transmission switch and ге­ estabIishes vacuum spark advance irrespective 01 whlch gear is engaged.

ТО (СА

$У$Т!"

Deceleration valve deceleration valve i5 u5ed to provide ап enriched mixture when the engine i5 оп overrun with the throttle closed. The valve screW5 Into the intake manifold and has two vacuum outlet ports. When the engine decelerate5 а vacuum i5 applied to the control роГ! and the valve ореП5 and allow5 а fuel/ air mixture to Ьу-ра55 the carburetor and pas5 directly into the intake manilold (Flg. 3.69) .

NОИ""" V ""' '" "' '''' О'О V" LV'

30

А

ЗО

Emission control system - maintena"ce and testi"g

...... о ......"., O .IТ R •• UTOR

$ W"CM

Fig . З.68 Transmiaaion regulated арат (TRS) system (Sec. 29)

view о' the specia/ test equ;pment and procedures there is little that сап Ье done in the way о' maintenance and testing {ог the emission сопсгоl system. 'П the event о{ а suspected malfunction о{ the system, check the security and condition о, all pneumatic and electrical connections then, where аррliсаЫе, refer to the following paragraphs 'ог 'urther in'ormation. !п

•

Electrically assisted choke heater

•

1 The only test that сап Ье carried out оп this a5sembIy, without 5pecial te5t equipment i5 а continuity check of the heater coil. If ап ohmmeter Is availabIe, check 1ог the specified re5istance. 11 по ohmmeter 15 availabIe, dlsconnect the stator lead from the choke сар terminal and connect it to опе termlnal of а 12V low wattage bulb (eg, in5trument panel bulbl. Ground the other terminal of the bulb and check that it illuminates when the engine 15 running. If it fail5 to i1Iuminate, check the alternator output and the choke lead for соп­ tinuity. If the bulb illuminate5, di5connect the bulb ground terminal and reconnect It to the choke lead. 11 the bulb does not illuminate when the engine is warm, а faulty choke unit 15 indicated.

PCVsystem

FUEL DECEL VALVE

Fig . З.69 Location 01 1uel decel valve (Sec. 29)

2 Remove all the h05es and component5 01 the 5Y5tem and clean them in kerosene ог ga50line. Ensure that all h05es аге free lrom апу ob5truction and аге in а seгviceabIe condition. Where applicabIe , similarly clean the crankcase breather сар and shake 1t dry. Install new parts as neces5ary, then install them оп the саг. СагЬоп canister з The сагЬоп canister i5 located in the engine compaгtment . То remove it, di5connect the two hose5, then undo the secur1ng nuts and remove the canister and bracket. The canister in5tal1ed оп 1973

•

Chapter 3 Fuel, exhaust and emission control systems

89

EGR system FUEL VAPOA

,

FUEL VAPOR PUAGE LINE

INL ET LIN E

4 The EGR valve сап Ье removed for clea ning, but where it i5 damaged. corroded ОГ extremely diгty it i5 preferabIe to in5t811 8 new valve. If the valve i5 to Ье cleaned. check the orifice in the body i5 clear but take саге not to enlarge it. If the valve сап Ье dismantled. internal deposits сап Ье removed with а small power-driven rotary wire brush. Deposits around the valve stem and disc сап Ье removed Ьу using а steel bIade ог shim approximately 0.028 in (0.7 тт) thick in а sawing motion around the stern shoulder 8t both sides of the disc. Clean the cavity and passages in the main body; ensure that the poppet wobbIes, and moves axially before reassembIy.

I

Thermactor system Apart from checking the condition of the drivebelt and pipe соп­ nection5, and checking the pump drivebelt 1en5ion, there is lit11e that сап Ье done without 1he U5e of 5pecial te51 eQuipment. Drivebelt ten5ion 5hould Ье checked Ьу а Ford dealer with а 5реСЁа' ten5ioning tool. However, thi5 Ё5 approximately eQual to t in (13 mm) of belt movement between the longe5t pulley run under moderate hand рге­ ssure.

5

AIR CLEANER

,

CARBON STORAGE CANISТER

t

Deceleration valve system

Fig. 3.70 Location of сагЬоп canister (Sec. 30) mode15 i5 larger than that u5ed оп replaced Ьу the smaller 5ize cani5ter.

еагНег

model5 and mU5t not

6 Special eQuipment i5 reQuired 10 сапу out а complete 1e5t оп the deceleration valve function and it i5 recommended that the саг i5 taken 10 а Ford dealer.

Ье

31 Fault diagnosis - fuel system А8а.оп!.

Symptom

, Air cleaner choked ог inlet duct system inoperative General leak5 from fuel 5Y51em Float chamber fuellevel 100 high Rich mixture Or8gging brakes Tires under-inflated Faulty choke operation

Excessive fuel consumption

·Мау

,

also Ье due

(о

'aufty condenser ог advance/retard system

Insufficient fuel delivery

ог

;п

3

d;str;butor OR ап em;ss;on controf system 'ault Clogged fuelline ог carburetor filter Fuel Inlet needle valve stuck Faul1y fuel pump Leaking рЁре connections Leaking inlet manifold ga5ket Leaking carburetor mounting fl8nge gasket Lean carbure10r mixture setting

weak mix1ure

32 Fault diagnosis - emission control system

The 'oflowing list ;s 'ог gu;dance that

а

оп/у,

s;nce

а

comblnation

о{. 'aufts тау

produce symptoms which аге

difПсult (о

diagnose. It is there'ore essentia!

Ford dealer ог em;ssion control spec;a!ist is consulted ;п the event о, probIems occuггing. Аеаао"!з

Symptom

•

Electrically assisted choke heater Long engine warm-up 1ime

Faulty choke heater

PCV system Fumes escaping from

Evaporative

еПяЁпе

сопtго!

system

Fuel odor ог rough engine running

I

Clogged PCV valve Split ог collapsed hoses

Choked сагЬоп canister Stuck fШег сар уа1уе Split ог collapsed hoses

•

Chaptar 3 Fuel. exhaust and emission control systems

90

•

R•••on/.

S .,mptom

Thermactor system Fum e em ission from exhaust

Air pump drivebelt incorrectlv tensioned Damaged air supply pipes

Split ог collapsed sensing hозеs Defective air pump Faulty pressure reHef valve

EGR system Faulty ог dirty EGR valve Split ог coltapsed hoses

Aough idling

Leaking valve gasket

C8ta/ytic conveгter Fume emission from exhaust

Damaged

ог

clogged catalyst

I

•

• •

•

•

,

•

I

Chapter 4 Ignition system Contents Condenser - removal , testing and installation . . . . . . . . . ..... Contact breaker points - adjustment ... ... . .... ... .. .. .. Contact bre aker points - removal and In5tallation ... . .. .. ... Distributor - dism antling . . . . . . . . . . . . . . ..... . . . . ..... Distributor - inspection ... ... , .. ... . . . . . . . . . ... ..... Distributor -Iubrication ...... .. . . . . . . . . . . . .. .... . . .. Distributor mod ulator - genera l ... . . ...... . ... ... . . . ... Distributor - reassembIy . . . . . . . . ... ..... .... ... .. • ...

I

б з

5 9 10 7 14 11

Distributor - гетоуаl and in5tallation ..... .... . . . . .. . .... Dwell angle - check and adjustment .. . . . . . . . ... . . .. . ... Fault diagnosis - i9n1tion system . . . . . . . . . .. .... .... •... General description . . . . . . . . . . . . . . . . . . . . . . ..... . . ... Ignition system - servicing and Federal regulations . .. . .... .. Initial (static) ignition timing .. . . . . . . . . .. . . . . . . . . . . . ... Spark plugs and НТ leads . . . . . . . . . . . .... ... .. ... .. ...

8 4

15 1 2

13 12

•

I Specification5

Spark plugs м а ke

I

I •

Autolite (Motorcraft )

Уеаг

Туре

Gap

BF-42 BF-42 BF-32 BF-42 BF-32 AF-32 BF-42 AF-32 AF-42 BRF-42 ARF-42 BRF-42 ARF-42

0.034 in

and engine

1965/ 66 - 260. 289. 289НР .... . .......... . . ...... . ... .. 1967/ 68-289 .. .... ........ .. ... .... ....... . . . . ... . 1967/ 68 - 302. 390. 427 . 428 .... ..• . • . .. . • . ......... . . . 1969-302 . 351 . 390 ........ . ...•........ . ........... 1969 - 428 ..... .... ... ... ... .. . , .... , ..... ...... .. . 1969 - 429 805S . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . .

1970 - 302 -2V. 351-W2V. 429 .... . ............ . . . . . .. . . 1970 - 302 Boss. 351-C4V .................. ... . . ... . . . 1970 - 351 -C2V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 I

1971 /7 2 -302. 351-W2V ....................... .. .... 19 71 / 72-351 -C4V.35 1-CJ. 351 BOSS.351HO .. . .......... 1973 - 302. 3 51 -w2v ...................... . • . • . • . . . . 1973 - 351 C-2V. 351-4VCJ. 429 -4V ..... .. ....... .. .....

. . . .

Coil

I

Primary resistance ...... ... .... . . . . . . . . . . . . . . . . . . . .. . . Secondaгy resistance ' . .... . . . , . . ... , . . . . . . ... . . .. ..... . Primary circuit resistor ... , ... . . ... . .. . . . .. . . . . . ...... . .

•

Condenser Capacity

,

4

. . . . . . . . . .. . . . . . .. . . . . .. . . . . . . . .. . . . . . . . . . . .. . Туре and gap:

. . . . . . . . . . . . . ... . . . ... .. ... . . . . . . . . . • .... ..

1.40 to 1.54 ohms t75°F) 7600 to 8800 ohms t75°F) 1.30to 1.400hms(75 ° F)

0.21 to 0.25 mfd

Distributor .. .. . . . . . . . ... .... . ...•. ... . . . . . . . . . .. . . Automatic advance , .. . . . . . . . . . . . . . . . . ..... ...... Direction of rotation .. . ....... , . . • . . . . . . . . . . . ... . Firing order: AII except 351 engine . ... . . . ...... . . .... . . . ..... 351 engine .. .. . . . . . . . . .... . . ... . . . . .. .....

Туре

.. .. . . ..... . .. ... .

Single ог dual conta ct breaker Vacuum and centrifugal Counterclockwise

. . .. . . . .. . . .

1 - 5-4-2 - 6 -3- 7 - 8 1 - 3 - 7 - 2 - 6 - 5 - 4 -8

10.В6 тт)

0.034 in (0.86 тт)

0 .034 in 10.86 0 .034 in 10.В6 0.034 in (0.86

0.035 in 0.035 in

ттl тт)

10.ВВ ттl 1 0 . ВВ тт )

0 .035 in (0.88

0 .035 in 0.034 in 0 .034 in

тт )

тт)

1 0 . ВВ ттl 1 0.В6 тт ) 10.В6 тт )

0.034 in (0. 86 тт ) 0.034 in (0.86 тт )

•

Chapter 4 Ignition system

92 Cha.гacteristics

Engine

Points яар in (тт)

Dwell angle (degrees)

Initial tim ing (static) (degrees ВТОС ) Мапиаl Auto

1965-260 ....... . . . . ... .... . . .... . .. ... . . . ....... . 1965-2 89 ... .... .. . . . ... . . . . . . . .... . . . . . . ...... .. .

0.01510,381 0.01510.381 0.02010.501 0.017 10.431 0 .02010 ,501 0 .017 10 ,431 0 .020 10.501 0.017 10.431 0.021 10.531 0 .021 10,531 0,017 10.431 0.016 10.401 0.017 10.431 0 .021 10.531 0,017 10,431 0.01710.431 0,01710.431 0,021 10.531 0.021 10.531 0,017 10.431 0,020 10.501 0.021 10.531 0,020 10.501 0,021 10.531 0,021 10.531 0.020 10.501 0,021 /0.017 10,53/0,431 0 ,021 10,531 0.021 /0,017 0 ,5310 ,431 0,020 10 .501 0.01710 ,43 1 0.01710.431 0.017 10.431 0,02010,501 0.02010,501 0.017 10.431 0.02010.501

27 27 27 29 31 29 32 29 27 27 29 29 29 29 27 29 29 27 27 29 30 27 32 27 27 32 27/29

4 8 10 6 12

4 8

6

6

12 12 6 6 6 6

12 12 6 6 6 6 6

1965 -

289НР

............ . .•......................•.

1966 - 289 ..... ..... ............ .. ........... • .•. • 1966-289НР . .... . . . ... . .... . . ... ..........• ... . . . 1967-289 .... ... ....... . . . ... . . . . .. . .. . . . . . . .... . 1967 - 289НР ... . ....... ... .. . . . . ....... .. . ...... . . 1967-390 . . . . . . . . . . . . . . . . . . . ... . . . . . . . . . . . . . . . . . . 1968 - 289 .. .... .. . .......... ............. ....... .

. . . . . .

1968 - 302 , 390 (therma ctor) .....• .. . ........ ...•... • .• .

1968 - 302, 390 ............. . . . .. ..... . . ...... , .. .. . 1968 - 390GТ .................. . ........ .... ......•. 1968-427. 428 .......... .... . .................. ' .. . 1969 - 302 ........ ' , , .. , , , . , , .•.. ' , , , .. ...... , .. , .. 1969-302 ....... . . . . . ........ . . ........ . . . ..... . . . 1969-351 .... ... .. ..... . . .. . . .... . . ... . . . . . . ... ' .. 1969-390 ..... . . . . . ........ ..... . . ............. .. . 1969 - 390 , , . , ..... . . . . . . . . . . . . . . . . . . . . . . . . . . . , , , . , 1969-428 ....... .. . .. ....• .•.• . • . .... . . . . . . . . . • . •. 1969 -428 ...... ... ... . ... .. •. • . .. . • • . .... . ....•.•. 1969 -429 Boss .. ... . ... ... ....• . • . ..... ..... ...... .

1970-302. " . ... . .. " ' ........ " . . " .......... "" 1970 - 302 Boss . . . . . . . . . . . . . . . . . . . . . . . .... . . . . . . . . . . 1970-351С ....... ..• .. . ... . . . . о о о 1970-351 W ...... ... • . .. . .... . О О О" ••

•

•

••••

•••••

••

•••

•

•••••

•

•••••

••

1970-428 ........... , ..... .... , ... ' . ........... ", 1970-429 .. ' .. ' ..... " ... .. " " ' .. "" ....... ' ... . 1971 - 302 , 351c,351w,351cs .. ....• .... ,., ..... . . " .. 1971-351 Boss .. ..... . .. .... ... . • . .. ....... . . .. ... . 1971 -429 . . . . . . . . . . . • . . . . . . . . .... .. • . . . . . . . . . . . . . . 1972 - 302 . 351С

... ... . , .......... , . . .. , ......... . "

1972-351W ...... 1972-351CJ . . . . . . . . . . . . . . . 0.0

0

•

•

•

•

•••••

о . о.

0

.0.0

0.

00.

о

•

•

•

о

•

•

•••

•

•

•••••••

••

•••••••••

1972-351CJ ........... "" .... ", . . .. " " " , .. , .. . 1972 - 351НО ........... , ... . ...... , .... , . " " , ... . 1973 - 302 . 351С2 . 351С4 ........... " . . . . ... . . . . . , .. . 1973-351c4(dualpoints) . . . . . . . . . .

o.

0

.0

о

•••

0

•

•

•

•••••••

6

6

6 6

6 6

-

6

6

6 1О

1О

6 16 6 10 6 10

6

27 29/29

6 6

6 6

28 28 28 28 28 28 2430 3235

10 6

10 6 6 16

6 10 6 10

16 10 refer to decal in engine compa rtment

Torque wrench settings Spark plugs:

8F32 , 8F42. 8RF42 " , . " , . . . .. •. , .. . .. , . , .. ' • .. . .. AF32 , AF42 . ARF42 , , .. , , , , , ..• . , . , ..... , , , , , , , , , ..

1

General description

In order that the engine сап гип correctly it is necessary for ап electrica l spark to ignite the fuel/ air mixture in the combustion chamber at exactly the right moment in relation to eng lne speed and load. The ignition system is based оп 1eeding low tension voltage from the battery to the соН where it is conveгted to high tension voltage. The high tension voltage is powerful enough to jump the spark plug gap in the cyllnders тапу times а second under high compression pressures. providing that the system is in good condition and that all adjustments аге correct. The ignltlo" system is divided into two cl rcuits, low tension and high tenslon . The low tensi'Jn circuit (sometimes known as the primary) consists of the Ьанегу lead to the ignition switch. resistor lead from the Ignition switch to the low tension ог primary coi l winding , positive terminal (+), and the lead 1гот the low tension coil winding , negative term inal Н, to the contact breaker points and condenser 1п the distributor. The high tension circuit consists 01 the hlgh tension ог secondary

lbfft

kgf m

15 to 20

2,07 to 2.76

1О to 1 5

1.38 to 2 .07

coil winding, the heavy ignition lead from the center of the соН to the center of the distributor сар, the rotor агт , the spark plug leads and spark plugs. The system functions in the following таппег. Low tension voltage i5 changed in the coil Into high ten510n voltage Ьу the opening of the contact breaker points 1п the low tension circuit. High tension voltage is then fed via the сагЬоп brush in the center of the distributor сар to the rotor агт of the distributor, and each l1те It comes in !ine with опе of the теlа' segments in the сар , which аге connected to the 5park plug leads, the openlng of .t he contact breaker points cause5 the high ten5ion voltage to build ир , jump the gap from the rotor агт to the appropriate metal segment and so via the spark plug lead (о the spark plug , where It Лпаllу jumps the spa rk plug gap before going to ground. The Ignition i5 advanced and retarded automaticaJly , to епзиге the spark occurs аl just lhe right in5tant for the particular toad аl the рге­ vailing eng ine speed . The ignition advance is controlled both mechanically and Ьу а vacuum -operated sY5tem. The mechanical governor com prises two weight s. whlch move оиl from the distributor shaft as the engine

,

•

•

Chapter 4 Ignition system

speed пsвs due {о centrifugal faree. As they тоуе outwards they rotate the сат relative 10 thв distributor shaft, and 50 advance the spark.. Тhe weights аге held in position Ьу tWQ light springs and It i5 the tension 01 the springs which is largely responsibIe far correct spark

I

manifold vacuum i5 high (eg during deceleration ог idling ) the secondary diaphragm retard5 the spark. As soon as the throttle is opened , the primary diaphragm takes control and cause5 the spark to advance. The purpose of this system is to decrease the emissio n of unburnt hydroca rbons at low throttle openings. А dual contact breaker type distributor is 1itted оп high output engines to glve а better high tension spark. Оп these models, the breaker plate is mounted оп а ball bearing. Other than the dual points, these distributors аге the same as the slngle contact breaker type.

advancement.

I

The vacuu m control consists 01 а diaphragm, опе side of which Is connected via а small Ьоге tube to the carburetor. and the other side to the C0[1t8Ct breaker plate. Depression in the inlet manifold and caг~ buretor, which varies with the engine speed and throttle opening , C8uses the diaphragm 10 тоуе , 50 moving the contact breaker plate. and advancing the spark. А spring within the vacuum unit retuгns the breaker plate 10 the normal position when the amount of manifold depression is reduced. 50те distributors аге fitted with а dual diaphragm vacuum control unit. The outer (primary) diaphragm senses carburetor vacuum just upstream of the throttle butterflies to advance ignition timing ; the inner (5econdary) diaphragm 5enses manifold vacuum. Therefore , wllen the

•

93

Igпitiоп

2

system -

sвrviсiпg апd

Federal

геgulаtiопs

In order to conform to the Federal regulations which govern the emission 01 hydrocarbons and с агЬоп monoxide from с аг exhaust systems, the eng ine, carburetion and ignition system have Ьееп suitabIy modi1ied. It is critically impoгtant that the ignition system is kept in good

,,,.АК

CONN ECTOA

PLUG

PRIMAAY RESISTANCE WIRE IGNITION

SWJТC H

aUlcK OISCONNEC T

~-- COIL

ВАТТЕА У

__

DISTRI8UTOA _ _ _ I?AIMARV CI ACUlT •

• ••••• SECONOA AY CIRCUIT

Fig.4.1

,

A DVANCE

'NC

ВААСКЕТ

СОПV8пtiопеl igпitiоп

eireuits (Sae . 1)

ШВ'А'СдТ"" W'CK

OlSTAI8UTOR

WEIGHT SPRING

САР

_ _....

COIL HIGH ТЕNSЮN _ __ WIAE TEAMINAL

САМ

MQVA8LE

ASSEM8L V

8АЕАКЕА

•

SPRING

I

WEIGHT САМ

PLATE CONTROL SLOT

OISTAIBUTOR

ADVANCE AOJUSTING ВААСКЕТ

HVPALON СОУ ЕА NOT USED ON ALL DISTRIBUTOAS

VACUUM ADJUSTMENT

STATIONARY SU8·PLATE LEVER

Fig. 4.2 Dual advane8 distributor with singla diaphragm (See. 1 )

•

GAP ADJ USTMENT

CENTRIFUGAL AD VANCE ADJ USTMENT HOLE

Fig . 4 .3 Distributor with dual c ontact breaker points jSec. 1 J

HIGtt POINT QF

Fig . 4 .5 Heel 01 breaker arm point 01 сат (Sec . ЗJ

оп

highest

Fig . 4 .4 Checking the contact breaker points gap (Sec . 3)

Fig. 4 .6 Adjusting the breaker point gap 158С . ЗJ

•

Chapter 4 Ignition system

95

сое

.:.ona order and to achieve this, accurate analvtical equipment is еес :d 10 check and reset the distributor function. This will Ье found _t у()(.' lOcal dealer. ""Oflilзtiоп contained in this Chapter is supplied 10 епаЫе the tюmе mechanic 10 set the ignition system roughly 50 enabJing starting of {М еnglпе . Thereafter the саг must Ье taken 10 the local Ford dealer fof па, tuning. Failure 10 do this сап result in heavy penalties.

з

Contact breaker points - adjustment

adjust the contact breaker points 10 the соггес! gap, first 'el ease the twa c1ips. securing the distributor сар 10 the distributor body, and lift away the сар. Clean the сар inside and out with а dry cloth. It is unlikely that the segments will Ье badly burnt аг scored, but if they аге the сар will have to Ье renewed. 2 Inspect the сагЬоп brush cantact lacated in the tap of the с ар 10 ensure tha1 it is поl bгoken and stands proud 01 the plastic surface. 3 Lift away the rotor arm and check the contact spring оп the (ор of the rotor arm. 11 must Ье cJean and have adequate tension to ensure good conlact. 4 Genlly ргу the contact breaker points ореп 10 examine the condil ion 01 their laces. 11 they аге гough , pitted ог diгty it will Ье necessaгy 10 remove them for resurfacing, ог 10г new points to Ье installed (see Section 5). 5 Presuming the points аге satisfactoгy, ог that lhey have Ьееп cleaned ог renewed . measure the gap between the points wilh feeler gau ges Ьу turning the crankshaft until the heel 01 the breaker агт is оп the highesl point of the cam (Fig. 4 .5). The gap should Ье as given in the Specifications. 6 If the gap varies from the specified amount slacken the contact plate securing screws. 7 Adjusl the contact gap Ьу inseгting а screwdriver in the nOlched hole in the contact breaker plate. Тшп clockwise to increase, and anticlockwise to decrease the gap. When the gap is correct, tighlen lhe securing screws and check the gap again (see Fig . 4.6). 8 Install the ГОl0Г arm and dislributor сар. Aetain in роsiliоп with the two clips. 1

4

То

Dwell 8ngl8 - check

8пd 8djUSlmвПl

Checking used points with а (ее/ег увuуе сап result in аn inaccurate уар setting, because о' the roughness о' the points, therefore it is Ьепег (о check the dwell аnу/е, if уои have а dwell тесег.

1 СоппеСl lhe dwell meter according 10 the maker's inSlructions. 2 Slaгt the епgiпе апd 'еl it idle. 3 Aead the dwell апglе оп the dwell meter and com pare il against the figure given in Specifications аl the Ьеgiппiпg of lhis Chapter. 4 SWilCh off lhe engine. 5 If the dwell angle is below the specified ligure, the breaker роiпt gap is 100 large. If lhe dwell angle is above the specified figure, the breaker point gap is too small. 6 11 necessaгy , adjust the breaker point gap as described in Seclian з.

7 Оп dual breaker distributors , adjust the dwell оп each set separately 10 gel the specified combined dwell. Oisconnect the wire 10 опе set of points while adjusling the other ог allernatively insert а piece о' plaslic belween the points 01 опе set 10 take it out of circuit. 8 Aemove the dwell meter.

Flg. 4.7 Aemoving contact breaker polnls (Sec, 5) then reset the gap, as described in Section 3 ог 4 . 6 Should the contact breaker poinls Ье badty worn, а new sel must Ье installed. As ап emergency measure clean the faces wlth fiпе emeгy рарег folded over а thin steel rule. 11 is necessaгy to rub the роiпts right down 10 the slage where all the pitting ha5 disappeared. When the surfaces аге flat а feeler gauge сап Ье used 10 reset lhe gap. 7 Finally, inSlall the rotor arm and distributor сар. Aetain in posilion with the two clips.

6

1 The condenser is installed in parallel with the сопtасl breaker points. If it develops а fault, it will cause ignition failure as the contacl breaker points will Ье prevented from correctly interrupting the low tension circuit. 2 If lhe engine becomes veгy difflcult 10 slart, ог begins 10 misfire and lhe breaker points show signs of excessive burning. then the соп­ ditiоп of the condenser must Ье suspect. Опе futther lest сап Ье made Ьу separating the points Ьу hand with the ignilion switched оп. 11 this is accompanied Ьу а bright flash, il is Indicalive that the сопdепsег has failed. 3 Without special tes1 equipment the only safe way 10 diagnose соп­ denser IroubIe is 10 replace а suspected unit with а new опе and note il there is апу imргоvеmепt. 4 То remove the condenser from the dislributor take оН the distributor сар and rotor arm. 5 Slacken the nut holding the condenser lead and low lension lead to the contact breaker polnts. Slide out the forked terminal оп lhe end 01 1he condenser low tension lead . Uпdо and remove the condenser retaining screw and remove the сопdепsег from the breaker plate . 6 То install the condenser, simply reverse the order of removal.

7

5

I

I

Сопlвсt

Condenser - removal, testing and in51al18tion

Dislributor - Iubrication

breaker polnts - removal and 1"51a1l8110n

1 If the contact breaker points аге burnt. pltted ог badly worn they must Ье removed and renewed. 2 Lift оН lhe rotor arm Ьу pul1ing it straighl up from the spindle. 3 Slacken the sheet metal screw that secure5 the condenser and 10w tension lead to the contact breaker point assembIy. SHde out the forked ends of the lead terminals. 4 Undo and remove the two screws that secure the contact bгeaker poinls base plate (о the distributor base plate. Lift away the points assembIy. 5 То InSlall the роiпts is the reverse sequence 10 гemoval . Smear а (гасе of grease onto lhe cam 10 lub ri cate the moving poinl heel . and

1 11 is impottant that the disttibutor cam is lubricated with petroleum jelly ог grease at 6000 miles (1 0000 km) ог 6 monthly intervals. Also lhe automatic timing сопtгоl weights and cam spindle аге lubricated with engine oil. 2 Great саге should Ье taken поl (о use 100 much lubricant as апу excess that finds i1S way onto the contact breaker points could cause burning and misfiring. 3 То gain access (о the cam spindle, lift away the distributor сар and rotor arm . Apply по more than two drops of engine oil опlо the fel1 pad . This will run down the spindle when the engine is hot апd lubricate the bearings. 4 То lubricate the automatic timing control allow а few drops of oil

4

9б--------------------------~~--------------------

CONOENSER

RETAINER ВАЕАКЕА

POINT ASSEMBLY

GROUND

MOVABLE

ВАЕАКЕА

/~LATE

FLAT WASHER SPRING WASHER

STAТlONARY

SUB-PLATE

LUBRICAТlNG ~ "" WICK --____~~~-~~

RETAINER

8 САМ

THRUST

ASSEMBLY

WEIGHT RETAINER

SPRING

SPRING

SHAFТ

UPPER BUSH

PIN PIN _ _ _ HOUSING DOUBLE OIAPHRAGM

OILSEAL

RETURN

•

BUSH PIN

VACUUM CONN 'TII'

~COLLAR DRIVE G CALIBRAТlNG WASHERS

"'-

/ ' PIN

~

Fig. 4.8 Exploded view of distributor (Sec. 9)

•

Chapter 4 Ignition system

•

10

oass

thfOUgh the holes in the contact breaker base plate through

... "IIC." the eight sided свт emerges. Apply поl тоге than опе drop of

10 (he pivot post of the moving contact breaker point. Wipe away excess oil and instalt the rotor агт and distributor сар.

()I,

8

Distributor - remova/ and in8t8118tion

1

Аетоуе

the air cleaner as described in Chapter

З.

2 Aelease the two spring clips, and гетоув the distributor сар and place il 10 опе side. 3 Disconnect the primaгy wire from the coil and the vacuum advance line(s) 81 the distributor. 4 Scribe а mark оп the distributor body and the cylinder bIock, 10 indicate the position of the distributor in the bIock. and al50 mark the position of the rotor оп the top edge of the distributor body. 5 Remove the distributor clamp bolt and lift out the distributor. Note: 00 not rotate the cronkshaft while the distributor is removed ог it wi/l Ье necessary СО time the engine as described in Section 1З. 6 ТО in5tali the distributor insert it in the engine bIock, ensuring that the pre viously scribed marks аге aligned and that the rotor is in exactly the same position it was in before the distributor was removed. 7 In51al l the clamp and securing bolt. 8 Reconnect the primary wire and the vacuum line (s). 9 Instatl the distributor с ар and air cleaner.

9

Distributor - dismantling

1 Remove the condenser and contact breaker assembIy, as described in Sections 5 and 6. 2 Using а small screwdriver, remove the C-clip retaining the vacuum advance lin k {о the moveabIe breaker plate (not applicabIe with dual points ). 3 Undo and remove the two screws retaining the vacuum advance unit and carefully remove the unit (with dual points, pull the unit straight ои' and t ilt the link downward to unhook itl. 4 Remove the retaining screws and lift out the breaker plate and sub-plate. 5 Mark опе of the distributor cent rifugal weight spring5 and its bracket . Also mark опе of the weight5 and its pivot. 6 Carefully unhook and remove the weight springs. 7 Lift the lubricating wick from the cam assembIy. Remove the spring clip retainer and lift the cam assembIy оН the distributor shaft. Remove the thrust washer. 8 Remove the retaining clip from the pivots and lift О Н the weights.

1 О Distributor - inspection 1

f

! I i

!

Check the co ntact breaker points for wear, as described in Section З . Check the distributo r сар for signs of tracking indicated Ьу а thin bIack line between the segments. Renew the сар ;f апу signs 01 tracking аге found. 2 If the metal portion of the rotor агт is badly burnt or loose, renew Ihe агт . If only slightly burnl, clean Ihe end with а 1ine 1Не. Check that the conta ct spring has adequate pressure and the bearing surface is clean and in good condition. 3 Check that the сагЬоп brush in the distributor сар is unbroken and stands proud of its holder. 4 Examine the centrifugal weights and pivots 10г wear and the advance springs for slackness. They сап best Ье checked Ьу comparing with new parts. If they аге slack they must Ье renewed. 5 Check the points a~sembIy (ог 1it оп the breaker plate , and the cam follower for wear. 6 Exam ine the fit of the spindle in the distributor body. If there is excessive side movement it wilt Ье necessary 10 either install а new bush ог obtain а new distributor body. 11 Distributor - reassembIy 1 lubricate the weight pivots . Install the weights in the correct position (the marked weight оп the marked pivotl and secure w ith the retaining clips. 2 1nstall the thrust washer оп the shaft.

97

3 lu bricate the иррег part of the distributor shaft and install the сат assembJy. ЕП5иге that the marked spring bracket оп the с ет aS5embIy is пеаг the marked spring bracket оп the sub-plate. 4 Instatl the сат assembIy retaining clip end the oil wick. 5 In$tall the weight springs with t he marked spring attached to the marked bracket. 6 In$tall the plate assembIy into the distributor body ensuring that the retain ing screw holes line ир. Install the retaining screws. 7 P05ition the vacuum advance unit оп the distributor body (with dual points hook the duaphragm link in pO$itionl and install the spring clip that secures the diaphragm link to the тоуеаЫе breaker plate (not dual points). In$tall the vacuum adva nce unit retaining screws. 8 Install the contact bre aker points but do not tighten the securing screws. 9 Insta ll the condenser and primary wire. 10 Adjust t he con ta ct breaker points as de$cri bed in Section З.

12 Spark plugs and

НТ

leads

1 The со ггес! 1unctioning of the spark plugs is vital for the соггес! running and efficiency of the engine. 2 At inteгva ls of 6000 mile5 the plugs should Ье removed. examined , cleaned, and If worn excessively, renewed. The condltion of the spark plugs will al$o tel l m uch аЬои! the оуегаll condition of the engine (see iIIustration оп page 99). 3 11 the insulator nose of the spark plug 1$ clean and white, with по deposits. this is indi cative 01 а 'евп mixture, ог too hot а plug. ( Д hot plug transfers heat away 1гот the electrode slowly - а cold plug transfers it away quickly). 4 The plugs instal led as standard аге as listed in Specifications at the beginning 01 this Chapter. 11 the tip and insulator nose are 'covered with hard bIack looking deposits, then this is ind icalive that the mixture is too rich. Should the plug Ье bIack and oily, then it is likely that the engine is fairly worn, as well as the mixture being 'оо rich. 5 If the insulator nose is covered with light tan to greyish brown deposits, then the mixture i$ correct and it 15 likely that the engi ne is in good condition. 6 If there аге апу traces of long brown tapering stains оп the outside 01 the white port ion о' t he plug, then the plug will ha ve to Ье renewed, as this shows that there is а 1aulty joint between the plug body and the in su lator, and compression is being allowed to leak away. 7 Plugs should Ье cleaned Ьу а sand bIasting machine, which wiН free them from са г Ьоп тоге thoroughly than clean ing Ьу hand. The machine will also test the condition of the pl ug$ under compression. Апу plug that fails to spark а! the recommended pressure shou ld Ье renewed . 8 The spark plug gap is of consid erabJe importan ce as, i1 it is (оо la rge ог too small, the size 01 the spark and its efficiency will Ье seriously impaired. The $park plug gap shou ld Ье set to the 1igure given in Speci1ications at the beg inning of this Chapter. 9 То set it , measure the gap w lth а feeler gauge, and then bend ореп , ог clo$e, the outer plug electrode until the correct gap is achieved. The center electrode should never Ье ЬеП! as this тау crack the insulator and cause plug failure i1 nothing worse. 1 О When insta lling the plugs, remember to use new plug washers, and connect the leads from the distributor in the correct firlng orde t. 11 The plug wire$ require по routine attention other than being kept clean and wiped over regularly . 12 At intervals 01 6000 miles, however, pull the wires ОН the plugs and distributor опе 8! а time and make sure по water has 10und its way onto the connections. Remove апу corrosion 1гот the bras$ ends, wipe the coltars оп (ор 01 the distributor, 8nd reconnect the wires.

13 Initial (static) ig"ition timing 11 the eng ine has Ьееп rotated with the di5tributor removed , it will Ье necessary to ге -Нте the ignition. 2 Ае1ег to the Specifications at the beginning of Ihis Chapter for the initial advance (staticl timing. 3 Turn the eng ine until No 1 pi5ton 1$ coming up to тое оп the сот­ pression stroke. This сап Ье checked Ьу removing No 1 spark plug and feel ing Ihe pressure being developed in the cylinder. If this check is not made it is all too easy 10 set the timlng 1800 out. The engine сап most 1

4

98

•

Chapter 4 Ignition system

ез.si ty ье

turned

Ьу

en9a9in9

{ар

gear and edging the

саг

alon9 (except

a utomatic). 4 Continue tuгпiпg the engine until the appropriate timing mark оп the crankshaft putley 15 Ёп liпе with the pointer (Fig. 4.9) . 5 Now. with the distributor and the rotor агт in the same position as was noted before геmоvзl, insert the distributor Into its location. Note that the rotor агт rotates as the gears mesh. Lift Qut the distributor far

enough 10 rotate the shaft

опе

tooth at

а

lime. lowering il home 10

check the direction of the rotor агт. When il points in the desired direction with assembIy fully home, install the distributor clamp plate. bolt and washer. Оо not fully tighten yet. 6 Gently {иrn the distributor body until the contact breaker points аге just opening when the rotor is pointing to the contact in the distributor сар which is connected to No 1 spa rk plug. А convenient way is to put а mark оп the outside of the distributor body in line with the segment in the cover, so that it shows when the cover is removed. 7 If this position cannot Ье reached, check that the drivegear has meshed оп the correct tooth Ьу lifting out the distributor опсе тоге. If necessary, rotate the driveshaft geat опе tooth and try again. 8 Тighten the distributor body clamp enough to hoJd the distributor, but do not overtighten. 9 If а stroboscopic timing light is used for а final ignition check, clean the timing scale оп the damper pulley and mark the specified degree line and the tip of the pointer with quick drying white paint ог with chaJk. 1 О Disconnecl the vacuum hose(s) from the vacuum unit and plug them with а pencil ог similar item. 11 Аип the engine to normal operating temperature and check that the idling speed is correct (see Chapler З). 12 Conne ct the timing light between No 1 spark plug and spark plug wire . 1 3 Start the engine and point the timing light at the white painted marks. They will арреаг stationary and if the timing is co rre ct they will Ье in alignment. 14 If they аге по! d1гectly opposite each other, adjust Ьу loosening the distributor body clamp and turning the distributoг housing as necessary to line-up the marks. The timing is advanced when the dist r ibutor is turned clockwise and retarded when turned counterclockwise. Tighten the clamp and recheck the timing. 15 If the engine speed is now in creased the white mark оп ·the pulley will move away from the fixed pointer, indicating that the centrifugal advance is operating. If the vacuum hose(s) аге unplugged and гесоп­ nected 10 the vacuum unil the operation of the vacuum unit сап Ье checked Ьу revving up the engine and watching the timing marks. 16 Aemove the liming light and reconnect the НТ wire {о the spark plug. 17 As а finaf check, take the саг 10 а Ford selVice station which will have the ргорег equipmenl {о correctly set the liming in relation to the fuel and em ission control systems installed оп the саг, particularly оп later models.

Fig. 4.9 Timing matks (Sec. 13)

thi

Fig. 4.10 Plugging the vacuum line (Sec. 13)

14 Distributor modulator - general 1 From 1970 some mode ls аге equipped with а d1stributor modulator system 10 reduce engine emissions Ьу control of the distributor spa rk advance. It consists of fouг major compone nts: а speed sensor, а thermal switch, ап electronic сопиоl amplifier and а three -way solenoid valve control ling vacuum applied to the distributor. 2 When loss of engine performance and excessive fuel consumption is experienced with symptoms of retarded ign1tion timing, the modulator system must Ье checked. This is а job for а Ford service station with the necessary lesl equipment (Fig. 4.12) . •

15 Fault diagnosis - ignition system far the majority of breakdown and running troubIes аге caused Ьу faults in the ignition system. either in the low tension ог high tension circuits. There аге two main symptoms indicating faults. Either the engine will not start ог fire , ог the engine is difficult {о slart and misfires. If il is а regular misfire, Ое the engine is running оп only six ог seven cylinders), the fault is almost su re to Ье in the secondary ог high tension circu it. If the misfiring is intermittent the fau lt could Ье in ei ther the high ог low tension circuits. If the саг stops sudden ly, ог will

Fig. 4.11 Checking the timing with

а

timing light (Sec. 13)

Ву

not start а! all, it is likely that the fault is in the low tension circuit. Loss of power and overheating, apart from faulty carburetion settings, аге normal ly due to faults in the distributor ог to incorгect ign ition timing. Е ngine

fails

Со

start

1 If the engine fairs to start and the саг was running normally when it was last used, f'rst check there is fuel in the fuel tank. If the engine turns over normally оп the starter motor and the ЬаНегу is evidently

•

•

Соттоп

spa

plug conditions

NORMAL Symptoms: Brown to grayish-tan color and slight electrode wear. Correct heat range lor engine and operating conditions. Recommendation: When new spark plugs аге installed, replace with plugs 01 the same heat range.

,

WORN

I•

Sympfoms: Rounded electrodes with а эmаl l amount of deposits оп the firing end. Normal color. Causes hard starting in damp ог cold weather and роог fue! есопоту. Recommendatlon: Plugs have Ьееп left in the engine too IOn9. Replace with new plugs of the sзте heat range. Follow the гес­ ommended maintenance schedule.

CARBON DEPOSITS

!

i

Symptoms: Ory sooty deposits indicate а гich mixture ог weak 19nitlon. Causes misfiring, hard starting and hesitation. Recoтmendation: Make sure the plug has the correct heat range. Check far а clogged air filter ог рroЫет in the fuel system ог engine management system. Alsо check far i9nition system ргоЫетэ.

ASH DEPOSITS I I

I

I

Symptoms: Light brown deposits encrusted оп the side ог center electгodes ог both. Derived fгom oil and/or fuel additives. Excessive amounts тау mask the spark, causing misfiring and hesitation during acceleralion. Recommendation: If excessive deposits accumulale over а shoгt time ог low mileage, install new valve guide seals 10 prevent зеер­ age of oil into the combustion chambers. AJso Iry changing ga9Oline brands.

t OIL DEPOSITS Sympfoms: Oily coaling caused Ьу роог oil contгol. Oil is leaking past worn valve guides ог piston rings into the combustion chamber. Causes hard starting, misfiring and hesitation. Recommendation: Correct Ihe mechanical condition with necessary repairs and inslall new plugs.

ТООНОТ Symptoms: 8Hstered, white insulalor, eroded electrode and absence of deposits. Яеsults ,п shortened plug life. Recomтendation: Check for the соггес! plug heat range, overadvanced ignilion liming, lean fuel mixture, intake manifold vacuum leaks, sticking valves and insufficient engine cooling.

PREIGNITION Syтptoms:

Melted eleclrodes. Insulators аге white, but тау ье dirty due 10 misfiring ог flying debris in the combuslion chamber. Сап lead 10 engine damage. Recommendatlon: Check for the coгrec! plug heat range, overadvanced ignition timing, lean fuel mixture, insufficient engine cooling and !аек of lubrieation.

HIGH SPEED GI AZING Symptoms: Insulator has yellowish, glazed арреагапсе. Indicates that combustion chamber temperalures have risen suddenly during hard acceleration. Normal deposits mel! 10 form а conducl ive coating. Causes misfiring а! h!gh speecls. Recoттendation: Install new plugs. Consider using а colder plug if driving habiIs wаrталt.

DEТONATION Symptoms: Insulators тау Ье cracked ог chipped . Improper gap setting techniques сап also result ,п а fractured insulator tip. Сап lead 10 piston damage. Recommendation: Маке sure I he fuel anti-knock values тее! engine requirements. Use саге when setling the gaps оп new plugs. Avoid !ugging the engine.

MECHANICAL DAMAGE Syтptoms:

GAP BRIDGING Symptoms: Combustion deposils lodge between the electrodes. Heavy deposits accumulate and bridge the electrode gap. The plug ceases 10 fire, resulting (п а dead cylinder. Recomтendatlon: Locate the faulty plug and гemove the deposits fгom between the electrodes.

Мау Ье caused Ьу а foreign object ,п the combuslion chamber о( the piston striking ап

incorrect reach (100 long) plug. Causes а dead cylinder алd could result in piSlOn damage. Recommendation: Яераiг the mechanical damage. Remove the fo(eign object fгom the engine and/or install the согтес! reach plug.

4

•

Chapter 4 Ignition system

100

".

IILIJE ТО ' GН IfION

\ '" тсн

Bt.ACK

Fig. 4.12 Distributor modulator system - schematic (Sec. 14) well charged , then the fault тау Ье in either the high ог low tension circuits . First check the НТ circuit. Note: If the battery is known (О Ье fully charged. rhe ignition Iight comes оп, and the starter motor fails (О

(urn the engine check the tightness 01 the leads оп the battery terminals and al50 the security о( the ground lead at its connection to the body , /! is quire

соттоп (ог

the feads

(О

have worked

1005е,

even

'" they look and !ееl зесuге. ff опе о{ the Ьапегу terminal posts gets very hot when try;ng (О work the staгter та(аг, this is а suгe indication о( 8

fsulty соппесаоп (о that terminal. 2 Опе of the mast соттоп reasons for bad staгting is wet ог damp spark plug leads and distributor сар. Remove the distributor сар. 11 condensation is visibIe internally dгy the сар with а rag and also wipe over the leads. Install the сар. 3 11 the engine still 1ails to slaгt. check that vollage is reaching the plugs Ьу disconnecting each plug lead (п шгп at the spark plug end . (п (5 mm) away 1rom the and holding the end of the саЫе about cylinder bIock. Spin the engine оп the starter motor. Sparking between the end of the саЫе and the bIock should Ье 4 fairly strong with а strRng regular bIue spark. (Hold the lead with rubber glove ог а thick dry cloth {о avoid electric shocks) . 11 voltage is reaching the plugs, remove them. and clean and regap them. The engine should now start. 5 11 lhere is по spa rk at the pJug leads. take off the НТ leads 1rom the center о! the distributor сар and hold il to the bIock as before . Spin the engine оп the starter опсе more . А rapid succession of bIue sparks between the end of the lead and the bIock indicate that the coil is (п order and that the distributor сар is cracked , the rotor arm is faulty . ог the сагЬоп brush in the 10р of lhe dislributor сар is по1 making good contact wilh the spring оп the rotor arm . PossibIy, the points аге in bad condition. Clean and reset them as described in Section З . 6 If there аге по sparks from the end of the lead from the coil , check the connections аl the coil end of the lead. If it is in order start checking the low tension circuit. 7 Use а 12V voltmeter о, а 1 2V bulb and two lengths 01 wire. With the ignit10n switched оп and the points ореп. test between the low tension wire to the coi l (it i5 marked 15 ог +) and ground. No reading indicates а break (п the supply from the ignition switch. Check the соп­ nections а! the switch 10 5ее if апу are loose. Reconnect them and the engine should run. А reading shows а faulty coil ог condenser, ог broken lead between the соil and the di5tributor. 8 Take the condenser wlre off the points a55embIy and with the points ореп tesl belween lhe moving point and ground. 11 there now i5

4

а

reading then the 1au1t i5 in the condenset. InSlall а new опе and the fault i5 cleared. 9 With по reading from the moving point to ground, take а reading between ground and the - ог 1 terminal of the coil. А readin9 here ShOW5 а broken wire which witl need 10 Ье renewed between the соН and distribuI0f. No reading confirms that the coil has 1ailed and mU5t Ье renewed , after which the engine will run опсе more. Remember {о (есоппес! the condenser wire {о the points assembIy. For the5e tests it is sufficient to 5eparate the point5 with а piece of dry рарег white testing with the points ореп.

Е ngine

misfires

1О If the engine misfires regularly. run it аl а fast Idling speed. PuH off each 01 lhe plug caps (п turn and lislen 10 the note of the engine. Hold the plug сар (п а dгy cloth ог гиЬЬег glove as additional protection against а shock from the НТ supply. " No difference in engine running will Ье noticed when the lead 1rom the de1eclive clrcuit is removed. Removing the lead from опе of the good cyl inders wll1 accentuate the misfire . 12 Remove It al::1out Ji: (п (5 mm) away from the bIock. Re-start the engine. If the sparking Is 1airly strong and regular. the fault mU5t Не in the spark plug. 13 The plug тау Ье 1005е , the in5ulation may Ье cracked. ог the poinls ma.,. have ЬиГПl away giving too wide а gap for the spark to jump. Worse 5till. опе of the points may have broken off. Either renew the plug, ог clean it. reset the gap , and then test it. 14 If there Is по spark аl the end of the plug lead. ог if it is weak and in termittent . check the i9nition lead 1гот the distributor to the plug . If the insulal10n Is cracked ог perished , renew the lead. Check the 1;:0nne ctions а! lhe distributor сар . 15 11 there Is s1111 п о spark , examine the distributor сар ca refully for tracking . This сап Ье recognlsed Ьу а уегу thin bIack 11пе running between lWO ог more electrodes, о, between ап electrode and some other рап 01 the distributor. These lines аге paths which now conduct electricilY acr05S the сар thus letting it run to ground. The only answer Is а new distributor сар . 16 If the 19n1t1on timing is too far retarded. It should Ье noted that the en9ine will tend to overheat. and there will Ье а quite notlceabIe drop ,п power. If the engine (5 overheatlng and the power Is down , and the 19nit1on timlng Is сопесС then the carburetor shoutd Ье checked, as 1! is likely that this is where the 1ault lies.

•

I r •

Chapter 5 Clutch Contents Clutch - insp8ction and renov8tion ., ...... . .... . . . • ,. .. Clutch pedal free-play - adjustment ........ . • . • . ........ Clutch pedal- removal and i"stallat1o" ........•.•.•.....

5 2 3

Clutch - removal and 1nst8118tion .. ....... ......•. •.....

4

Fault diagnosis - clutch

......•.... .. ...... • .•.......

7

General description .......•............•.•.•• . • . •.. Pilot bush - renewal ......• ...• . • •.. ... .•••. • •• . . •..

1 6

•

Specific8tions

Туре

..................... . ........ , ........... . . .

Single

dгy

disc

Clutch adjustments Clutch pedal free-play (engine running) ........ ........ .. . • ..

0.875101 .125 in (22 10 28.5

тт)

Release lever rod adjusting nut-to-swivel sleeve clearance:

1 9 66 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1967 through 68 ............ ... ................ • . . 1969 through 71 , 390 and 428 engines .... . • . ... ... . . • • . 1969 through 71 , all other engines .........• . . . . . .......

1972 lhrough 73 ................................. .

Torque wrench settings

IbI ft

kgfm

Flywhee l housing-to-engine bolt ................ . . .. . . . . . . Pressuгe ptate and соуег assembIy-tо-flуwhееl bolt ............ .

401050 121020

5.5106.9

1

2

1.6t02.7

General description

The centrifugal single dгy disc type clutch, consisting of the clutch disc, pressure plate and clutch release bearing, is actuated Ьу а pedal and mechanical1inkage. When the clutch pedal is in the engaged position , the clutch disc is clamped between the friction surface of the engine flywheel and the face of the clutch pressure plate Ьу the pressure of the ргеззиге plate springs, and thus drive from the engine is transmitted to the transmission through the ~Iutch disc which is splined to the transmission input shaft. Friction 1ining material is riveted to the clutch disc and the splined hub is spring-cushioned to аЬзогЬ transmission shocks. When the clutch pedal is depressed the clutch release 'еуег moves the release bearing against the clutch fingers, which in turn, moves the pressure plate away from the clutch disc, dis-engaging the clutch and disconnecting the drive to the transmission.

,

0.128 in (3.25 mm ) 0.206 in (5 .23 тт ) 0.178 in (4.52 mm) 0.136 in (3.45 тт) 0.194 in (4.92 тт)

Clutch pedal freo-play - adju8tment

f

The c/utch peda/ adjustment must Ье checked whenever the cfutch does not disengage ог engage ргорег!у, ог when new cfutch paГls аге installed. !nct?rrect pedal free-play will result "n clutch friction.

I

1965 models

'''tI'ASE 8EARING

RElEASE .....~ FINGE R

rRANSMISSION IN Pu r SHAFТ PLATE ANO COV ER

С ШКН

OISC

Fig. 5.1 Cutaway view of clutch 1 Measure the amount of free-play at the clutch pedal; it should Ье between 0.875 in (22 mm) and 1.125 in (28.5 mm). 2 If necessary, adjust thв clutch pedal-to-equalizer rod . То increasв the amount of free-play, 'оозеп the геаг adjusting nut and tighten fгont nut. То reduce the fтee-play, loosen the fгont nut and tighten the геаг nut. 3 After obtaining the specified free-play tighten both nuts against the trunnion. 4 Finally , check that thв pedal free-play, with the engine running at 3000 грт, is 0.50 in (12.7 mm ). If necessary, re-adjust the clutch

ни8

аззетЫу

(Sec. 1)

pedal-to-equalizer rod to obtain the exact free-play of the clutch pedal.

1966 rhrough 1973 models 5 Disconnect the clutch return spring from the release 'еуег. 6 Loosen the release 'еуег rod locknut and adjusting nut. 7 Моуе the clutch release 'еуег reaгward until the rele8se bearing lightly contacts the clutch pressure plate release fingers. 8 Adjust the rod length until the rod seats in the release 'еуег pocket.

Chapter 5 Clutch

102 9

Inser1

а

feeler gauge between the adjusting nut and the swivel

s!eeve. th e n t ighten the adjusting nut, finger -tight, against the gauge. Тhe

specified thickness of feeler gauge, according to model , i5 given in

Specifica tions at the beginning of this Chapter. 1О Tighten the locknut against the adjusting nut, taking

саге

not to

disturb the adjustment . 11 Install the clutch return spring.

12 Operate the clutch pedal to actuate the clutch mech anism at 1east five times, then re- check the fr.ee-play setting with the specified feeler gauge. Re-adjust if necessary. 1 3 Аэ а final check. measure the pedal free- play with the engine running at approximately 3000 грт . If the peda l free- play i5 not at least 0.50 in (12.7 тт ), re-adjust the pedal free-play. Failure to ensure this minimum amount of peda l f ree travel will result in рге ­ mature release bearing and clutch failure.

A551ST SPRING BR ACKET - • ~

>-.:"

FR EE PlAY DIM.

ЩО~ 15'20 LВ. FТ.

СШ Т СН

...--- '00

EQUAllZER

VIEW IN CIRCLE U 302 AND 351 ENGINE

. __

.,. .

ВОО Т

FREE PlAY DIM.

iiфl

SPi'(I NG BU5HIN G

390 ENGINE VIEW IN CIRCLE V

BRAK E PEDAL

-~

,::--____, 8USH IN G

RElEA5E ROD ASS EMBL у

~/ EQUALIZER BRACKET

" '-

--' " ' RETAIN ER

BUSHING

BU5HING

PIVOT - - - - - " RETAI NER - - - - ' ' ' ' '

REL EASE ROD - - - _

"----

ВRACKE T

351 ENGINE SAME AS МA. I N VIEW ЕХСЕРТ AS SHDWN

390 ENGINE SAME AS МA.IN VI EW ЕХСЕРТ AS SHOWN

Fig. 5.2 Clutch

реdаlапd

linkage (1969) (Secs. 2 and 3)

DU TER

INNER

АС' Т

ASSIST

СШ Т СН

EQUAllZ ER RDD _ _•

-

ВА'

RE'LEASE RDD

Fig. 5.3 Clutch pedal and linkage (1971) (Secs . 2

PEDAL ASSEMBL У

апd 3)

,

Chapter 5 Clutch

I

СОТТЕЯ

PIN

BU$HING

'2

I

ЯЕОD.

СШТСН

ASSY .

STua 2

PEDAl

ВЯАКЕ

103

CYllNDER

BUMPER

Д$$У

СОТТЕЯ PIN СШТСrl

SPA(ER 4 ЯЕао .

ТО

PEDAL EQUALIZER ЯОD

FLUID lEVEL IN 8ЯАКЕ

l

MASTER CYLINDER MUST ВЕ

FROM 1/ 4 Т О 1/2 IN(HE5 FROМ тор

/"

ASSIST SPRI NG ВЯАКЕ PEQAL

PU5H

STUD

'2

QVERCE NTER ADJUSTMENT

ЯОD

RELEASE LEVER ЯОD

ЯЕао.

CLUTCH PEDAL

SQUARE WRENCH

ASS IST SPRING AS$Y

ASSIST SPRING О.

DI$C _ _

PLA TE AND CQVER

REТURN

СШТСН

PEDAl

-

FREE TRAVE L

SPRING

INNER BRACKEТ

,

ClUTCH

-------,- "~,~'-

..... 'J

0.206 I

PILOT 8EARING

GAP

12t1 INCH ,

~

QVERCENТER ADJUSТMENT

ADJUSTMENT

-"-";

FELTWASHER /~ '2 ЯЕаD .

.#' OUTER URACK EТ

EQUALIZER

Fig . 5.4 Clutch pedal and linkage (196811Secs. 2 and 3)

/ з

Clutch ped81- rеmОУ81апd installation

Models through 1968 1 Depress the clutch pedal and inseгt а 0.25 in (6.3 mm) spacer in the assist spring adjustment gap. 2 Remove the equalizer rod-to-clutch pedal securing pin and disconпес! the rod from the clutch pedal . 3 Disconnect the brake pedal pushrod from the brake pedal. 4 Remove the retaining clip fTom the end of the clutch pedal shaft, then гетоуе the shaft, bushings, clutch pedal and brake pedat from the

inner cowl bracket (see Fig. 5.5) , and the two screws securing it to the dash panel . 15 Аетоуе the two screws securing the pedal suppoгt bracket to the upper cowl Ьгасе , then lower 1t away from the steering column studs and remove it from the саг. CLUTCH PEOAL

ASSISТ

ТОР fNNER COWl· TD.BRACКET 5 SCREW

зuррогt.

I

5 Instaltation is the reverse of гетоуа! procedure. Lubricate the bushings w ith engine оН before assembty. Adjust the clutch pedal freeplay as described in Section 2 .

Models

t I I

I I

(гот

CL AМP

1969

6 Disconnect the battery ground с аЫе. 7 Remove the steering cotumn as described in Chapter 11. 8 Remove the two capscrews attaching the brake master cytinder ог booster to the dash panel, then the two screws securing the pedat suppoгt bracket to the Clash panel. 9 Work1ng inside the саг, disconnect the clutch pedat-to-equalizer rod а! the ctutch pedat Ьу removing the retainer and bushing . 10 Secure the ctutch pedal against the bumper stop with а small С ­ clamp. 11 Disconnect the stoptight switch at the connector. 12 Аетоуе the switch retainer and slide the stoplight switch off the brake pedal pin just far enough for the switch outer hole to clear the . pin. Now lower the switch away from the pin . 13 Аетоуе the master cylinder pushrod , bushing and nyton washer from the brake pedal pin . 14 Аетоуе the screw securing the pedal support bracket to the top

-

Fig. 5.5 Removing the clutch pedal (Sec.

З)

Chapter 5 Clutch

104

• 6 Mount the bracket [п а vise and remove the small C-clamp, then .sюwlv pivot the clutch pedal away from the Ьитрег until the assist spring сап Ье 1ifted from its seat (1969 through 1971 models). 17 Оп 1972/ 1973 models pivot the pedal away from the bumper until it comes 10 rest оп the opposite flange оп the brake pedal SUpport bracket, then remove the forward bolt securing the assist spring bracket to the support. Using ап adjustabIe wrench, hold the assist spring bracket and slowly pivot the bracket away fгom the spring until it свп Ье lifted from its эеаt. 18 Remove the retaining clip fгom the clutch pedal shaft then with draw the clutch pedal shaft assembIy and bushings (гот the pedal support bracket. 19 Installation i5 the rever5e of the removal procedure. Lubricate the bU5hings before 1n5tal11ng them in the brake and clutch pedal а55етЫ1е5. Adjust the clutch pedal free-play as described in Section 2.

4

СШТСН ARBOR

DISC

• •

Clutch - remov81 a"d inst8118tio" PLATE

1 Remove the transmission as described in Chapter 6. 2 Disconnect the clutch release lever retaining 5pring from the relea5e lever. З Di5connect the starter motor саЫе, then remove the 5tarter motor attaching bolt5 and Jift away the starter motor. 4 Remove the bolt5 5ecuring the eng1ne геаг plate to the front lower part of the flywheel hou5ing. Remove the flywhee l hou5ing lower cover of 50 equ1pped ). 5 Remove the flywheel hou5ing securing bolts and move the hou5ing back just 'аг enough to clear the pre5sure plate. then move it to the right to free the pivot from the clutch equalizer Ьаг. Take саге not to disturb the linkage and a55ist spr1ng. 6 Unscrew the six pressure plate cover 5ecuring bolts опе turn at а time. to prevent di5tort10n of the cover а55етЫу . when relea5ing the 5pr1ng ten5ion. 7 If the same pre55ure plate and cove r a5se mbIy Is to Ье re-1nstalled . mark the cover and flywheel 50 that the assembIy сап Ье 1n5tal'ed 1п its original position. В Remove the clutch cover а55етЫу and the clutch di5C from the ftywheel. Make а note of whlch way round the clutch disc Is in5tal'ed. 9 It 15 important that по oil ог grease gets оп the clutch di5C frictlon lining5. ог the pre55ure plate and flywheel faces. 11 i5 advisable to handle the parts with clean hands and to wipe down the рге55иге plate and flywheel faces wlth а clean dry rag before installing the clutch cover assembIy. 1О Place the clutch disc and pre5sure plate assembIy 1п p05ition оп

the flywheel. If the same assembIy is being

ге-iПSlаllеd,

align Ihe

matching marks made at removal. and install the 5ecuring bolts. Tighten the bolt5 alternately а few turns at а tlme until the clutch d15C i5 gripped lightly but сап 5t111 Ье moved . 11 The clutch d1sc must now Ье centered 50 that when the transmission Is in5talled . the input 5haft splines will ра55 through the 5pl ines in the clutch di5C hub. 12 Centering сап Ье carried ou t Ьу inserting а screwdriver through the clutch а55етЫу and moving the clutch di5C as песе55агу to obtain соггес! centerlng. Alternatively. if ап old input shaft is availabIe. this сап Ье u5ed а5 ап агЬог to center the disc; this will eliminate all guesswork and achieve тоге accurate centering of the clutch disc. 1 3 After the clutch disc has Ьееп located correctly . tightеп the securIng bolts I п ап еvеп and diagonal sequence to ensure the cover assembIy is secured without di5tortion. Tighten the bolts to the spec ified torque wrench setting. 14 U5ing а lithium base grea5e. lightly lubricate the out5ide diameter of the tran5miS5ion fгопt bearing retainer. both 5ide5 of the release lever fork where it contacts the release bearing spring clips, and the release bearing suriace that contacts the pres5ure plate release fingers. Fill the grease groove in the release bearing hub . then clean all exce5S grease from inside the Ьоге . otherwise grease will Ье forced onto the splines Ьу the tran5mission 1nput shaft bearing retainer and will contaminate the clutch dlsc. 15 Install the release bearing and hub оп the (elease lever. 16 Insta ll the felt washer оп the pivot in the ftywheel hou5ing and 5liр the pivot into the clutch equalizer shaft. taking саге not to disturb the linkage ; at the эате time locate the housing оп the dowels in the cylinder bIock. Install the securing bolts and tighten them to the specified torque. 17 Insta ll the 5tarter motor and connect the саЫе.

Fig. 5.6 Centering the clutch disc using

а

special

агЬог

(Sec. 4)

1В

In5tall the transmission as described in Chapter 6. 19 Check апd. if necessaгy . adjust the clutch pedal free-plav as described in Sectlon 2.

5

Clutch - inspection and renovation

1 Examine the machined faces of the ftywheel and the pressure plate for scores, rldges ог Ьигп marks. Minor defects сап Ье removed Ьу machining. If badly scored ог burnt . they must Ье renewed. 2 Check the wear оп the cl utch finger5 ; if there is а COn5iderabIe difference in wear between the fingers. the exce5sively worn finger is binding and the pressure plate assembIy must Ье renewed. Check the pressure plate for warpage us1ng а steel rule as shown in Fig. 5.В. З Lubricate the pressure plate. with grease , between the dr1ving lugs and the edges of the pressure plate open ings as shown in Fig . 5.9. Depre5s the pressure plate fingers fully. apply the grease . and thеп move the fingers up and down until the grease is worked in. 4 Examine the clutch disc for worn ог loose facing5 . distortion. loose nuts at the hub. and for broken springs. 11 апу of these defects exist then the clutch disc must Ье renewed. 5 Wipe all оН and dirt off the release bearlng; It i5 pre-Iubricated and should not Ье cleaned with solvent. Inspect the bearing retainer for loose spring clips and rivets. Hold the bearing inner гасе and rotate the outer гасе. Н it is rough ог noisy. renew the bearing.

6

Pilot bush - renewal

1 If the pilot bush is worn ог loose in the crank5haft Ьоге it must Ье renewed. 2 The old bush сап Ье removed Ьу using а round Ьаг that is а close fit in the bU5h. Fill the bush with grease and then drive the Ьаг into the bU5h , this will hydraulically drive the bush out of the crankshaft Ьоге . З Soak the new bush for at least half ап hour in englne oil before instal1ing in the crankshaft Ьоге . 4 Use а suitabIe diameter 5tepped mandrel which will ensure that the bush is not distorted or damaged when being driven in . 5 Wipe оН а" excess oil. Оо not lubricate the bush with grease of апу type.

,1

7

Fault diagnosis - clutch

1 There аге four main faults to which the clutch and release mechanism аге ргопе. They тау occu r Ьу themselve5. ог in conjunction with апу of the other faults. They аге clutch squeal . slip . spin and judder.

C!utch squea! 2 If оп taking up the drive ог when changing gear. the clutch squeal5. thls is indicative of а badly worn clutch release bearing. З As well as regular wear due to normal use . wear of the clutch release bearing is much accentuated If the ctutch is ridden ог held

,

Chapter 5 Clutch

105

о

о

о

о

о

О

f,

о

о

-- ---

,

о

NORMAL WEAR

о

EXCESSIVE WEAR

Fig. 5.7 Checking the clutch fingers 10r wear (Sec. 51

•1'''''

flywheel ог pressure plate faces, ог the pressuгe plate 1t5elf 1s faulty. 6 The reason for clutch sJip 1s that due to опе of the faults above. there is insufficient pressure from the pressure plate, ог insufficient friction from the friction plate to ensure solid drive. 7 If small amounts of oi l get O"to the clutch. they will Ье burnt off under the heat of the clutch engagement, and in the process. gradually darken the 11n1ng5. Excessive оН оп the clutch wil l buгn off leaving а сагЬоп deposit which сап cause quite bad clutch slip, or fierceness .

spi" and judder. а

Fig . 5 .8 Checking the ptessu te plate for warpage (Sec. 5)

If clutch slip is suspected, and confirmation 01 this condition is required, thete аге several tests which сап Ье made. 9 With the engine in second ог third gear and pulling lightly , sudden depression of the accelerator pedal may cause the engine 10 increa se its speed without апу increase in road speed. Easing оН оп the accelerator wШ then give а delinite drop in engine speed without the саг slowing. 1О 'П extreme cases 01 clutch slip the engine will га се under normal acceleration conditions.

Clutch spin 11 Clutch spin is а condition which occurs when there is ап obstruction in the clutch linkage , incorrect release bearing clearance. ог oil may have partially burnt ОН the clutch Hning and have left а resinous deposit which is causing the clutch disc 10 stick 10 the pressure plate ог Ilywheel. The disc may also Ье slicking оп the input shaft splines. 12 The reason for clutch spin is that due 10 апу, ог а comblnation 01, the faults ju st listed , the clutch pressure plate is по! completely freeing from the center plate even w ith the clutch pedal fully depressed. 13 If clutch spin is suspected. the condition сап Ье confirmed Ьу extreme difficulty in engaging first gear from rest, difficulty in changing gear. and veгy sudden take-up 01 the clutch drive at the fully depressed end of the clutch pedal travel as the clutch Is released. 14 11 the clutch linkage is checked and the clutch pedal free travel Is correct, then the fault lies internally in the clutch and it will have 10 Ье removed 10г examination. ,

Fig . 5 .9 Pressure plate lubrication points ISec. 5)

I

!

down 10г long periods in gear. with the engine running . То minimise wear 01 lhis component the саг should always Ье taken out 01 gear at traffic lights and 10г similar t raffic hold ups. 4 The clutch re lease bearing is not ап expensive item but difficult (о get 81.

Clutch sПр Clutch slip is а self-evident condition which occurs when lhe clutch friction plate is badly worn, oil ог grease have got ОПlО the

5

Clutch juddeг 15 Clutch judder is а self-evident condition which occurs when the transmission ог engine mountings аге loose от (оо flexibIe, when there is oil оп the face 01 the clutch friction plate. от when the clutch pressure plate has Ьееп incorrectly adju5ted. 16 The гвазоп for clutch judder is due to опе of the faults just listed. the clu tch pre5sure plate i5 not freeing smoolhly from the friction disc and i5 snatching. 17 Clutch judder normally occurs when the ClulCh pedal is released in lir51 ог reverse gears, and the whole саг shudders as il moves forward ог backward.

5

Chapter 6 Transmission Contents

Д - Manual transmission Fault diagnosis - тапиаl transmission . . . . . . . . . . . . . . ... .. 25 Gearshift control (early 4 -speed models) - removal and installation ...... ...... . . . . . . . . . . . .. ... . ... ... 21 Gearshift control (later 4 -speed models) - remova l and installat ion . ...... ...... ... . . . . . . . . . . . .. ..... . 24 Gearshift li nkage (early З - sрееd m odels) - adjustment ....... . 10 Gearshift linkage (l ater З - sрееd models) - adjustment ..... . . . 1 1

(3-speed) - d1smantting ..... .. .. .... .. . ... Transmission (4-speed) - dismantting . . ... ....... ...... . Transmission f3-speed) - examination and renovat1on ........ Transmission (4-sрееdJ - examination and renovation ... .. •.. Transmission (3-sрееdJ - reassembIy ... .... .... .... • . . .. Transmission (4-speed) - reassembIy ... . . . . . . . . . . . . . . .. .

General description . .... . ....... . . . . . . . . . . . . . . . . . . . 1 Input shaft (3-speed) - dismantling .... . . . . . . . . . . . . . . . . . 4 Input shaft ( 4 -sрееdJ - dismantling . ..... . .... • . . .... ... 14 Input shaft (З-s рееd) - reassembIy ........ .... .•. . . . . . . 7 Input shaft ( 4-sрееd J - reassembIy ..... .......... . . . .. . 1 7 lock-rod {late r 4 -speed models ) - adj ustm ent . . ... . .. . . • ... 23 Output shaft (3-speed) - dismantl ing ........ ..... • • . •... 5 Output shaft 1 4 -sре еd J - dismantling .. ... . ... . .... . .... . 1 5 Output shaft (3-speedl - reassembIy ....... .... ........ . 8 Output shaft 1 4-sрееdJ - reassembIy ..... ..... ......... . 1 8 Sh1ft linkage (ea rly 4-speed modelsl - adjustment . .... ..... . 20 Sh1ft linkage (later 4-speed тodels l- ad justment . ........ . . 22 Transmiss10n lock-rod - remova l and 1nstallation .... ... .. . . . 1 2 2 Transmission - removal and 1nstallation

Fault diagnosis - automatic transтission ..... ... .....•.. . FMX transmission - band adjustment . .. ..... ... . . . • •. .. General description . .. .. ...... . . .. ...... ... ... . .. .. Intermediate band (С4 and С6) - adjustment . . . . . . . . . . . . . . Kickdown rod - adjustment . . . . . . . . . . . . . . . . . . . . . . . . . .. low and reverse band (С4 only) - adjustment . . . . . . . . . . . . . . Manual shift linkage - adjustment . . . . . . . . . . . . . . . . . . . . ,. Neutral start switch (С4 and С6 transmission) - adjustment ... . Neutral start switch (FMX transmission and С6 transm ission with 429 СЮ engine) - adjustment . . . . . . . . . . Special towing о( recovery information . . . . . . . . . . . . . . . . . .. Transmission fluid level - checking ..... ... ... ..• . • , .... Trans mission lock-rod - adjustment ...... •.• . .... ...... . Transmission - removal and instal lat10n ... .... .. ...... ...

Part

TransГfl1ssion

Part

В

- Automatic transmission

Specifications

Мапuаl tгansmission

Number of gears 3-speed transmission 4-speed trans mission Туре

of gears

Synchromesh

· . . . . . . . . . . . . .. . .. .. .. · . . . . . . . . . . . . . . . . . .. . .

. . . . . .. . . . . . . . . . . . .. . . . .

.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. , . . . . . . . . . . . . . . . . .

3 forward. 1 reverse 4 forward , 1 reverse Helical, constant mesh AII forward gears

Countergear endplay ..... ... ... .. . . . ........ .. ... .

0.004 to 0.018 in (0.1 О to 0.45 mm )

Reverse idler gear endplay .... . . . . ... . .. ... . . ..... .

0.004 to 0.018 in (0.1 О to 0.45 mm )

.

.. .. .. .. . . . .

Ford manual transmission lubricant (ESW-M2C83-8)

3-speed transmission · . . . . . . . . . . . . . . . . . . . . . 4-speed transmission · . . . . . . . . . . . . . . . . . . . .

. .. . . . . . . . . . .. . . . .

3.5 US pts (1.7 litre) 4.0 US pts (1 .9 litre)

Lubricant type . .

. . . . . . . . . . . . . . .

Refill capacity

.

.. ....

.

.

.

. . .

А utomatic tгansmission Туре

........ ... . .... ... .... ... . ... ....... . . . . . . . .

Lubricant type ............... ...... ..... . . . . .. . . . .

С4 , С6 ог

FMX

Automatic transmission fluid ESW- M2C33-F type F

Refill capacity (approx) Туре С4 :

302 351 Туре Туре

си

in engines .. .... ....... • . . . . ... .... ........ . си in engines . . .. . .. .......... • ..... ....... _ ... С6 . . . . . . . . . . . . . . . . . . . .. ....• . . .. ... . . ......... FMX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -

.

3 13 6 16 9 19

9 US qt (8. 5 litre ) 10.25 US qt 19 .6Iitr_1 12.5USqt(11.8Iitre) , 1.0 US qt (10.4 11tre)

38 37 26 35 32 36 30 33 34 27 28 31 29

Chapter 6 Transmission Toгque

wrench settings

107

lbfft

kgf m

30 to 36 19 to 25 30 to 36 20 {о 25 1О {о 20 201030 37 to 42 15 to 20 101020

4.1104.9 2.6 to 3.4 4. 1 104.9 2.7t03.4 1.3t02 .7 2 .7t04.1 5.7105.8 2.0t02.7 1.3t02,7

23 to 28 281040 12 to 16 12 to 16 23 {о 33 151028 12 to 16 35 to 40

3.2 to 3 .8 3.8 to 5 ,5 1.6t02.2 1.6t02.2 2.2 to 4.5 2.0103.8 1.6t02.2 4.8 to 5.5

Manual transmission Inpul shah bearing retainer bolt: З-speеd

transmission .... . . . .. . .... . . 4 -speed transmission .... . . . .. . .. . . Extension housing-to-case bolt . . . .. . •. . . . . Cover-to-case ЬоН. .. . . . ..... .. . .• . . . filler plug . . . . . . . . . . . . . . .. .. . . . . . . . • . . . . . Orain plug . . . . . . . . . . . . . . . ... . . . . . •. Transmission-to-flywheel housing bolts ..... . TRS switch ......... . ... . . Lock-rod adjustment nut ..... . . . . . . . . • • • • • • • • •

Automatic transmission Conve rter-to-flywhee l nuts ... . Converte r housing-to-case .... . Oil рап bo!ts . . . . . . . . . . . . . . . Conve rter cover-to-housing bolts Transmission-to-engine bolts .. Converter drain plug ....... . Downshlft lever-to-sh aft .... . Band adjustme nt screw locknut РААТ А

1

· . . . . · . ...

. . .

.. . ..,

•

• • • • • • • • •

• • • • • ••

... . .. . . .. . .. .. . ..

· . .. .. .. , . . . ... .. , . · . . . . . ..... . · . . . ........ . ·.... . . . . . , .

. , .

.... ....

. . . . . . .. .. . . . . .. .. . .

• • • • • • •

.

. . . . . . . . . .

•••••••

.

....

.. . . ..

- Manual transmission

General de5cription

The manual transmission installed оп models covered Ьу this тапиаl Is а three ог four forward speed and reverse {уре. with synchromesh action оп all forward gears. AII forward gears аге engaged throu9h synchro hubs and rings {о obtain а smooth. sllent shift from опе ratio {о another. AII forward gears оп the output and input shafts аге in constant mesh with their corresponding gea rs оп the cou ntershaft gear cluster, and аге helicalcut {о achieve quiet running. The reverse geaT, which is not synchronized. has straight-cut gear teeth and drives the first gear through ап Interposed sl iding idler gear. The gears аге engaged inside the casin9 Ьу means of Jhe shift forks, shift rails, а detent mechanism and associated parts. The gears аге selected Ьу а floor-mounted shift lever. Th e system of interlocks and detents in the transmission case prevents the selection of тоге than опе gear speed at the same time. and helps 10 hold апу gear in the selected position. From 1970 the 4- speed {уре transmission is fitted with а Hurst shiher contro) assembIy which should not Ье dismantled. The only parts {о Ье removed from it аге the 5hift lever, shift lever handle , backup light switch retai ner and 5witch . 11 is protected from road splash Ьу а rubber Ьоо! whlch fits tightly over the shifter mounting plate.

the crossmember. Disconnect the shift rods from the shift levers Ьу removing the reta ining сНр, f lal washer and spring washer. Remove the bolts that secure the shift linkage control bracket to the extension housing and tie the assembIy out of the way. 9 Support the en9ine with а jack positioned under the геаг of the engine, place а bIock of wood between the jack and the oil рап, and remove the extension housing-to-engine геаг support attaching bolts. 1О Raise the геаг of the en9ine high enough to take lhe weight from the crossmember. Remove the bolts reta ining the crossmember to the frame side supports and withdraw the crossmembeT. 11 Support the transmission with а jack and remove the transmission-to-flywheel housing bolts . 12 Carefully move the transmission and supporting jack rearward l1Пtil the inpul shaft is clear of the clutch housing; then lower the transmission to the ground. 13 ОО not depress lhe clutch pedal while the transmission is removed . Ве10ге inst allin9 the transmission ensure that the clutch release lever and bearing аге correctly located in the clutch housing. 14 Installation of the transmission is the reverse 01 lhe removal procedure. Apply а smear of grease оп the input shaft spl ines. Take саге not {о put апу strain оп the input shaft , but note that it тау Ье necessary to rotate the engine {о align the clutch disc and input shaft splines. Don't forget to refill the t ransmission with the correct grade of oil.

6 2

Transmission - removal and In5tal18tion

1 When the transmi 5sion has to Ье removed from the саг. it сап Ье taken out from below without having to remove the engine. А соп­ siderabIe amount of working height is required beneath the саг and idea lly ramps ог ап inspection pit should Ье u5ed. However, provided that suitabIe jacks and supports аге availabIe, the task сап Ье accomplished without {оо much difficulty if the саг is 5upported оп jack stands. 2 Di5connect the Ьанегу ground lead. 3 Remove the transmission drain plug , (i f 50 equipped), ог lower exte nsion housing bolt and drain the oil into а suitabIe containef. 4 Disconnect the ' front of the driveshaft from the (еаг of the transmission , as described in Chapter 7. and tie the shaft out of the way. 5 Disconnect the speedometer саЫе from the extension housing. 6 Disconnect the TRS (t ran5mission- regu lated spark) switch, seat belt sensor and back-up light switches (if 50 equipped ). 7 Оп three-speed transmissions, remove the gearshift selector assembIy from the extension housing . 8 ОП four-speed transmissions. disconnect the parking brake саЫе from the equal izer lever and separate 1he lever from 1he crossmember. Remove 1he hairpin retainer securing the саЫе to the ttansmission геаг support crossmember, then pull lhe са Ые assembIy forward and out of

з

Tran5mi55ion

(З - 5рееd)

- di5m8ntling

1 Place the complete unit оп а bench ог tabIe and ensure thal you have the following tools availabIe , in addition to the погтаl range of wrenches, etc.: (а) 2 pairs о' snap ring pliers - 1 expanding and 1 contracting (Ы Сорре, headed hammer, а! least 21Ь (с) Selection о' steel and brass drifts (d) Suitable containers (о hold sma/J parts (е) Enginee"s vise, securely mounted (f) Selection о' steel tubing 2 Dismantling of the transmission without the 10regoin9 еquiрmелt is not impossibIe , but will Ье very difficult. Read the whole of this Section before starting work. 3 Undo the capscrews securing the cover to the case, and remove the cover and gasket, 4 Remove the IOn9 spring and detent plug 1гот the top left-hand side of the case. (Early models have а retain ing screw : оп later models the cover retains the springJ. 5 Undo the capscrews attaching the extension housing to the case and remove the extension and gasket. 6 Undo the capscrews securing the front bearing retainer, and remove the retainer and gasket. 7 Remove the filler/ level plug from the right-hand side of the case

•

108

Fig. 6 .1

З-sрееd

transmission (Sec. 1)

LOW AND REVERSE SLIDING SLEEVE AND GEAR

FIRST·$PEED OUTPUT

5ECQND·$PEED

BEARJNG 5HДFТ

SECOND AND SYNCHRQNIZER

'нрит 5HAFT

INPUT

GEAR

SHAFТ SHAFТ

ЮLЕR

GEAR

GEA.

НОТI,

All FORWARD SPEED •

GEARS 'Н CONSTANT Mf;SH WIYН • COUNTER5HAfТ GEAR

Fig. 6.2 Internal c omponents and power 110w

(З-sрввdJ

(Sec . 1 )

,---------------------------------------------------------------------109

Fig. 6.3 4-speed transmission (Sec. 11

THIRD SPEED

FIRST

АНО

SECOND

SPEED SYNCHRONIZER

дно FQURTH SPEED SVNСНIЮNIZЕR

THIRD

SPEED GEAR SHAFТ

INPUT SHAFT

JDLER GEAR COUNTERSHAFT _ CLUSTER GEAR

......

REVERSE SllDlNG GEAR

НОТЕ:

All

HELICAL GEARS

IN CONSTANT MESH WITH соиНТЕИ$НАFТ GEAR

Fig. 6.4 Iпtегпаl components and power flow (4-speed) (Sec. 1)

•

Chapter 6 Transmission

110

, '1

GASKEТ

ниМВЕ.

PLA ТЕ

PLUGS

Fig. 6.5 Transmission C8se and 8ssociated parts (3-speedl (Sec. 3)

SEТ

SCREW

--",

SURFACE

SCREW .. ......-

ДНО 3RD SHIFT FORK РШG

INTERLQCK

e"LUG

1 ST

дНО SHIFТ

2ND SHIFТ

Fig. 6.7 Removing the countershaft roll pin (З-SР88d) (58С. З)

1sт AND REVERSE SHIFТ RAll

Fig. 6.6 Exploded view 01 shift rails апd forks (З-sрвud) (Sec. 3)

С/отр

Dummy Shoft

Fig. 6.8 Removing

thв

countershaft

{3-sрееdJ

(Sec. 3)

Fig. 6.9 Removing the output shaft bearing (З-SР88d) (58С. З)

and , working through the plug opening, drive out the гоll pin that secures the counte rshaft in the сазе, using а suitabIe sized drift (see

Fig . 6.7) . 8 Using а piece of tublng 01 slightly smaller diameter than the countershaft and about 1 t in shoгter, drive the countershaft out of the геаг of the casing , while supporting the countershaft gear cluster. Leave the tubing in the gear cluster to prevent the needle rollers from dropping out, and lower the countershaft gear cluster and thrust washers to the bottom of the case. 9 Оп some models, remove the snap-ring securing the speedometer

-

drivegear оп the output shaft. Slide the gear off the end of the shaft and remove the gear lock-bal l fгom the shaft. 10 Remove the snap-ring retaining the геаг bearing оп the output shaft and , using two screwdrivers placed between the outer snap-ring and сазе , carefully lever the bearing out of the case and slide it off the end of the output shaft. If the bearing cannot Ье removed in this таппег а special tool (No Т6ЗР - 7025 -д) (see Fig. 6.9) is availabIe from Ford dealers. 11 Place both shift 1evers in the neutral (center) position. Aemove the set-screw securing the 1stlreverse shift fork to the shift гаН then slid e

Chapter 6 Transmission те

rail OUt of the геаг of the case. 12 Slide the 1s tlr8verse synchronizer forward as far аз possibIe. then rotate т е shift fork upward and lift it out 01 the саsе. 13 Push the 2пd/Згd speed shift fork rearward 10 the 2nd speed position 10 ga in access to the retaining set-screw. Remove the set-screw пот

the fork then. using suitabIe pliers

ог

grips, rotate the shift rail

throu gh 900 as shown in Fig. 6.10. 14 Uft the interlock plug out of the case with а magnet and then {ар те геаг end of the 2пd/Згd shift га1l 10 remove the expansion plug

from the front of the case. Withdraw the shift rail. t 5 Remove the 2nd/3rd speed shift rail detent plug and spring from

111

bearings that тау have lallen out of the gear cluster. Note: There аге

25 needfe bearings in each end о{ the gear cluster. 21 Aemove the shift levers 1гот the side 01 the case Ьу undoing the securing nuts, withdrawing the levers and then sliding the shafts out 01 the case. Oiscard the O·ring seals. 22 00 not remove the TAS switch (;1 so equipped) Iгот the сазе, unless the switch is damaged. Aemoval 01 the switch will damage the plastic sealing tape. 23 The dismantling 01 the input and output shaft assembIies is described in the 10110wing Sections.

the case. 16 Pull the input shaft and bearing from the front of the case. 17 Rotate the 2пd/Згd speed shift fork upward and lift it from the case. 18 Carelully lift the output shaft assembIy out through the top 01 the case. 19 Drive the reverse idler gear shaft out 01 the case and lift the reverse idler gear and two thrust washers Irom the case. 20 Lift the countershaft gear cluster, thrust washers, and dummy shaft lгот the case. If а dummy shaft was not used collect апу needle

2ND

4

Iпрut

shaft (3-speed) -

dismапtliпg

1 The only time the input shaft requires dismantling is when the bearing ог shaft requires renewing. 2 With а pair 01 e)(panding snap-ring pliers, remove the small зпар­ ring which retains the bearing оп the input shaft. 3 With а soft-headed hammer gently tap the bearing 10гward and then remove it lrom the shaft.

SHAFТ АНО

дно

LEVER

I TOOL-T52T 6500-0JO

l

,

I

r Fig. 6.1 О Aotating the

2пd / Згd

SHIFТ

LEVER

speed shaft rail (3-speed) (See. 3) Fig. 6.11 Rеmоviпg the shift levers and shafts (З-sрвеd) (See. З)

6

INPUT

SHAFТ

ROLLER

AND

\ BEAII:ING II:ING

II:INGS

с',1:1

Fig. 6.1 3 Fig. 6.12 Lосаtiоп 01 TRS switeh some models. (See. З)

оп

Iпрut

shaft dismantled (See. 4)

....

-_ ._---

5

Тrапsmissiоп

Chapter 6

112

Output shaft

IЗ-sрввd)

4 Now гетоуе the next snap-ring and press the shaft out of the reverse gear and synchronizer sleeve assembIy, (see Fig. 6.15). 00 not attempt to гетоуе the 1st/reverse synchronizer hub from the shaft Ьу tгying ta hammer it ог Ьу prying it оН with levers as this will ргоЬаЫу cause damage to the synchronizer assembIy. 5 When dismantling the synchro hubs and sleeves, first refer to Fig. 6.16 and 6.17 , and etch аг lightly punch alignment marks оп each part. 6 Push the sleeves аН the hubs and separate the inserts and insert springs, making а nate which way round they аге installed. 00 not mix 1st/reverse synchro hub parts with thase fram the 2пd/Згd synchro hub assembIy.

- dismantling

1 For dismant1ing. mount the plain section of the shaft in а vise with 50ft jaw-grips. As each companent part is removed from the shaft make а note of its position and which way raund it is installed, then place it оп а clean sheet of рарег in the order of removal. 2 Aefer 10 Fig. 6.14. Remave the snap-ring from the front of the output shaft and slide the bIocking rings, the synchranizer hub and 2nd gear оН the shaft. 3 Аеmауе the next snap-ring and the tabbed thrust washer, then slide the 1 st gear and bIocking ring оН the shaft.

BLOCKING RING BLOCКlNG

~ING

SНAFT

SPEEDCМEТER

DRIVE GEAR

RINGS

./

LOCK BALL

I

OUTPUT •

)-1--

1ST GEAR

SNAP RINGS REAR REVERSE GEAR днр SLEEVE

THRUST WASHER

Fig. 6.14 Exploded view of output shaft assembIy IЗ-sрееdJ ISec. 5) Fig. 6.15 Removing 1 sl/reverse synchronizer IЗ-sрееdJ (Sec. 5) FRONT INSERT SPRING

ALIGNMENT MARKS

RING AND REVERSE GEAR

Fig. 6.16 Exploded view ot 1 stlreverse synchronizer

IЗ-sрееd)

(Sec. 5)

HUB AND SlEEVE

RtNG

•

~

tNSERT SPRtNG

Fig. 6.17 Exploded view ot 2пd/Згd synchronizer

IЗ-sрееdJ

(Sec. 51

•

Chapter 6 Transmission

8

Tran.miuion

IЭ-sрееd)

- examination

апd

113

renovation -'--PRESS

1 С1вап and then 8xsmine аll the dismantled рагtз far general wear, distor1ion and damage. 2 Examine the gears 10г excessive wear and chipping 01 the teeth.

RAМ

Renew аз necessary. 3 Examine the countershaft far signs 01 wear, where the countershaft gear cluster needie bearings гuл. 11 а smaH ridge сап Ье lel1 8t either end 01 the shaft it should Ье renewed. 4 The synchro btocking rings will ргоЬаЫу Ье badly WQГП and It is 1аlзв economy not to renew them . New rings will improve the smoothness and speed 01 shift considerabIy. 5 The needle roller bearings located between the позе 01 the output shaft and the annulus оп the геаг 01 the input shaft аге al50 liabIe (О wear and should Ье renewed. 6 Examine the condition of the two ba ll bearing assembIies, опв оп the input shaft and the опе оп the output shaft. Check them for noisy operation , 100senes5 between the inner and outer гасез and for general wear. Normally they 5hould Ье renewed оп а transmission that . . 15 Ьв1по rebuilt after а high тilеаов . 7 If the synchro hubs аге woгn 1! will Ье necessary to renew а сот plete assembIy аз the рагtз аге not supplied separately. 8 If the bush ing 1п the extension housing 1з woгn it 1з recommended that you take the housing to your 'осаl Ford repair statlon to have the bushing renewed. 9 Тhe 011 seals in the extension housing, the input shaft bearing retainer and the selector lever О-г1по зеа!з should Ье renewed аl each dlsmantling. Drive out the old seals with а drlft. When Installing new seals carefully tap the seals Into place, using а piece of wood to spread the load evenly, so that they enter their houslngs squarely. 10 The only paгt of the output shaft that 1з Iikely to Ье worn is the paгt where it enters the input shaft. However, examlne il thoroughly for апу signs of зсог1по ог picklng-up, and if damage 1з аррагеп! it should Ье renewed .

7

Input shaft IЭ-sрееdJ - ге88ветЫу

1 When installing the bearing оп the shaft ensure that the groove, cut 1п the outer periphery of the bearing , faces away from the оеаг. If the bearing Is installed the wrong way round It will not Ьв possibIe to fit the large snap-ring which retains the bearing in the housing. 2 Using the jaws of а vise as а suppoгt behind the bearing, tap the beari ng squarely into place Ьу striking the геаг of the input shaft with а soft-faced hammer. 3 Insta ll the snap-ring which retains the bearing in posilion оп the input shaft.

8

Output shaft (З-sрееdJ - Г8авветЫу

1 AssembIe the synchro hubs. Positlon the inseгt spring in the hub of the 1 st/reverse synchronizer. Make sure that the spring covers 811 the inseгt gfQOves. Start the hub оп the sleeve until the index marks, made at dismantling, properly allgn. Position the three inserts in the hub, ensuring that the small end Is оп the inside of the hub, then slide the sleeve and reverse gear onto the hub. 2 Fit опе i nseгt spring into а groove of the 2nd/3rd synchro hub, ensuring that аll three 1пзегt slot5 аге fully covered, then with the index mark5 оп the hub and 51eeve aligned staгt the hub into the sleeve. Place the three inseгts оп top of the retaining 5pring and push the a5sembIy together. Fit the remaining inseгt spring so that the 5рг1по ends cover the same 510t5 а5 the other spring. ОО not stagger the springs . 3 Before assembIlng the оеагз and synchro hub onto the output shaft lubricate the 5haft machined surfaces and splines with fresh transmission oil. 4 Carefully press the reverse оеаг and synchronizer assembIy onto the shaft, аз shown in Fig . 6. , 8, then Install the retaining snap-ri ng. 5 In5tall the bIocking г1по оп the tapered surface of the 1 st gear and slide the 1st gear onto the output 5haft with the bIocking ring facing toward the геаг of the 5haft. Rotate the gear аз песеззагу to engage wlth the three notches in the bIocking rlng with the synchronizer inseгts .

""'- ОUТРU l

SHAFT·

SYNCHRONIZER

Fig. 6.18 Fitting the 1st!reverse svnchronizer

(З-sрееdJ

(Sec. 8)

6 Secure the 1 st оеаг in position with the thrust washer and 5пар• rlng. 7 Install 1he bIocking ring onto the tapered surface of the 2nd gear. Slide the 2nd оеаг. wlth its bIocking ring , onto the shaft, en5uring that the tapered side of the оеаг face5 toward the front of the shaft. 8 Finally, slide the 2nd/3rd gear synchronizer onto the end of the shaft, and install the retaining snap-ring.

9

Tr8nsmission

(З-sрееdJ

-

геавветЫу

, Lubrlcate the O-ring seals and Install them оп the shift lever shafts. Install the shafts in the сазе and position а shift lever оп each shaft and secure them with а flat washer, lockwasher and nut. 2 Lubricate the reverse idler оеаг thrust surfaces in the сазе with а film of oil and install the two thrust washers in position. Hold the reverse idler gear in position and ins1all the reverse idler shaft. 3 Меазиге the rever5e idler gear endplay with а feeler gauge. If the endplay 1з not within the limits given in Specifications at the beginning of thls Chapter, remove the thru5t washers and in5tall washers of а sultabIe thickness to obtain the specified endplay. When the endplay 1з within limits, install the retaining roll pin . 4 Smear some grease Into each end of the co untershaft gear and inseгt the 25 roller bearlngs and а thrust washer оп each end of the оеаг. InstaJl the dummy shaft, used at dismantling. inside thf' countershaft gear to keep the bearings in рlасе . 5 Place the countershaft оеаг and dummy shaft assembIy in the case. Place the case in а veгtical positlon , align lhe gear Ьоге and the thrust washers with the bores in the case, and install the countershaft. 6 Position the case horizontal and , using а feeler gauge, check the endplay of the countershaft gear. If the endplay i5 not within the limits glven in Specifications at the beginning of this Chapter, replace thethrust washers with washer5 of the required thickness to obtain the specified endplay. 7 After ensuring that the endplay is within limits, install the dummy shaft in the countet5haft оеаг and leave the countershaft оеаг in the bottom of the сазе until the input and output shafts have Ьееп Instal'ed. в Install the output 5haft assembIy into the сазе through the top of the сазе. 9 Install а new snap-ring in the groove round the геаг bearing assembIy and drive the bearing along the shaft un1il it enters tM apeгtuгe in the геаг of the case. Ensure that the groove in the bearing is

IЮLL

I

ЮLЕR

GEAR

SHAFТ

Fig. 6.19 Fitting the геуегзе idler О88Г 8nd shaft (З-sрееdJ (Sec. 9)

8

114------------------------------------------------------------------------"' BEARINGS (25

ЕАен

~i O

\

BEARING REТAINER

8EARING REТAfNER

ROLL P1N

Fig. 6.20 Exploded view of countershaft gear (3-speed) (Sec. 9)

Fig. 6.21 Adjusting the gearshift linkage (3-speed) (Sec. 10)

"OD

V1EW 11'4 ORCLE W LOCK ROO АТТдСНМЕНТ

GAUGE PIN HOlE (LlSE

ALIGNМENT НО.

15 DRILl)

АНО REVERSE

SHIFT ROD

"00 ADJUSTMENT SLOI

Fig. 6.22 Gearshift linkage with lock-rod (later models) (Sec. 11 J

•

•

Chapter 6 Transmission toward

те геаг

of the case.

1О In51all а new retaining snap-ring оп the output shaft. 11 Сов' the Ьоге of the input shaft with а thin fllm of grease and 1П51а ll

12 In51all the input shaft, Згd gear and synchro rlng assembly through the front of the CBse, making sure that the end of the output shaft i5 correctly located in the гоНег bearing recess of the input shaft. 13 Install а new snap-ring in the front bearing gгoove and tap the bearing alon9 the input shaft until il enters its housing in the саsе. Carefully 1ар the bearing fully home. 14 Position the 2пd/Згd 9еаг shift fork оп the 2пd/Згd gear synchro hub. в

detent plug spring and

а

ptug in the case.

16 Push the 2пd/Згd 9еаг synchro hub as far as possibIe toward the геаг of the case (2nd speed position). 17 Align the hole in the shift fork with the case and push the 2nd/3rd gearshift rail in from the front of the case. It will Ье necessaгy to depress the detent plug to епаЫе the rail to enter the Ьоге. Push the rail inward until the detent ptug engages the forward notch (second speed position ). 18 Secure the fork with the set screw and then move the synchronizer to the neutral position. 19 Instalt the intertock ptug in the case. When the 2nd/3rd gearshift гаН in the neutral position, the top of the intertock plug wiJI Ье stightly lower than the surface of the 1stireverse shift rail Ьоге. 20 Push the 1 st/reverse synchronizer forward to the 1st speed position and instalt the 1 st/reverse shift fork in the synchronizer groove. Rotate the shift fark into the correct position and push the 1 st/reverse shift rail in from the геаг of the case. Push the гаН inward until the center notch (neutral) is in line with the detent Ьоге . 21 Secure the fork to the гаН with the set screw. 22 Install а new shift rail expansion plug in the front of the case , flush with ог to 0 .60 in (12 тт) below the face of the case to prevent interference with the clutch housing assembIy. 23 Place the transmisslon case in а vertical pasition and working through the filler hole. align the Ьоге of the countershaft gear and the thrust washers with the Ьоге of case using а screwdriver ог simllar tool . 24 Insert the cou ntershaft from the геаг of the case and push the dummy shaft out of the countergear with the countetshaft. 8efore the countershaft Is completety inserted, ensure that the roll pin hole in the shaft Is aligned with the hole in the case, then drive the countershaft Into place and install the гоН pin. 25 Check that the countershaft gear rotates smoothly. 26 tnstall а new front bearing retainer snap-ring onto the input shaft. 27 Install the input shaft bearing retainer and new gasket; ensure that the оil return slot Is at the bottom of the case. 28 Apply gasket sealer to the bearing retainer bolts and tighten them to the specified torque. 29 Install the speedometer drivegeaг lock-ball into the hole in the ou tput shaft, hold the ball in pasition and slide the drive gear оУег it. Secure with а snap-ring. 30 Coat а new extension housing gasket with sealer and position it оп the case . Coat the threads of the attaching screws with sealer. install the extension housing to the case and tighten the securing screws to the specified tarque. 31 Rotate the input shaft Ьу hand and check that all the gears сап Ье selected in turn and both shafts rotate smoothly. 32 Install the remaining detent plug and spring in the case. Оп early models Install the retaining screw; оп later models the spring is retained Ьу the соуег. 33 Coat а new соу ег gasket with sealer, install the top соуег and tighte n the capscrews to the specified torque. 34 Tighten the drain plug to the specified torque and Install the filler/ level plug temporarily.

1 О Gear shitt linkage learly З-sрввd models) - adjustment Loasen the three shift linkage adjusting nuts. Insert а 0.25 1п (6.3 тт) diameter rod through the control bracket and 'еуег alignment holes as shown in Fig. 6.21 . 2 Tighten the three linkage adjustment nuts and remove the alignment rod. 3 Start the engine and shift the selector 'еуег to each position to ensure that it aperates freely. 1

11 Gearshift linkage (18t8r З-sревd models) - adjustment

the 15 roller bearings.

15 Inslat!

115

Оп models 'гот 19708 tf8nsmission lock-rod connects the lower

steering column shift tube (о the т8пи81 tr8nsmission reverse lever. It locks th8 tf8nsm;ss;on ;п reverse g88f when the ;gn;t;on sw;tch is ;п the LOeK position. Adjustment С8П Ье cBrr;ed out only when the shift controJ BJignment ;s correct. 1 Place the hand shift 'еуег in neutral. Loosen the lock-rod-to-Iever nut. 2 Align the hole [п the steering column socket casting with the column alignment mark (see Fig. 6.22), and insert а 0.18 in (4.5 тт) dlameter pin . The column castlng must not rotate with the pin in positlon. 3 Tighten the tock-rod adjustment nut to а torque of 1О to 20 'Ы ft

11.3102.7 kgf ml. 4

Check for correct opetation .

12 Transmission lock-rod - removal 8nd install8tion 1 Disconnect the rod at the transmission 'еуег. 2 Аетоуе the retaining сliр and pull the rod out of the grommet located [п the 'еуег attached ta the steering cotumn shift tube and lift away the rod. 3 Installation is the геуегзе of the гетоуаl procedure . Adjust the lock-rod as described in Section 11 . 13 Tr8nsmission (4-speed) - dismantling 1 Refer to Section 3 and саггу out the operations [п paragraph 1 through 6. 2 Support the countershaft gear and, working from the frant af the case. push the countershaft aut of the геаг of the case using а dummy shaft (refer to Section 3, рага 8). Leave the dummy shaft [п the gear cluster, to prevent the needle rollers from dropping out, and lower the countershaft gear to the bottom of the case. 3 Place the 1st/2nd gear shift 'еуег and the reverse shift 'еуег in the neutral position. Position the Згd/4th gear shift 'еуег to engage with the Згd gear. 4 Аетоуе the Згd/4th speed shift fork securing screw, tap the inner end of the shift гаН to unseal the expansion plug from the front of the case; then withdraw the 3rd/4th shift rail from the front of the case. Collect the interlock pin fram the shift rail. 5 Remove the 1stl2nd speed shift fork securing screw and slide the 1st/2nd speed shift rail out of the геаг of the case. 6 Аетоуе the interlock plug and detent ptug from the top of the case. 7 Remave the snap-ring retaining the speedometet drivegear оп the output shaft, then slide the gear off the shaft and collect the speedometer gear drive ball . 8 Remove the output shaft bearing reta ining snap-ring and, using two screwdrivers, placed between the outer snap-ring and case, carefully 'еуег the bearing out of the case and slide it aff the end of the output shaft. If the bearing cannot Ье removed in this таппег а special tool (Na Т 64Р-7025-В) will Ье required. 9 Аетоуе the Input shaft and bearing assembIy, and the bIocking ring from the front of the case. 10 Моуе the output shaft to the right-hand side of the case, to provide clearance for the shift forks, then lift out the Згd/4th and 1st/reverse shift forks. 11 Hold the thrust washer and 1 st speed gear to prevent them from sliding off the shaft and гетоуе the output shaft through the tap of 1tte case as shawn [п Fig. 6.25. 12 Remove the reverse gear shift fark set-screw. rotate the геуегsе shift rail 90 0, and then slide the shift rail out of the геаг af the case. Lift out the reverse shift fork. 13 Аетоуе the reverse detent plug and spring. 14 Using а dummy shaft ( а suitabIe piece of tubing will do) remove the reverse idter gear shaft as shown in Fig. 6.27 . 15 Lift the reverse idler gear and thrust washers from the case. taking саге to keep the dummy shaft [п position to prevent the needle rollers dropping out. . 16 Lift the countershaft яеаг, thrust washers and dummy shaft assembIy from the case.

6

Chapter 6 Transmission

116

_-SРRlNG

fI •

DEТENT PLUG

06,,;:' С.2- :

. / FIRST AND SECONO

5РЕЕО

SHIFT RAIL

. ,::; - _ ; , '

~SCREW

AND FOURTH ~ - - SPHD SHIFT FORK

__ ....

FIRSТ

FIRST AN REYERSE 5РЕЕО

AND SECOND

SPEED

SHIFТ

SHIFТ

FORK

FORK

DETENT PLUG-+(j

_.

_INTERLOCK P'IN ~

SCREW~'"'~'\1 THIRD AND SPEED SHIFТ RAIL

rDEТENT PLUG

OUTPUT ТО

МОУЕD

RIGHT SIDE OF CASE

Fig. 6.24 Removing the shift forks

DEТENT

PLUG......-{)

SPRlNG _.

REVERSE

SHIFТ

REVERSE

RAll

158С.

FORK

-~, ~

(4-sрееdJ

131

THIRD AND FOURTH 5YNCHRONIZER

EXPAN SION

PlUG

ВОН

I

DRAIN PLUG

Fig. 6.25 Fig. 6 .23 Exploded view of shift rails and forks (4-speed) {Sec. 131

Lifting out the output shaft

assembIy (4-sрееdIISес. 1 З)

IDlER GEAR

SHAFТ

1001_ Т64Р·7140-А

Fig. 6.26 Rotating the reverse shift rail (4-speed) (Sec.

1ЗJ

Fig. 6.27 Removing the reverse idler gear shaft (4-speedl (Sec. 131

17 Undo the retaining nuts and remove the three shift levers. 18 Remove the three cams and shafts from inside the case . Discard the O-ring from each shaft. The dismantling of the input and output shafts is described in the following Sections.

14 Input shaft (4-speed) - dismantling This procedure is as described in Section 4.

•

Chapter 6 Transmission

I

15 Output shaft (4-speed) - dismапtliпg

17 Input shaft (4-speed) - reassembIy

1 Refer 10 Section 5 and proceed аз in paragraph 1. 2 Ае1ег 10 Fig. 6.28. Аетоуе the snap-rlng from the 1ront of the shaft and then slide the Згd/4th gear synchro hub, bIocking ring and Зrd gear off the shaft. 3 Aemove the ne)(t snap-ring and the 2nd gear thrust washer, then slide the 2nd gear апd the bIocking гlпg off the shaft. 4 Аетоув the ne)(t sпар- гiпg. 5 Аетоуе the thrust washer, 1 sl gear апd bIocking ring from the геаг 01 the shaft. Press the shaft out 01 the 1 stl2nd synchro hub. ОО not attempt to remove It Ьу trying to hammer ог ргу 11 off with levers as this will ргоЬаЫу damage the synchronizer assembIy. 6 When dlsmantНng the sупсhго hubs and sleeves, 11Г5! refer to Fig. 6.29 апd etch ог lightly punch аligпmепt marks оп each part. 7 Push the sleeves off the hubs апd separate the inserts and iпsегt springs, making а note which way round they аге Iпstаllеd. 00 поt mi)( the 1stl2nd 5ynchro hub parts with th05e from the Згd/4th synchro hub.

16

Тгапsmissiоп

117

{4-speedl- examination and renov8tion

This procedure is as described in Section 6.

This procedure is as described in Section 7.

18 Output shaft (4-speedl -

геаззвтЫу

1 Assembte the synchronizers. 1"5tall the hub in the sleeve. making sure that the index marks. made 8t disassembIy аге in аligпmепt. Posit;on the three inserts i"to place оп the hub then the insert springs, making $ure that the irregular surface (hump) is seated in опе of the

inserts. 00 not stagger the springs. 2 Before assembIing the gears and synchro hub O"to the output shaft, lubricate the splines and machined surfaces of the shaft with fresh transmission 011. 3 Install the 1stl2nd gear synchro hub onto the front of the output shaft with the shift fork groove toward the геаг 01 the shaft. The synchro hub is а press-1it оп the shaft and to avoid damaging the зуп­ chronizer аззетЫу, Install the synchro hub wlth the teeth end facing toward the геаг of the shaft. Fit the snap-ring. Place the bJocking rlng оп the 2nd gear. 4 5 Slide the 2nd gear onto the shaft, making sure that the inserts in the synchronizer engage the notches in the bIocking ring. 6 Install the 2nd gear thrust washer and snap-ring. $РЕЕDОМЕТЕК

ORIVE

SHAFТ

SEAL RING

RING

THRUST W'

FIRST

GEAR

SHAFТ

а....О

I

SPEEDOMEТER GEAR

•

DRIVE ВА LL

SNAP RING

6

THRUST WASHER THIRD SPEED GEAR

BLOCКlNG

RING

RING FIRST AND SECOND SPEED SYNCHRONIZER RING

SECOND SPEED GEAR SNAP RING

THIRD AND ЮURТН SPEED SYNCHRONIZER 5NAP RING

Fig. 6.28 Exploded view 01 output shaft assembIy (4-speed) (Sec. 15)

•

118------------------------------------------------------------------------' ЕТСН

INSERT_ INSERT SPRING

INSERT SPRING

1

FtRST AND SECOND SPEED SYNCHRONIZER

INSERT SPRINC _INSERT SPRING

HUMP

\ GROOVE ТО FACE TOWARD FRONT

THIRD AND FOURTH SPEED $YNCHRCNIZER

L---- OF

TRAN$MtSSION

Fig. 6.29 Dismantling the synchronizers (4-speed) (Sec. 15)

REVERSE GEAR

САМ

AND SHAFT AND SECDND SPEED

САМ

AND SHAFT

():2 . ·D·RING , D·R

~

THIRD AND FDURTH САМ

AND SHAFT

SPE~

FIRST AND SECOND SPEED

SHIFТ

LEVER

1

r

,

J

REVERSE

SHIFТ

LEVER

,

THIRD AND FOURTH SPEED

SHIFТ

LEVER

Fig. 6.30 Exploded view of сатз and shafts. and shift levers (4-speed) (Sec. 19)

•

Chapter 6 Transmission 7 S rк:le the Эrd gea r onto the shaft with the tapered sur1ace toward the front and tЛеп place а bIocking ring оп the Згd gear. 8 Slide the З rd/4th gear synchronizer onto the shaft and make sure mat те inser1s engage the notches in the bIocking ring. In5tall the

119

gear. Install the dummy shaft, used 8t dismantling, inside the

countershaft gear to keep the bearings in place. 3 Aefer to Section 9 , and С8ГГУ out the procedures described in

paragraph 5 through 7.

retaining snap-ring. 9 In51all the bIocking ring оп the 1st ge8t and then s1ide the gear onto tЛ е геаг of the output shaft. 10 I"st sll the thrust washer оп the гваг 01 the shaft.

19 Tr8nsmission l4-speed) - reassembIy 1 Lubricate the O-ring 5eals and install them оп the shift 'еуег shafts. Slide each сат and shaft i"to position in the transmission case, install the shift levers оп the shafts and secure them with а flat washer, lockw8sher and nut. 2 Smear зоте grease l"to each end 01 the countershaft gear and inseгt the 21 roller bearings and retai"ing washer in each e"d 01 the

4 Smear зоте gr8ase in the Ьоге at e8ch end 01 the reverse idler gear, hold the dummy shaft in the gear and install the 22 roller Ьеаг­ ings and the retainer washer in each end of the gear. 5 Install the reverse idler sliding gear оп the reverse idler gear with the shift fork groove toward the lront. 6 Apply а thin lilm 01 grease to the thrust surfaces in the case and locate the thrust washers in position, then install the reverse idler gear, sliding gear and dummy shaft in position and 1nstall the reverse id ler shaft. Make sure the shift 10rk groove is toward the lront of the case . 7 Check the reverse idler gear endplay with а leeler gauge. 11 the endplay is not within the limits given in Specifications 8! the beginning 01 this Chapter, repl8ce the thrust washers, as neces5ary to obtain the specilied endplay. 8 In5tal1 the reverse ge8r shift rail detent spring and plug , hold the

COUNТERSHAFТ

REТAINER

WASHER

WASHER

THRU$T

ROLLER 8EARINGS'

GEAR 8EARINGS REТAINER

WASHEIf

Fig. 6.З1 Exploded view of countershaft gear assembIy 14-speed) (Sec. 19) REVERSE GEAR

REТAINER

ROLLER

8

WASHER

WASHER

REТAINER

-

WASHER

IDLER GEAR

SLIDING аЕАР: • it>22З WASHER

Fig.

6.З2

Exploded view of

геуегзе

idler

оеаг

8ssembIy (4-speed) (Sec. 19)

Chapter 6 Transmission

120

•

teverse sh ift fork in place оп the reverse idler sliding gear and push the shift rail in from the геаг of the case. Install the shift fork securing

screw. 9 Install the output shaft assembIy through the tap of the сазе, аз shown in Fig. 6.25 , taking саге that the thrust washer does not s1ide оН .

1О InstaH the 1stJ2nd and 3rd/4th shift forks оп their respective gears. 11 Install а detent plug in the detent hole and position the reverse shift rail in neutral, then зтеаг the Згd/4th gear shift rail interlock pin w ith grease and in5tall 1! in the shift rail. 12 Push the Згd/4th gear shift гаН into place with the three detents towards the outside of the сазе . 1 3 Move the front synchronizвr into Згd gear and in5tall the Згd/4th gear shift fork 5ecuring 5crew, then move it to the neutral position and in5tall the 3rd/4th яеаг 5hift гаВ detent plug , 5pring and bolt in the lefthand 5ide of the са5е . In5tall the interlock pin (tapered end5) in the са5е .

14 Slide the 15t12nd яеаг 5hift fork into place and in5tall the 5hift fork • 5еСUГIПg 5crew . 15 Smear а thin fBm of grea5e ёп the Ьоге of the input 5haft and in5tall the 15 roller bearing5. 00 not apply too much grea5e а5 it coutd bIock the оё' hole5. 16 In5tall the front bIocking ring оп the 3rd/ 4th яеаг 5ynchronizer and in5tall the input 5haft яеаг in the са5е, making sure that the output shaft 5pigot enter5 the roller ЬеагёПЯ5 ёп the input 5haft and that попе of the bearing5 drop out. 17 Place а new ga5ket оп the input 5haft Ьеагёпя retainer, coat the securing bolt5 w ith 5eatant, then in5tall the retainer and tighten the bolt5 to the 5pecified torque . 18 In5tal l а new 5nap-ring in the ягооуе оп the геаг bearing and drive the bearing along the 5haft until it enter5 the case, then install а new retaining sn ap-ring оп the output 5haft. 19 P05 it ion the са5е vertically (see Fig. 6.33 ), align the counter5haft gear and thrust wa5her5 with the Ьоге in the case then insert the counter5haft gear and pU5h the dummy 5haft out of the countergear. Check that the countergear rotate5 freely. 20 In5tal l the 5peedometer drive gear 10ck-ЬаН into the hole ёп the output 5h aft and 51ide the drivegear оуег it. In5tall the retaining 5пар­ rin g. 21 P05it ion а new extension hou5ing gasket оп the case . Coat the

attaching screw5 with 5ealant, in5tall the exten5ion hou5ing and tighten the 5creW5 to the specified torque. 22 In5taJl the drain and filler plUg5. 23 Aotate the input 5haft and check that all the gear5 сап Ье 5elected in turn, and that both shaft5 rot8te 5moothly. 24 In5tall the гетаёпёпя detent plug and spring in the case. ОП early model5 install the retaining screw ; оп later model5 the 5pring i5 retained Ьу the соуег. 25 Coat the соуег securing 5creW5 with sealant and u5ing а new gasket in5tall the соуег оп the case . Tighten the securing cap5crew5 to the specified torque. 26 Соа! the 3rd/ 4th яеаг shift гаёl plug Ьоге with sealant and in5tall а new expansion plug.

20 Shift linkage (early 4-speed models) - adjustment 1 Loosen the three 5hift linkage adjustment nuts. Insert а рёесе of 0 .25 in (6 .3 тт) diameter rod through the 2 control bracket and levers а5 5hown ёп Fig. 6 .34 . 3 Tighten the three linkage adjustment nut5 and then гетоуе the alignment rod. Check the operation of the gearshift 'еувг. 4 21 Gearshift control installation

models) -

гетоуаl

REVEIlSE

SHrfТ

DUST

'00 FrRST AND SECOND SPEED I ROD

TOOL

Fig . 6.33 Installing the countershaft (Sec. 19)

and

1 Аетоуе the 5ё)( 5creW5 securing the 5hift 'еуег boot retainer, and slide the retainer and boot up the 'еуег . Аетоуе the plungers ' and 5prings from the 'еу ег ( 5ее Fig. 6.35). Undo the two 5h ift lever-to-trunnion 5ecuring bolt5 and гетоуе 2 the 5hift 'еуег. 3 From under the саг disconnect the three shift rods fTom the tran5mission Ьу removing the hairpin-type retaining clips. 4 Аетоуе the three bolt5 attaching the 5hift a5sembIy to the exten5ion hou5ing and withdraw the 5hift a5sembIy. 5 Аетоуе the back-up light 5witch from the 5hift аS5етЫу. 6 U5ing 5пар-гёпя plier5, гетоуе the snap-ring from the end of the selector shaft, then the flat washer and spring. Аетоуе the two se curing bolt5 and pul l the retainer, selector 7

GEAR

COUNТERSHAFT

(early 4-speed

LINKAGE ADJUSTMENT NUTS SHlfТ

THtRD АНО FOUIITH SPEED SHlfТ ROD

Fig. 6.34 Adjusting shift linkage (eatly 4-speed models) (Sec. 20)

•

Chapter 6

•

Тrапsmissiоп

121

I

I

RETAI

SHIFT LEVER ASSEMBL У ____.::

SPRING PLUNGER

SELECTOR

SUPPORT

1 • 2 SE LECTOR LEVER

STRAIGHT PIN пJ

/

NEUTRAL INDEX

· 4 SELECTOR LEVER

ВААСКЕТ

RETAINER FLAT WASHER/ SNAP

•

TRUNNION

STRAIGHT PIN ( LONG J

/

PIN REVERSE SELECTOR LEVER

~

..

сuтт Е:::R_ _

FLAT WASHER

SPRING

STUD

WAVE WASHER Fig. 6.35 Removing gsarshift control (early 4-speed models) (Sec. 21) 'еуегs

and bracket from the shatt. Using а pin punch drive the short selector

8

8 'еуег pin from the shaft, then drive the long trunnion pin from the shatt , and гетоуе the trun-

nion and shaft. 9 Clean and examine all the parts for wear and damage. Lubricate all friction surfa ces. 1 О Installation i5 the reverse 01 гвтоуаl procedure. Adjust the shift linkage as described in Section 20.

GAUGE PlN A ~I GNМ!NJ tЮLf (USE NO.

~O

. .";,;','oH. S HI FТ ''''

ROD

22 Shift linkage (Iater 4-speed models) - adjustment 1

Disconnect the battery ground lead from the negative terminal.

2 With the shift 'еувг in neutral, pull the lower boot up far enough to insert the alignment 'tool, (see Fig. 6.38) into the shift control assembIy . Make sure the tool is completely through and located in the notches оп both sides of the shift contro l housing. 3 If the al ignment tool enters free ly the adjustment 1s correct. For апу lever that is out of alignment, loosen the nuts attaching the shift control rods to the shaft levers and disconnect the reverse shift rod at the shift control assembIy. Rotate the reverse lever (the опе in the center) clockwise to shift into reverse gear. 4 Tighten the two forward-speed shift rods at the control assembIy. 5 Rota te the reverse lever cou nterclockwise until it stops, then attach the reverse shift rod to the control assembIy. 6 Remove the alignment tool. Connect the battery ground lead and

' ' ' ' ' " , 5HIFl CON1ROL ROD •

'0« REVER5E LOCK

5HIFТ

CON1ROL ROD

"DJUS1M EN ! NUT

аоо

Fig. 6.36 Shift linkage (later 4-speed models)

Chapter 6

122

Тrапsmissiоп

1~

1/ ." DIA .....--",....

THI N RUlE OR РIЕСЕ OF . 015" Т О . 020" THI(K SHIM STOCK. INSERT Т О Д О ЕРТ Н

ALIGNMENT TOQl - МАКЕ FROM 1/ 4 DIA. ROUNO STOCK

O F APPAOXIMATELY 1" AN D PUl L lE VE R ои т

SНIП

НANOLE

O F CONTROl A5SEM BLУ. SHtFT LEVER

о

•

7/ 16 FLAT WASHER

7! 16l0CK WASHER

CARRIAGE

SHIFT CONTROL

PIVOT

TRANSMISSION

ТО

EXТENStON

MOUNТlNG PLAТE

7/ 16-14)(3 НЕХ 80LT

,

·1 •

-

•

LI GHT

Fig. 6.37 Removing the shift lever 118t8r 4-speed modelsllSec. 24)

SWIТCH

LIGHT SWIТCH REТA\NER

.........

3,tв..16)( НЕХ

2. 75 U.B . S. НЕАО 80L Т

5HIFТ

ASSEМBLY

Fig. 6 .38 G88r shift controlassembIy (18t8r 4-SР88d models) (See8. 22 and 24)

install the boot. 7 Check that the shift shift positions.

mвchanism

operates smoothly through

аll

the

23 Lock-rod 118t8r 4-speed modelsl - adjustment Adjustment of the lock-rod is the for 3-speed tгапsтisзiопs.

зате аз

described in Section 1 1

24 Ge8rshjft control (Iater 4-speed models) inst8118tion

1

remov81 8nd

Disconnect the battery ground lead from the negative terminal.

2 Аетоуе the shift lever аз shown in Fig. 6.37. 3 Undo the four screws attaching the bezel and the upper and lower shift lever boots to the floor; гетоуе the bezel and upper boot. 4 Working under the саг, гетоуе the nuts зесuгiпg the shift rods to the shift control 'еуегз. 5 Disconnect the back-up light switch connector and гетоуе the switch Ьу pulling it from the retainer. 6 Taking саге not to damage the boot, puH the opening for the transmission shifter mounting plate down and ОУег the shift аззетЫу. 7 Аетоуе the bolts securing the shift control аззетЫу to the mounting plate оп the extension houslng and withdraw the control аззетЫу.

8 Insta11ation 1З the геуегзе of the removal procedure. Adjust the shift linkage аз described in Sections 23 and 24. Check that the shift mechanism operates smoothly through all shift positions.

25 Fault diagnosis - m8nual transmission Symptom

ReasonJs

Weak ог ineffective synchromesh

Synchronizing сопез worn, split Worn bIocking rings

Jumps out of gear

Detent springs broken Detent notches worn

ог

damaged

Excessive noise

Oillevel too low Incorrect grade of oil in transmission Bearings worn ог damaged Gear teeth worn ог damaged

Excessive difficulty in engaging gear

Clutch adjustment incorrect

,

•

Chapter 6 Transmission РААТ В

123

- Automatic transmission

26 Gen8ral description Тhe

three types of automatic transmission . С4 , С6 and FMX, used оп Mustang models аге З-sрееd units сараЫе of providing automatic upshifts and downshifts through the three forward gear rati05, and al50 тапиаl selection of 1ir51 and second g88(5. Тhe transmissions аге уегу similar consisting basically of а torque converter. planetary gear train, two multiple disc clutches and а hydraulic control system. Due 10 the complexity of the automatic transmission unit, if репаг­ тапее i$ not ир 10 standard, ог overhaul i5 necessaгy , it i5 imperative that this Ье 18ft 10 the 'осаl Ford repair 5t8tion who will have the special equipment required for fault diagnosis and rectification. It is Imponant that the fault Is diagnosed before the transmission unit Is removed fTom the саг, if at аН posslbIe. The content of the following Sections is therefore confined 10 supplying general information and апу seгvice information that сап Ье used Ьу the owner.

27 Special towing

ог гесоуегу

information •

1 Should it Ье necessary to have the саг towed to а repair station it must по1 Ье towed for more than 20 miles (32 km) and the speed must not e)(ceed зо mph (48 kph). Towing is permitted provided that the transmission is not damaged. that the oil level is correct and the selector lever is in the N position. 2 If there is а fault in the transmission ог the towing distance is more than 20 miles (32 km), the driveshaft should Ье removed. as described in Chapter 7, and the геаг of the transmission sealed to prevent the ingress of diгt . As ап alternative, the саг сап Ье suspended and towed with the геаг wheels off the ground. 3 Оп cars with automatic transmission it is по! possibIe to tow-staгt the саг.

28 Transmission fluid level- checking 1 When checking the fluid level. the fluid must Ье at its normal operating temperature - appro)(imately 150° F (65 0 С). This is best achieved Ьу driving the саг for about 5 miles (8 km) under noгmal running conditions. Park the саг оп 'еуеl ground, apply the parking brake and depress 2 the fo01 brake pedal. 3 Allow the engine to idle and shift the selector lever through аll the positions three times, then position the lever at Р. Do not switch off the engine during the fluid level check. 4 Pull the dlpstick out of the tube, wipe it clean and push 11 all the way back inlo the tube, then puH it out and check the fluid level. 5 The fluid level should Ье аЬоуе the ADD mark; if necessary, top-up with fluid , through the dipstick tube , to maintain the level between the ADD and FULL marks оп lhe dipstick. Use only the specified fluid in the transmission.

29 Transmissio" - remov81and 1"8181181io" 1 Jack-up the саг, and suppoгt it securely with jack stands, to obtain the ma)(imum possibIe working height under the саг. Disconnect the battery. Place а large drain рап beneath the transmission oil рап, then 2 working from the геаг, loosen the attaching bolts and allow the fluid to drain. Remove all the bolts e)(cept the two front ones, to drain as much fluid as possibIe , then temporarily refit two bolts at the геаг to hold it in place. Оп РЕА and PEF models of С4 transmission the fluid is drained Ьу removing the dipstick/filler tube. 3 Remove the torque сопуегtег dra1n plug access соуег from the lower fron1 side of the сопуегtег housing. 4 Rotate the engine , Ьу means of а wrench оп 1he crankshaft pulley attaching bolt, until the сопуегtег drain plug is accessibIe , then remove the plug and collect the fluid in the drain рап. After the fluid has Ьееп drained, install and tighten the drain plug. 5 Remove the four flywheel-to-conveгter attaching nuts, cranking

, Fig. 6.39

Сопуепег

drain plug loc81ion (Sec. 29)

the engine as necessary to gain access to the nuts. 6 Аетоуе the driveshaft, as described in Chapter 7 . and соуег the end of the transmission with а polythene bag to prevent the ingress of diгt . 7 Remove the staгter motor retaining bolts and position the staгter out of the way. 8 Remove the nuts that attach each muffler inlet pipe to the e)(haust manifolds. Separate the pipes from the manifolds and Bllow the exhaust system to hang оп the геаг a)(le. 9 Disconnect the speedometer саЫе from the e)(tension housing. 1О Disconnect the kickdown rod from the 1ransmission downshift 'еуег, ~nd the shift rod from the manual lever. Оп models with а column lock-rod, disconnect the rod at the transmission . 11 Disconnect the vacuum hose from the vacuum unit and remove it from the attaching clip оп the transmission. 12 Аетоуе the f1ller tube and dipstick. Оп some models the fШег tube is secured {о the cylinder head with а bolt. 1 3 Disconnect the staгter inhibitor (neutral staгt) switch leads from the retaining cl ips and connectors. 14 Position а trolley jack beneath the transmission and raise it so that 1t takes the weight of the transmission. 15 Remove the two nuts securing the engine геаг suppoгt to the crossmember. 16 Raise the transmission just enough 10 гетоуе the weight from the crossmember, гетоуе the crossmember-to-frame side support зесuг­ ing nuts and lift out the crossmember. 17 Remove the bolts attaching the engine геаг suppoгt 10 the e)(te"sion housing and remove the suppoгt. 18 Disconnect the fluid cooler lines at the transmission and plug them (о prevent the ingress of diгt. 19 Suppoгt the геаг of the e"gine with а jack ог other suitabIe

8

suppoгt .

20 Ensute that the transmission is securely mounted

оп

the trolley jack, then гетоуе the conveгter-to-engine bolts (С4 - five bolts; св and FMX - si)( bolts). 21 Carefully move the transmission rearward and downward, and remove it from under the саг. 22 Installation 01 the transmission is the геуегзе of the removal procedure, but the following po1nts should Ье noted: (а)

Rotate the converter to вliуn the drain plug with ;Is hole in the f/ywhee! (ь) Do not allow the trensmission 10 take в 'nose-down' ettitude as the converter will move forwBrd and disengage {гот the ритр уеаг

(с)

Adjust the kickdown rod end selector linkage as described in Sections ЗА, З 1 and З2 (d) After lowering the саг 10 Ihe ground. {ill the transmission with f/uid со bring the !evel ир 10 the FULL mark оп the dipstick; then check end top-up the f/u;d !evel as described in Section

28. 30 Manual shift linkage - adjus1ment 1 2

Place the transmission selector 'еуег in the D position. Jack-up and suppoгt the саг. Working underneath the

саг,

loosen

~

Chapter 6 Transmission

124

t..r,e manuall ever shift rod retaining nut (эее Fig. 6.40) and position the transmission manual lever 'п the О detent. 3 With the transmission selector lever and manual lеУег ,п the D positions, tighten the retaining nut 10 а torque of 1О to 20 'Ы ft {1 .3 10

2.7kgf

mJ.

4 Check the operation of the transmission in each selector lever position.

31 Transmission lock-rod - adjustment

models {гот 1970 а transmission lock-rod connects the lower steering column shift сuЬе to the mапиа! reverse /еуег. It locks the transmission ,"п reverse when the ign;tion switch 15 ,"П the LOCK posit'-on. 8efore attempt;ng tQ adjust the lock-rod ensure that the тапив! Iinkage is correctly adjusted as described ,"п Section ЗА. 1 Loosen the lock-rod retaining nut (see Fig. 6.40) оп the transmis-

ЗЗ

Neutral 5t8rt 5witch

(С4

8nd

С6

tf8n5mission5) - 8djustment

1 Loosen the two switch attaching bolts. 2 With the transmission selector lever 1п N (neutral) position, rotate the switch and install а No 43 drill Into the gauge pin holes. It must Ье inserted а fuH 0.48 in (12.30 тт) into the three holes of the switch (see Fig. 6.41). 3 Tighten the switch attaching bolts and гетоуе the drill. 4 Check the operation of the switch. The engine should start only when the transmission selector lever is in the N ог Р positions.

Оп

sion manuallever. 2 Place the selector lever in the О position. 3 Align the hole in the steering column socket casting with фе column alignment mark and Insert а 0.18 in (4. 5 тт) diameter pin. The column castlng must not rotate with the pin in position. 4 Tighte n the lock-rod retaining nut to а torque of 1О to 20 Ibf ft ( 1.3 to 2 .7 kgf т). 5 Aemove the alignment pin and check the operation of the linkage.

tгапsmissiоп апd С6

34 Neutral st8rt switch (FMX

transmission

wittl 429 CI О engine) - 8djustment 1 Shift the selector lever to N (neutral) positlon. 2 Undo the selector lever handle securing screws and remove the handle (see Fig. 6.401. 3 Aemove the dial housing securing screws and remove the housing. 4 Аетоуе the two pointer back-up shield securing screws and remove the shield. 5 Loosen the two screws securing the neutral start switch to the selector 'еуег housing. 6 Adjust the switch in accordance with the information оп the switch adjustment plate (see Fig . 6.42). •

32

Кickdown

rod - adjustment 35 Intermediate band (С4 and С61- adjustment

1 Disconnect the throttle and kickdown rod return springs. 2 Ho ld the carbureto r throttle lever in wide ореп position against the stop . 3 Hold the kickdown rod against the 'through detent' stop. 4 Тигп the adjustment screw оп the carburetor kickdown lever to obtain а clea rance of 0.04 to 0.08 in (1 to 2 тт) between the screw and the throttle lever. 5 Release the carburetor and transmlssion levers to the normal free position. 6 Install the throttle and kickdown rod return springs.

GRОММЕТ

~'

1 The intermediate band is used to hold the sun gear stationary to provide the second gear ratio. If it Is not correctly adju5ted there .will Ье поticеаЫе slip during fir5t to second gear change instead of the usual crisp action. 2 То adjust the intermediate band, undo and remove the adjustment screw locknut located оп th6 16ft-hand side of the transmission. 3 Tighten the adjusting screw, using а torqu6 wrench S6t to 1 О 1Ы ft 11.4 kgf т), and then back-off the adjustment screw turns оп С4 transmissions of 1 t turns оп С6 transmissions.

'!

_R ETAI NING CllP

I, 1 - ' - - - - COLUMN

().

$НIП

lEVER ТYPICAL

ЗЕТ SCREW

GAUGE PI N _ _ _ _ _ AllGNMENT HQlE (и $Е NO 150.ill)

WHEN MARKED •

r-ЮТ Е:

GROMMET ми$Т ВЕ REPlACED I F ROD 1$ REMOVED.

G

$ElECTQR LEVER POtNТER

L

ВАск·иР SН I ELD

• '00

$TART & BACK·UP LAMP CIRCUIT (FM X .ONLY )

I L EVER ENGAGE FLATS OF STUD 11'1 SLOT OF ROO BEFORE APPL YING TORQUE

,

lOC K ROD RETAINING " От

"ОТ

ЗЕАТ

SH IFT ROD

Fig. 6.40 Manual shift linkage - automatic transmission (Secs.

BEL Т

WARNING CIRCUIT (FMX TRANS. ONL У)

31 and 34)

•

Chapter 6 Transmission

125

NEUTRAL

SТART

ДНО

Fig . 6 .41 Neutral 5t811 switch adjustment (С4 and св tгапsmissiоп) (Sec. 33)

• NEUTRAL

All GNМENT МдRК

NEUTRA L

ACT UAT QR

РQSIТЮN

LEVE R

Fig . 6 .43 Adjusting intermediate band 150с.351

Fig. 6 .42 Neutral start switch adjustment (FMX transmission and св tгепsmissiоп with 429CI D enginel (Sec. 34)

Т59Р·77З70·8

Fig. 4

6.44

Adjusting

low 150С. 361

(reverse

band

'"sta ll а new locknut and tighten it to the specified torque, while

holding the adjusting screw to prevent it turn ing. 37 FMX transmission - band adjustment Э6

Low and r8verS8 band (С4 only) - adjustment

1 The low and reverse band is in operation when the selector lever is in the 1 о г R position. It holds the low and reverse pinion carrier stationary. If il i5 not correctly adjusted there will Ье а noticeabIe malfunction of the transmission, indicated Ьу there being по drive in the R position and also по engine braking when the selector 1ever is in the first gear position . 2 То adjust the low/ reverse band, undo and remove the adjusting screw locknuI. 3 Tighten the adjusting screw, using а torque wrench 5Bt to 1 О Ibf ft (1.4 kgf т ) and then back-off the adju5ting screw а full three turns. 4 1nstall а new locknut and lighten it 10 the specified torque, while holding Ihe adjusting screw 10 prevent it turning.

Adjustment of the front and геаг bands оп FMX transmissions necessitates the гвтоуа' of the transmission 0;1 рап and speciaJ adjusting wrenche5 5hould Ье u5ed. It i5, therefore, recommended that thi5 adjustment should Ье done Ьу the local repair station.

38 Fault diagnosis - automatic tгапsmissiоп As has Ьееп mentioned elsewhere in this Chapter, по service repair work should Ье considered Ьу апуопе without the specialist knowledge and equipment required 10 undertake Ihis work. This is al50 relevant 10 fault diagnosis. If а fault is evident саггу out the various adjustments previousty described and 1f the fault still exists consult the local repair station ог spec1alist.

Chapter 7 Driveshaft Contents Driveshaft - balance . . . . . . . . . . . . . . . . . . . . • . . . . . . • Driveshaft - removal and installation .............. . Fault diagnosis - driveshaft ..................... . Front universal joint - dismantling, overhaul and reassembIy

•

6

• •

General description . . . . . . . . . . . . . . . . . . . . . . . . . . . . Аеаг universal joint - dismantling, overhaul and reasseтbIy Universal joints - inspection and repair .............. .

2 7 4

• • • • • •

1 • • • •

5 3

Specific8tions

Туре

.................. . •

•

•

• • • • • • •

•• •

• •

•• •

•

• •

• •

•

One-piece tubular with single Cardan type universal joint at each end

• •

Torque wrench settings U-bolt nuts

1

.................. .

• • • • • • • •

•

IbI ft 8 to 15

• • • • • • • • • • • • •

General description

2

Drive i5 transmitted from the transmission to the геаг axle Ьу теапз of а finely balanced tubular driveshaft. Fitted at each end is а universal joint which allows for veгtical mavement of the геаг axle. Each universal joint camprises а four legged center spider, four needle тoller bearings and two yokes. Fore-and-aft movement of the геаг axle is absorbed Ьу а sliding spline in the front of the driveshaft which slides оуег а mating spline оп the геаг of the transmission mainshaft. АН models аге equipped with the sealed type of universal joint which requires по maintenance. The driveshaft is а relatively simple companent and is fairly еазу to overhaul and repair, provided that зраге рагtз аге readily to hand.

kgfm

2 10 2.07

Drive8haft - removaland in8tallation

1

Chock the front wheels, jack-up the геаг of the саг ог position the гваг of the саг оуег ог оп а гатр. 2 If the геаг of the саг is jacked-up, supplement the jack with support bIocks зо that danger is minimized should the jack fall. 3 If the геаг wheels аге off the ground, place the саг in gear and apply the parking brake to ensure that the driveshaft does not turn when ап attempt is made to loosen the four nuts securing the propeller shaft U-bolts to the геаг axle pinion flange. 4 Mark the pinion llange, U-bolts and driveshaft зо that they тау Ье re-installed in their original position. 5 Undo and гетоуе the four nuts secuгing the two U-bolts to the pinion flange, and гетоуе the U-bolts.

Fig. 7.1 ExpJoded view of driveshaft (Sec. 1 ) 1

2

3 4 5 б

7 8 9

Snsp-ring 8earing сир Thrust besring Sesl Spider Sliding spline

10

1

2

9

8

/

/- / ~~/

Nut

U-bolt Pinion flsnge

<#J

4

1

5

О

-

10 Nv/

-

з

/

7

Ф

ф~ <#J

-

8

2 з

_ 4 5

•

•

Chapter 7 Driveshaft 6

,

127

Slightly push the driveshaft forward 10 separate the spider

assembIy fгom the pinion flange. then lower the end of the shaft and puH it rearward 10 disengage the transm ission mainshaft splines. 7 Place а large сап ог tra y under the геаг of the transmission extension 10 ca tch а пу oil which is likely 10 leak from the end when the d riveshaft is removed . 8 Installation of the driveshaft is а reversal of the аЬоуе procedure. Ensure thal the previou sly made mating marks аге aligned .

I з

Universel joints - inspection and

гера;г

1 W ear in the needle гоНег bearings is characterised Ьу vibration in the drive-line. 'clonks' оп taking up the drive, and in extreme саsеs of tack of lu bric8tion , metallic squeaking, and ultimately grating and shrieking . 2 It is easy to check if the needle roller bearings аге worn with the driveshaft in position. Ьу trying to turn the shaft with опе hand. the other hand hold ing the геаг axle pinion flange when the геаг universal loint is be ing checked. and the front half coupling when the front univeгsa l is being checked. Апу movement between the driveshaft and the front and the гваг half couplings is indicative of considerabIe wear. If woгn , the old bearings and spiders will have to Ье discarded and а гера ; г kit, comprising new universal joint spiders, bearings, oil seals, and retainers purchased. Check also Ьу trying to lift the shaft and notici ng а пу movement in the joints. 3 Exam ine the driveshaft splines for wear. If worn it will Ье necessa ry to purchase а new front coupling, ог if the yokes аге badly worn , а п exchange driveshaft. It is not роssiЫе to install oversize Ьеаг­ ings and journal s to the ttunnion bearing holes.

4

Front universal joint -

dismапtliпg,

ovethaul and

4.1 Aemoving

а

snap-ring

гваззвmЫу

1 Clea n away аll traces of dirt and grease from the snap-rings located оп the ends of the bearing cups; геmоуе the snap-rings Ьу pressing their ореп ends together with а pair of snap-ring pliers, and ' еу ег them out with а screwdriver (photo). Note: If they аге d;fficult to

tap the bearing сир 'асе resting оп the top 01 the spider with а soft-'aced hammer which will ease the pressure оп the snap-r;ng.

геmоуе

2 Take off the bearing cups оп the driveshaft yoke. То do this select two sockets from а socket set, опе large enough to fit completely оуег the bearing с ир and the other smaHer than the bearing cup. 3 Ореп the jaws of the vise and with the sockets opposite each other and the universal jo;nt in between , tighten the vise and force the narrower socket 'о тоуе the opposite cup partially out of the yoke into the larger socket. 4 Ает оу е the сир with а pair of pliers. Аетоуе the opposite сир , and then free the yoke from the driveshaft. 5 ТО ге тоу е the remaining two cups now repeat the instructions in paragraph 3 ог use а socket and hammer. 6 Ае соу ег the thrust bearing from inside each сир and remove the seal from the base of each spider jouгnal. 7 Before reassembIing, using new parts as necessary, thoroughly clean out t he yokes and journals. 8 Install new 0;1 seals to the spider journal5 and then аssеmЫе the needle rol lers in the bearing cups with the a55 istance of some grease. 9 FiII ea ch bearing сир about опе third fuH with а universal grease, not forgett;ng to install the thrust bearing5 fir5t. 1 О Install the bearing cups оп the 5pider and рге5З them home so that they lie squarely in position. Install the snap-rings and 5ettle the cups Ьу tapping the w hole aS5embIy with а soft-faced hammer (photos). 11 Check that angular movement of the universal joint is free thгoughout its full range without signs of stiffness.

5

Rear universal joint -

dismапtliпg,

overhaul

апd

4 . 10А

In5tal1ing the caps

7

reassembIy

This is easier tha n for the front universal joint as опlу two 5pider cups have to Ье removed as described in the pгe vi ous Section. The remaining cups simply slide off the spider journa ls, these being held in position Ьу two U-bolts and small lips оп the pinion flапgе сир location5.

4 . 10В

Pressing in the caps

Chaptsr 7 Drivsshaft

128 • 6

approximately 450 away from each other and retest (Fig. 7.4) . 9 Continue to rotate the clips apaгt 1п smaHer amounts until the vibration has Ьевп eliminated.

Oriveshaft - balanC8

1 11 the vibration from the drive-line has Ьевп traced to the driveshaft and yet there аге по traces of wear, then the driveshaft i5 ргоЬаЫу out-of-balance. This сап 8150 occur апег overhaul. 2 First detach the driveshaft from the drive pinion 118nge and ге­ in5t811, having rotated the shaft through 1800; if this does ПО1 сиге the troubIв then the foltowing sequence should Ье followed: 3 SuitabIy suppoгt the геаг 01 the саг 50 that the wheels аге clear 01 the ground. Chock the 1ront wheels 50 that there i5 по chance of the саг moving off the 5UPPOгtS. 4 Staгt the engine and with top gear 5elected run at а 5peed of 40 to 50 mph (reading оп speedometer). 5 дп assistant 5hould now place а сгауоп ог piece of chalk 50 that it just contacts the геаг end of the drive5haft. Obviously great саге must Ье taken to avoid injury (Fig . 7.2). 6 In5tall two worm-dr1ve type h05e сliР5 оп the drive5haft 50 that the heads аге 1800 from the chalk mark. Тighten the clip5 (F1g. 7.3). 7 Staгt the engine again and run at а 5peed of 65 to 70 mph (reading оп speedometer) . If по vibration i5 felt. lower the саг and road te5t . 8 Should , however, а vibration 5t111 e)(ist, rotate the clip5

•

AXLESTAND

Fig. 7.2 Marking the driveshaft (Sec. 6)

CHAl

MAR!(

,, • i

,

'-. . ../" •

Сl дМР~ 1800FR~ CH Al!( MAR!(

Fig. 7.3 Inst81li"g the worm-drive typa

7

сliра

Fig. 7.4 Moveme"t limit 01 clamps (See. 6)

(See. 6)

Fault diag"osis - driveshaft

Symptom

Авааоп/а

Vibration

Wear in sliding sleeve sp1ines Worn univer5al joint bearings Driveshaft out-of-balance Distoгted driveshaft

Knock

ог

'cl onk' when taking up drive

Worn universal joint bearings Worn геаг a)(le drive pinion splines Loose геаг drive flange bolt5 E)(Ce5Sive backla5h in геаг a)(le gears

•

•

, , I

Chapter 8 Rear axle

I

,~

Contents

, •

AxJeshaft - removal and installation .................... . Ax leshaft bearing - renewal (ball bearing type) . . . . . . . . . . . . . Axleshaft bearing/oil seal- renewal (taper roller bearing type) Axleshaft oil seal- renewal (ball bearing type). ...... .. Differential- overhau l (conventional type) ... . .... . Differential- overhau l (limited s1ip type) ..... . .... .

2

4 5

3 8 9

Differential carrier - removal and installation . . . . . . . . . . . . . . Fault diagnosis - геаг axle .......... . . . . . . . . . . . . . . . . . General description ......... . .... ......•.•.•......

6 12 1

Pinion oil seal- renewal ........... . ... • . . . .. ... .... А ваг a)(le - removal and instal lation .. , . . . . . • . • . . . . . . .. Wheel stud - гетоуа' and Installation .. , . . . . . . . • . • . . ..

1О 7 11

Spocific8tions

.

.. . .......... •

•

•

•

•

•

• • •

.. ....... . , ........

• • • • • • • • • • • • • • • •

•

•

•

•

•

• • •

. ... . . . . .. . . , . , . . .

•

•

•

•

• •

• • • • • • • • •

•

•

•

Туре. . .

Ratios

•

Axle oil capacity I

Oil type:

I

Conventional axle .. Limited slip axle ...

• • • •

•

•

. •

4.0 U5 pints (2 liters)

•

• • • • •

•

•

•

•

• •

•

•

•

• • • • • • •

•

•

• • • • • • • •

•

•

•

•

••••••••••••• • ••• • ••• • •••• ••••• • •••

Torque wrench settings

I

8earing сар bolts ... ..... ..... •...• ........ •.•.•.•.• .. Adjusting nut lock bolts . ........• . .. .•.• .. . . . • . • .• .• . • . . Carrier to housing nuts .........•......•.. . ....•.•.•.•.. Pinion retainer to caгrier bolts ....•. • .•.•................ • Crownwheel attaching bolts . . . . . .. . .•.•............•.•.. Axle shaft bearing retainer nuts .... . .•....... . . . • .• . • . • • . Pinion bearing preload (new bearing) ..•..• . •.. . . . ..•.• . •..

• I

\

•

I

1

1

General doscription

The геаг axle fitted to the Mustang models is а semi-floating hypoid gear type and 1з attached to the chassis Ьу tongitudinal leaf springs and telescopic shock аЬзогЬегз. The differential аззетЫу has а гетоуаЫе carrier and the сот­ plete аззетЫу са п Ье withdrawn from the axle casing without having 10 гето уе the axle from the саг. The Traction-Lok limited slip differential is offered аз equlpment optional оп зоте Mustang сагз and provides improved traction in ice ог snow conditions and also during hard acceleration. The procedure for rem oving and installing the limited зliр differential is exactty the зате аз that used for the conventional type. Unless the песеззагу tools and gauges аге avaitabte, it is not recommended that the геаг axle is overhauted, although the procedure is described later in this Chapter for those who have the песеззагу equipment . With the гетоуаЫе carrier type axle, It 1з recommended that the differentia l unit is either renewed оп ап exchange basis, ог the original unit taken to your Ford dealer for reconditioning.

2

Axloshaft -

готоуа'

and installatlo"

Place the саг оп 'еуе' ground, chock the front wheels, 'оозеп the геаг wheel nuts оп the side to Ье worked оп, ог both sides if both axleshafts аге to Ье removed, then jack-up the геаг of the саг and геrnоуе the wheels. Position jack stands underneath the саг. 1

differential carrier

• •

•

•

гетоуаЫе

3.00 : 1; 3.25 : 1. ог 3.50 : 1 depending

•

•

•

.

•

•

Semi-floating hypoid with

оп

eng ine type

ESW-M2C- 105-A ESW-M2C- 119-A IbI ft 70t085

kgf m 9.5to 11.6

12 10 25 251040 301045 701085 201040 171027

1.66 10 3.46 3.46105.4 4.15106.1 9 .51011 .6 2.7105.4 2.35103.86

2 Aelease the parking brake, then гетоуе the brake drum securing screw and take off the brake drum. 3 Undo and геmоуе the four bolts retainlng the axleshaft beari ng housing to the axle casing. These bolts аге accessibte with а socket оп ап extension thгough the holes in the axleshaft flange (Fig. 8.3). 4 It should Ье possibte at this stage to геmоуе the axl eshaft Ьу simply pulling оп the flange , especially if taper bearings аге installed, but if this fails, install the roadwheel оп the studs and tighten down two opposite nuts just enough to prevent movement of the wheel оп Ih • • uds. 5 5itting оп the ground, with опе leg either side of the wheel and braced оп the spring, get а firm hold оп the outer edge of the tire and pull straight outward аз hard аз possibte. 6 The axleshaft seals аге made out of а synthetic material and аге easily damaged. When withdrawing the shaft take саге that the sp1ined end does not cut the inner lip of the sea l. 7 Installation is the геуегзе of the гетоуа' procedure bu1 again, саг&.. must Ье taken to avoid damaging the seal. If а taper rotler bearing is installed, the outer bearing should Ье removed fгom the axle housing using а stide hammer. and installed onto the taper bearing befoгe installing the shaft.

3

Axleshaft oil s081- r8newal (ball b88ring typa)

1 Аеmоуе the axleshaft аз described in the previous 5ection. 2 The зеа' seats just inside the outer end of the axleshaft housing and ideally а slide hammer should Ье used to extract It. However, it сап Ье removed using а hammer and chise l, but great саге shou ld Ье

8

~

NUT WASHER

•

.

\ '\. ,

~

•

EXISTING HOLE IN SIDE RAIL

PLATE

,,

BOLT

ВААСКЕТ 2 АЕОО.

'V

SHOCK ABSORBER

CLIP BOL Т

•

';,.(;;:;j.

- WASHER

BUMPER ....... WASHER

~ ~ .;

AXLE ASSY

.-

WASHER •

-

NUT

DRUM DRIVESHAFT CLIP

'-

•

VENT

AXLE ASSY

\:

•

/

•

• ,

NUT ----- AXLE SHAFT

• ________, ,

BUMPER UNIVERSAL JOINT

• CLIP

•

HOSE

WEDGES

__ , ,,..-_- SPRING

, ,

_ _ INSULATOR NUT 1,

Fig. 8.1 Location 01 rear

,

8)(18 аааетЫу

(Sec. ,)

•

- SHACKLE

NUT

•

Chapter

В

Rear axle

131

I,•

r

AING

AXLE SHAFT

I

•

G'SКEТ

~,

BEARING

,

THRUST ....... WASHER DIFFERENTIAL

~ f

SIDE

fLAT WASHER (LIMIТED SllP t>lL '( )

DRIVE

СЕДА ДТТДCHIНG

i30LT

СЕДА

DIFFERENTIAL QIFFЕАЕNПАL CASE СОУЕА

•

~

DIFFERENTIAL PINION

BEARING RETAINER

I

СЕдА

_ - - - - - THR \JS T WASHER

!

(!)"'--'ADJUSTING NUT

I

HOUSING DRIVE

DIFFE CASE

PINI(X<4 BEARING SPACER

I

BEARING С АР

PLNION FRONT BEARING

SHIM Q.RING RING

С ЕдА

PILOT RE TAIN ER

DE

D.

•

PI LOT BEAR ING

PINION SEAL

FLANGE

Fig. 8.2 Exploded view of 8xle components (Sec. 1)

!

I

I I 8

Fig. 8.3 Removing the 8xlesheft retaining nuts (Sec. 2) Fig. 8.4 Alternative method 01 extracting axleshaft (Sec. 2) I

taken not to damage the axle housing, otherwise oil will seep past the

,

outside of the new seal. 3 Make а note of which way round the

•

sез l

is located in the housing

before removing it ; usually the metal clad side of the seal faces toward

the roadwheel. 4 Smear same gasket sea ler around the outside casing of the new

I

seal and drlve 1! evenly into place using а wood-bIосk having the same outside diameter as the seal. 5 Install the axleshaft аз described in Section 2 .

4

ог а

tubular drift

Axleshaft baaring - renewal (ball Ьааг1по type)

i

I

1 Refer to Section 2 and remove the axleshaft assembIy. 2 Using а hammer and sharp chisel make зеvегаl deep nicks in the bearing retainer ring. This will release its grip оп the axleshaft and

allow it to Ье slid off the shaft. If it i5 tight however. 5plit It with а sharp chisel. 3 Place the axle5haft upside-down in а vi5e so that the bearing retainer is оп the top of the jaws and the axleshaft flange is under thel'(l and . using а soft-faced hammer. drive the axleshaft through the bearing. If this proves difficult it wi ll Ье necessary to use а garage press. Note which way round the bearing is installed. 4 Place the retainer plate and new bearing (correct way roundl оп the axleshaft . 5 Place the axleshaft vertlcally between the jaws of а bench vlse. flange uppermost. so that the 1ппег track 15 resting оп the top of the vl se jaw5. U5ing а soft-faced hammer drive the axleshaft through the bearing until 1! is seating fully against the shaft shoulder. 6 The bearing retainer should next Ье installed, the sequence for this being the same as for the bearing. Do not attempt to install the bearlng and retainer at опе 90.

132

Chapter 8

7 8

Pa ck the bearing with а little multi-purpose grease. In5tall the axleshaft assembIy as described in Section 2.

5

Axleshaft bearing/oil seal- renewal (tapar roller bearing type)

Ава,

axle

Note: 8ecause 8 spec;al press has (о Ье used (о remove and re-install this (уре о{ Ьеаг;пу, it is recommended that the compfete shaft 8ssembIy is taken (О а Ford dealer who wilf have the ргорег equ;pment (О саггу out the job. However, the procedure is described {ог those

who have the necessary equipment. 1 Withdraw the axleshaft, аэ described in Section 2. 2 Secure the assembIy in а vise, the jaws of which have Ьееп equipped with 50ft metal protectors. 3 Огill а hole in the bearing retainer and then remove Ьу splitting it with а cold chisel. Take саге not to damage the shaft during these operations. 4 Using а suitabIe press, draw off the comblned bearing/oil sea!. 5 ТО the axleshaft install the bearing retainer plate, the new bearing (seal side towards differentiaO and а new bearing retainer. 6 Apply pressure to the retainer only, using а press ог bearing puller, and seat the components against the shoulder of the axleshaft flange. 7 Install the axleshaft, as described in Section 2. 6

Differential carrier -

гетоуаl

and

Аваг

axle - removal and 1nstallation

Chock the front wheels, jack-up the геаг of the саг and support 1t оп jack stands placed under the геаг frame member. 2 Remove the wheels, brake drums and axleshafts as described In Section 2. 3 Remove the driveshaft as described ёп Chapter 7. 4 Disconnect the lower end of the shock absorbeгs from the axle housing. 5 Remove the brake vent tube (if so equipped) from the brake рёре junction and retaining cJamp (see Chapter 9). 6 Remove the brake pipes from the clips that retain them to the axle, but do not disconnect апу of the pipe unions. 7 Remove the brake linings and bгake backplates, and support them with wire to avoid straining the hydraulic brake lines which аге still attached (see Chapter 9). 8 Support the weight of the axle оп а trolley jack and remove the nuts from the spring retaining U-bolts. Remove the bottom clampi ng plates. 9 Lower the axle assembIy оп the jack and withdraw it from the геаг of the саг. 1 О The axle assembIy is installed using the reverse procedure to that of removal. Tighten the U-bolt and shock absorber nuts to the torque figures given ёп Chapter 9 Specifications. 1

8

Fig. 8.5 Drilling the bearing retainer (taper Ьеагёп; type) (See. 5)

iпst8118tiоп

1 То remove the differential carrier assembIy, drain the оН from the axle Ьу removing the drain plug (if so equipped) ёп the base of the banjo casing, jack-up the геаг of the vehicle, remove both гoadwheels and brake drums and then partially withdraw both axleshafts as described in Section 2. 2 Disconnect the driveshaft at the геаг end, as described ёп Chapter 7, Section 20. 3 Undo the self-Iocking nuts holding the differential carrier assembIy to the axle casing. If ап oil drain plug has not Ьееп fitted pull the assembIy slightly forward and allow the 011 to drain into а drain рап. The саггёег complete with the differential unit сап now Ье lifted clear with the gasket. 4 Before installing, carefully clean the mating suгfaces of the саггёег and the axle casing and obtain а new gasket. Installation is then а direct reversal of the above instructions. The nuts retaining the differential саггёег assembIy to the axle casing should Ье tightened to the specified torque.

7

H.I""6

Differential- overhaul (сопvепtiопаl type)

Most professionaf garages wiff prefer (о renew the complete differential C8rrier assembIy as а unit if it is worn, rather than to

•

•

Fig. 8.6 Splitting the bearing retainer with а ehisel (Sees. 4 апd 5) dismantle the unit (о renew апу damaged ог worn parts. То do the job correctly requires the use о' specia/ and expensive tools which the majority о' garages do not have. The primary object о' these specia/ tools is to епаЫе the mesh о' the crownwheel to the pinion to Ье very accurate/y set and thus ensure that noise is kept to 8 minimum and а 'опу service Ше is achieved. The differential assembIy shoufd Ье stripped as folfows: 1 Remove the differential assembIy from the геаг axle, as described ёп Section 6. 2 With the differential assembIy оп the bench begin dismantling the unit. 3 Undo and remove the bolts, spring washers and lockplates securing the adjustment cups to the bearing caps. Aelease the tension оп the bearing сар bolts and unscrew the 4 differential bearing adjustment cups. Note from which side each cup originated, and mark with а punch ог scriber. 5 Unscrew the bearing сар bolts and spring washers. Ensure that the caps аге marked so that they may Ье installed in their orlginal positions оп reassembIy. 6 PuH off the caps and then lever-out the differential unit complete with crownwheel and differential gears. 7 Аесоуег the differential bearing outer tracks and inspect the Ьеаг­ ings 1ог wear ог damage. If evident, the bearings will have to Ье renewed. 8 Using а universal puHer and suitabIe thrust bIock draw off the .old bearings. 9 Remove the bolts and washers that secure the crownwheel to the differential са9е. Mark the relative positions of the cage and crownwheel, if new parts аге not to Ье installed, and lift off the crownwheel. 1О Clamp the pinion flange in а vise and then undo the nut. Апу damage caused to the edge of the Ilange Ьу the vise should Ье carefully filed smooth. 11 With the nut removed, pull off the splined pinion flange . Тар the end of the pinion shaft, jf the flange appears to Ье stuck. 12 The pinion, complete with spacer and геаг bearing сапе, may now Ье extracted from the геаг of the housing. 13 Using а drift carefully tap out the pinion front bearing and oil seal.

Chapte,8

1ЗЗ

score-marks, ehipping and general wear. Obtain new gears

15

23 Inspeet the thrust washers for signs 01 wear

То

dismantle the pinion assembIy detach the bearing

sрасег

and

the (еаг bearing сопе using а universal puller. Аесоуег зпу shims found between the геаг bearing and pinion head. 16 Тар out the differential pinion shaft locking pin which is tapered at onе еnd

,

axle

14 Check те bearings far signs of wear and jf evident the Quter tracks must ье removed using а suitabIe 50п metal drift. гетovе

,

Ава,

and must

Ье

pushed out from the crownwheel side of the

case. 17 Push the differential pinion shaft out of the сазе and rOlate the pinions around the differential gears, 50 that they тау Ье extracted through the apertures in the C8se. Cupped thrust washers аге installed between the pinions and the case, and may Ье extracted after the pinion s have Ьееп removed. 18 Remove the dlfferential gears and thrust washers 1rom the differentlal case. 19 Wash all parts and wlpe dгy wlth а clean 11nt-1ree cloth. 20 Again check all bearlngs 1ог slgns 01 wear ог plttlng; If evldent а new set of bearings should Ье obtained. 21 Examine the teeth 01 the crownwheel and pinion 10г pitting, scoremarks, chipping and general wear. 11 а crownwheel and pinion аге required а matched assembIy must Ье installed ; under по circumstances тау only опе part 01 the two Ье renewed. 22 Inspect the differential pinions and side gears for signs of pitting ,

аз

пе сез загу.

ог

deep seoring.

Obtain new thrust washers as пеееззагу. 24 Опее the pin ion 011 seal has Ьееп disturbed It must Ье discarded and а new опе obtained. 25 Commenee reassembIy Ьу lubricating the differential gear thrust washers and then positioning а flat washer оп each differential side gear. Position the two gears 1п the case . 26 Position the cupped thrust washers оп the machined faces in the case, and retain in position with а smear 01 grease. 27 locate the pinion gears in the case dlametrically opposite each other, and rotate the geats to move the pinion gears in line with the holes in the shaft. 28 Check that the thrust washers аге stlll in place and push the spider shaft through the case, thrust washers and pinions. 11 the pinions do not line-up they аге not diametrically opposite each other, and should Ье extracted and repositioned . Measure the play 01 the gears and, If necessaгy select new thrust washers to obtain 0·005 to 0·007 in (О. ,

3 10 0·1 В тт) play.

29 Insert the locking pin (tapered end 11r5t) and lightly to prevent the pin working out. 30 Exam ine the bearing journals

LEFT .A.XlE

оп

the differential

рееп

са5е 1ог

the case

burrs, and

SН.A.FТ

RING GE.A.R

DIFFERENTI.A.L PINION _ __

DIFFERENTI.A.L _ _..., _ __ C.A.SE

I

•

DRIVE PINION

_ ..

T.A.PERED ROLL ER BEARINGS

PI NION PILOT BEAR ING

r

_ _ FLANGE

BE.A.RING

8

PINION REТAINER

Fig. 8.7 Details о, basic differentialand axleshaft components (Sec. 8)

"'" '"' ,

RfAR 8EARING

SPACER

FLANGE FRONT 8EAR!NG

.

! ROLLER

,

SHIM

"

Fig. 8.8 Pinion g08r and associated components ISoc. 8)

-

Chapte,8

134

Ава,

axle

ТНRUST

- - PINIQN

SHAFТ

•

PINION

SНAfТ

PIN ТНRUSТ

•

.. ,

Fig. 8.9 AssembIing the differential c8sing ISec. 8) i"5tall the ditferential bвaring cones O"to the differential case using а su itabIe diameter tubular drift. Make sure they аге installed the correct way round. 31 Examine the crownwheel and different ial case for burrs, sсогв ­ marks and dirt. Clean as necessary and then i"5tall the crownwheel. Take саге to line-up the bolt holes and апу previously-made marks if the origi"al parts аге being re-used . 32 I"stal l the crownwheel-to-differential case securing bolts and tighten (п а diagonal таппег to the specified torque wrench s8tti"g. зз Using а suitabIe diameter drift carefully drive the pinion bearing cups i"to position (п the f1"al drive hОU5iпg. Make 5ure that they аге the correct way гоuпd . 34 Slide the 5him onto the pinion 5haft апd locate behind the pinion head, then iП5tа l l the iппег сопе and гасе of the геаг bearing . It i5 quite 5ati5factory to drive the геаг bearing оп with а piece 01 tuЫпg 12 to 14 iп (30 to 35 cm) long with 5ufficient internal diameter to jU5t lit over the pinion 5haft. With опе end of the tube bearing again5t the гасе , tap the top end 01 the tube with а hammer, 50 driving the Ьеагiпg 5quarely down the 5haft and hard up аgаiП5t the uпdеГ5idе 01 the thrU5t wa5her. 35 Slide а new col lap5ibIe 5расег over the рiпiоп 5haft апd in5ert the a55embIy into the differential carrier. 36 tП5tаlt the pinion lront bearing outer track апd га с е 101l0wed Ьу а new pinion оН 5eal. 37 In5tall the рiпiоп drive l lange and 5crew оп the pinion 5ell- locking nut апd torque-tighten it to 175 Ibf ft (24· 1 kgf m) and check the рiпiоп turning torque u5ing either а 5uitabIe torque gauge ог а 5pring Ьаlа пс е апd length 01 cord wrapped round the pinion drive llange. The correct pinion turniпg totQue 5hould Ье : Огig1П81

be8rings

Toгque wгench

Рu" о п spгing

12to 181btin

balance 1210

(0 · 14100 · 21бkgfm)

18/Ы

(5108 kgf)

26 'М in 26 'М

(0 ·24 10 о · з 1 kgf т) (9 10 11 kgf)

New be8r1ngs Toгque wгench

(о

Рu" оп

(о

the lore90in9 li9ures add 3 'Ы in (0·035 kgl m) 11 а new plnion 011 seal has Ьееп installed. 39 Throughout the nut ti9htening process, hold the pinlon l1аП9е

38

ТО

20 spгing balance 20

PINION GEAR

Fig. 8.1 О '"st81Ii"g the pi"io" веег and retainer (Sec . 8) Quite still with а suitabIe tool. 40 11 the pinion пut is overtightened , the nut саппо! Ье unscrewed to correct the adjustment as the pinion зрасег will have Ьееп overcompressed ; the а55етЫу will then have to Ье di5mantled and а new collap5ibIe type spacer in5talled. 41 In5tall the differential cage to the differential carrier and insta ll the two bearing саР5 , loc8ting them in their orlglnal p05ition5. 42 Тighten the bearing сар bolt5 finger-tight and then screw in the two adjustment cups. 43 11 it i5 now necessary to position the crownwheel relative to the pinion. If p05sibIe mount а dial indlcator gauge and with the ргоЬе re5ting оп опе 01 the teeth 01 the crownwheel determine the backla5h. Backla5h may Ье varied Ьу moving the whole dltferential aS5embIy using the two adju5tment CUp5 until the required setting Is obtained. 44 Tighten the bearing сар 5ecuring bolt5 and recheck the backla5h 5etting.

! r-------------------------------------------------1~

i

I

•

Fig. 8.11 Crownwheel and pinion indexing marks ISec. 8)

, I

IN WHICH GEAlS WERE LAPPED

Сопес!

10011'1 cont8Ct

I

t НеаУу cOntact В! tooth lое, towards the сеп!те. Мove pinion 8W8Y from

Cfownwheel

, ,

НеауУ сопlас;:1 with 'ое, 111 'ОО1'" fJenk ЬоНот. Мove pinion 8W8Y 'гom crown·

Fig. 8 .12 Correct meshing of crownwhoel and pinion. and repositioning guide for incorrect tooth meshing 158С . 8)

wheel епс! crownwheel from pinion

, i

,

•

\ 8 НеауУ COf1tact 81 10011'1 hееl впс! towards 'м сеп!г • . Моуе

pin ion towerd, crown-

wto~1

, I

НеаУу contact ОП "'ее!, 81 10011'1 'асе. Моуе pinion towardS crownwheel ,тО

crownw heel towards pinion

н

12 08

Chapte,8 Rea, axle

136

45 Тhe best check the DIY motorist сап make to ascertain the correct meshing of the crownwheel and pinion is to sтеаг а littl8 engineer's

а

necessity it should Ье renewed. WARN ING: Never staгt the саг and put it ;n ge8f with оnе wheel jacked ир BS, unHke the conventionel different;81, the lim;ted slip type will cause the wheel still оп the ground to tuгn w;th possibIy disestrous resu/ts.

Ыи е

onto the crow nwheel and then rotate the pinion. The cantact m ark should арреаг right in the middle of the crownwheel teeth . If the mark appears оп the t08 ог the heel of the crownwheel then the crownwheel must Ье moved either пвагег ог further away from the pinion . The various tooth patterns that may Ье obtained аге iIIustrated

•

1 О Pinion

(Fig. 8 .12). 46 When the correct meshing between the crownwheel and pinion has Ьвеп obtained install the adjustment cup lock plates, bolts and spring washers. 47 The differential unit сап now Ье installed to the axle casing.

9

8881- renew81

1 Jack-up the геаг of the саг and зесиге оп stands under the badyframe and axle casing. 2 Aemove the roadwheels and brake drums. 3 Disconnect the driveshaft 1roт the pinion drive 11ange as described in Chapter 7. 4 Using either а spring balance and а length of cord wrapped round the drive pinion, ог а torque wrench IIЫ in) check and record the turning torque ofthe pinion. 5 Hold the drive pinion quite stШ with а suitabIe tool and remove the pinion self-Iocking nut. 6 Remove the washer, driveflange and dust deflector, and then ргу out the oil seal. Do not damage ог lever against the pinion shaft splines during this operatian. 7 Тар in the new oil seal using а piece of tublng as 8 drift. Do not inadvertently knock the end of the pinion shaft. 8 Repeat the operations described in paragraph 37 through 40 Section 8, but ensuring that the final pinion turning torque figure agrees with that recorded before dismantling. 9 Inst811 the brake drums, driveshaft and r08dwheels, and lower the

Differential- overhaul (Iimited slip type)

The Traction-Lok lim;ted slip differential ;s ;nstalled оп some cars as аn орОоn (о the conventional type. This type of differential is соn­ s;derabIy тоге compHcated than the convent;onal type, having а clutch mechan;sm attached to the crownwheel, the spr;ngs of wh;ch аге preloaded to 1500 'Ы (680 kgf). It;s not there(ore adv;sabIe (ог the home mechanic to attempt str;pp;ng and repairing this type о( un;t. То check the operation of the lim;ted slip facility the following tests сап Ье carried out: 1 11 the ргорег tool cannot Ье obtained, make up а torque wrench adaptor as shown in Fig. 8.14. 2 Jack-up опе wheel and support that side 01 the саг оп а jack stand. 3 Aemove the hub сар and attach the adaptor plate as shown in Fig. 8.14. 4 Make sше the transmission is in neutral and the parking brake is released and, using the torque wrench, attempt to turn the wheel. 5 The wheel should not start to turn until at least 40 'Ы ft (5·5 kgf т) is showing оп the torque wrench. Опсе the wheel is tшпiпg the torque required to keep it rotating may Ье lower than the initial breakaway torque 1igure but this is acceptabIe. 6 The wheel should turn with ап even pressure throughout the check without slipping ог blnding. 7 If the initial rotation 1igure is below 40 'Ы ft (5· 5 kgf т) the limited slip facility is nat operating ta its full capabllity and, although it will nat eHect the normal running of the саг, if maximum геаг wheel traction is PINION

оil

саг.

11 Wheel stud - removal and i"8t8118tio" 1 The usual геавопз for renew81 of а wheel stud аге that either the threads have Ьееп damaged ог the stud has broken, this usually being caused Ьу overtightening of the wheel nuts. То renew 8 wheel stud, remove the axleshaft assembIy аз described in Section 2. Using а parallel punch of suitabIe diameter drive the old stud through the flange towards the bearing. 2 То install а new stud place it in its hole from the геаг of the 11ange and using а bench vise with а socket placed in front of the stud ргевs it fully home in the fl8nge (Fig. 8.15).

SНдFТ

ОIFFЕRЕNТlдL РINЮN SНдFТ

PI NI ON GЕ дR THRUST WД SНЕR

PINS PINI ON SIDE

GЕД R S

GЕДR GЕДR

JST

WД SНЕR

SНдFТ

SHIM(S) (AS REQ'O. )

CLUTCH HUB

СдSЕ· TO·COVER

DIFFEREN'HAL СДSЕ caVER

RETAINING SCRE WS

SIOE THRUS T

GЕдR WДSНЕR

-----:1". ,

CENTE R BLOCK (SHORT РINЮN SНДFТ S ЕдТ')

SНдFТ

I I

GЕДR

PINIQN GЕдR THR UST WASHER THRUST

~; .

SIOE GEAR

•

SPR ING РLДТЕ _4ДЗ26

•

••

•

..... ,

.

•

wдSНЕR

CLUTCH EAR GUIOES

STEEL ClUTCH РLдТЕS

RING

GЕДR

RЕТдlНING

BOL тs (10)

Fig. 8.1 3 Exploded view of Traction-Lok limited slip typa differentiel (Sec. 9)

•

Chapter 8 Rear axle

137

I •

Fig. 8.14 Checking the operation of the limited slip facility Traction-Lok differentiallSec. 9)

12 Fault diagnosis -

геа,

оп

Fig. 8.15 Inserting а new stud i"to the 8xleshaft flBnge (Sec. 111

axle

Symptom

Reason/s

Vibration

WОГП

•

axleshaft bearings Loose drive fla"ge bolts

Out-of-balance driveshaft Wheels require balancing Insufficient lubricant Worn оеагз and differential components generally

Noise

'Clu nk'

оп

acceleration

Oill eakage

ог

deceleration

Incorrect crownwheel and pinion mesh Excessive backlash due to wear in crownwhee l and pinion teeth Worn axleshaft ог differential side gear sptines Loose drive 11ange bolts Worn drive pinion fla"98 splines Faulty pinion ог axleshaft oi l seals Blocked axle housing breather

8

•

•

Chapter 9 Braking system Сбпtепts

Bleeding the hydraulic svstem ........................ . Brake master cylinder - dismantling, 8xamination and геаssетЫу Brake master cylinder - removal and installation ............ Brake pedal - removal and installation ................... Brake pedal trBvel- measurement and adjustment ... • •.•... Ca liper anchor plate - removal and installation .......•.•... Fault diagnosis - braking system ................. • .•... FlexibIe hoses - inspection. removal and installation ......... Front and геаг drum brake shoes - adjustment ............. Front and геаг drum brake shoes - inspection, removal and installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front and геаг brake whee l cylinders - removal and Installatlon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front brake disc and hub - removal and installation ......• . .. Front dlsc brake саНрегз (1964 through 1967 models) removal . overhaul and Installatlon . . . . . . . . . . . . . . . . . . • . . . Front disc brake calipers (1968 through 1973 models) overhau l ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . • . . .

2

18 17 19 21 9 26 4 16

11

12 1О

Front disc brake pads (1964 through 1967 models) removal, inspection and Installatlon . . . . . . . . . . . . ...... . .. Front di5C brake pads (1968 through 1973 modeI5)removal, in5pection and installation . . . . . . . . . . . . . . . . . • . . . Front drum brake backplate - removal and In5tallation ........ General desc~iption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Parking brake - adju5tment . . . . . . . . . . . . . . . . . . . . . . . . . . . Parklng brake саЫе - removal and in5t811ation . . . . . . . . . . . . . Pressure differential va lve - centrallzation . . . . . . . . . . . . . . . . Рге5зше differentlal va lve - гетоуа' and In5t8118tion .. ....... Аеаг drum brake backplate - геmоуа' and in5tallation ........ Vacuum 5егуо unit (brake booster) - description . . . ... . . .... Vacuum servo unit (brake booster) - removal and installatlon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wheel cylinders - in5pection and overhaul . . . . . . . . . . . . . . . .

5 7

15 1

22 23 3 20 14

24 25 13

6 8

Specific8tions

System type ..................................... .

Drum brakes all round as 5tandard. with option of servo~assisted front disc brakes

Service brake

• • • • • • • •

• • • • • • • • • •

Hydraulic

Parking brake

• •

•

Mechanical, to

•

•

•

•

•

•

• • • • • • • • • •

• • • • •

•

• • • • • • • • • • • •

• • •

•

•

•

•

• • •

• • • • •

•

• •

•

геаг

wheels only

Drum brakes Diameter . . . . . . . . . . . . . . . . • . . . . . . . . . . • . • . . . . . . . . . . . . . Whee l cylinder diameter . . . . . • . . . . . . . . . . . . • . . . . . . . . . . . . . Drum regrinding limit . . . . . . . . . . • .• . ....•.••.. .• . • . • . . . . Brake 11n1ng wear limit: А iveted ..... ... . . . . • . • . . . . . . . . . . . . • . • . . . . . . . . . . . Bonded . . . . . . . . . . . . . . • . • . • . ... . . . . • . • . . . . . . . . . . .

10 in (254 тт) 1.0 Ёп (25.4 тт) 10.060 in 1255.6

тт}

*0.030

in (0.8 mт ) from top of rivets Ёп (0.8 mт) totallining thickness

Disc brakes Туре :

Models through 1967 ............... • ............... 1968 through 1973 models . . . . . . . . . . . . . . . • . •......... Brake d imensions (fixed callper type): l ining thicknes5 (new) . . . . . . . . . . . . .. .. .• .•. ... •.•.• . . . wear l',т." L·'n'ng Rotor diameteг . . . . . . . . . . . . . . . . . . . . . . . . • . • . . ....... Rotor thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . • . • . • . .. Brake dimensions (floating caliper type): Llning thlckness 10uter) . . . . . . . . . . . . . . . . ..•.•.... .. •.. llning th1ckne5s Оппег) . . . . . . . . . . . . .. ... . . • • • •....• . . . we а г l'1т." . . . . . . . . . . • . . . . . . . . . . . . . . • . • . • . • . . . L·.nln9 Rotor diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rotor thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. ..................... .... .. . .. ... .

Note: Regr/nding the disc brake rotor to the correct fimits requires the use

Four-piston , fixed caliper Single-piston , floating caliper 0.4З6

in 111 .1 тт} 0.066 in 11.8 тт} 11.960 in IЗОЗ.в тт}

1.240

Ёп

О.ЗЗЗ

in 18.5

0.362

Ёп

(31 .5

mт)

тт}

(9.2 тт) О.ОЗО in 10.76 тт} 11.29 in (286.8 тт) 0.935 in (23.7 тт) о! а

special Rotunda finishing

Сооl

and this task should Ье entrusted to

Ford dealer

Master cvlinder Туре

...............•...•.•.•......•.......•.• . •. . .

Воге

• • • • • •

•

•

•

•

•

•

•

• • • •

•

• • • • •

•

•

•

•

• • • • •

•

• • • • •

•

•

•

•

•

•

•

•

Single cylinder (mode ls through 1966) ог tandem cylinder (1967 models onwards)

1.0

Ёп

(25.4

тт)

а

,

i

I

Chapter 9 Braking system Brake pedal Free he'ght (power brakes) Free height (standard brakesJ ..

Peda travel (power brakesJ ... Peda l {гауе' (standard brakesJ

· . · . •

•

. .. .. •

•

.... .

Мах

· . . .

.... . . . .

• • ••

••••••

6.25

· . .. .. . .. . . . . . . . . . . . .. . ....

Torque wrench settings 8 1eed valves (sc rews)

...................• . . . ..

. .....

Hydraulic pipes: Brake hoses . . .. . . . . . . . . . . . . . . . . . . . • . . . . . . . • • • Brake pipe . . . .. . ....... . • , . ..... . • • . .• ,., . , · . • Upper anchor plate bolt (disc) ... . •.... . . . . . •..•.•... • • Lower anchor plate bolt (disc) . . . • . . . . . . . . . . • .•. •.... • • • Parking brake assembIy bolts . . . . . . . . . . . . . . . • . ....... • • • Master cylinder bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . • • • Wheel cylinder bolts . . . . . . . . . . . . . . . . . . . . . . . . . . • . . . • Pressure differential valve mounting nuts and bolts ....•.. Front backplate nuts and bolts . . . . . . . . . . . . . . . . . . . . . . . · . Аеаг backplate nuts and bolts . . . . . . . . . . . . . . . . . . . . . . . • • Servo unit to dashpanel . . . . . . . . . • . . . . . ..•.• ..• . •.. . • • · Parking brake securing bolts .... . ....... . • • •. . •.•... • • • •

• •

• •

• • • •

·. ·. • •

.. • •

~,

,

I

i

!

I ~

1158

ттl

Min 5.56in(141 6.43 in (163

тт)

7.49 ,п (190 тт) 1.75 in (44 тт) 2.58 in (65 тт)

-

lbfft

kgl m

2.5 to 5.5

0.35 to 0.78

12 to 20 10t015 90 to 120 55 to 75 13t025 13t025 5 to 7 7 to 11 9 to 14 20 to 40 13t025 20 to 25

1.6t02.77 1.38 to 2.07 12.4 to 16.60 7.6 to 10.2 1.8 to 3.4 1.8 to 3.4

тт)

•

0.7101.0 1.0t01.53 1.1t02.5 2.77 to 5.5

1.6 to 3.4 2.77 to 3.4 • necessaгy.

I

I

iп

139

1

General description

The standard braking system installed оп the Mustang comprises hydraulically-operated drum brakes оп the front and геаг wheels, with а cabIe-орегаtеd parking brake actuating the геаг brakes only. Front disc brakes and а vacuum brake booster аге optional equipment оп аll models. The front and геаг drum brakes аге virtually identical in design, being self-adjusting with а dual-piston wheel cylinder expanding both shoes. Тhe self-adjuster mechanism comprises а саЫе. саЫе guide, adjusting lever, adjusting screw assembly and ап adjuster spring. The саЫе '5 hooked оуег the anchor pin at the top and is connected to the lever at the bottom, and is passed along the web of the secondaгy brake shoe Ьу means of the саЫе guide. The adjuster spring is hooked onto the primaгy brake shoe and also to the lever. The adjuster operates only when the brakes аге applied and the саг 1З backing-up. Also only when the secondaгy brake shoe is аЫе to тоуе towards the drum beyond а certain limit. Д dual master cylinder braking system is used оп 1967 and later models, and comprises а dual master cylinder, pressuгe differential valve assembIy and а switch . The switch ,з located оп the differential valve and operates а dual brake warning light which Is located оп the instrument panel. Тhe self-centering pressure differential valve аззетЫу body has а stepped Ьоге to accommodate а sleeve and seal which 1з instaHed over the piston and into the large valve body Ьоге in the front brake system агеа .

The brake warning light switch is located at the center of the valve body and the spring-Ioaded switch plunger locates ,п а tapered shoulder groove ,п the center of the piston. When ,п this condition the electrical circuit through the switch 1з broken and the waгning light оп the instrument рапе! is extinguished . The front disc brake assembIy comprises а ventilated disc which , оп application of the brake pedal . is gripped between friction pads housed ,п а cal iper unit. Models prior to 1968 аге equlpped with fouг­ piston fixed caliper disc brakes while !ater models have the single piston floa1ing саliрег type. All models equipped with disc brakes have а proportioning valve in the hydraulic pipeline to the геаг brakes. This maintains а рге­ determined pre5su re ratio between the front and геаг brakes and reduces the possibility 01 the геаг wheels locking-up under heavy braking conditions. 1912 and later Mustangs have а metering valve in the front brake line which prevents the Iront discs from carгying the majority 01 the braking loads at low operating pressures (light brake application), thus extending brake pad li1е.

and top-up il 2 Check аll brake line unions and connections for possibIe leakage, and at the зате time check the condition of the flexibIe hoses which тау have perished. 3 If the condition 01 а caliper ог wheel cy1inder is in doubt, check 10г signs of Iluid leakage. 4 If there is апу possibility that inco rrect fluid has Ьееп used in the system , drain all the fluid out and Ilush through with alcohol. Aenew all piston seals and cups as they wiH Ье affected and could possibIy lail under pressure. 5 Gather together а clean jar. а 12 inch (300 тт) Jength 01 rubber ог pJastic tubing which lit5 tightly оуег the bleed valves and а tin of the correct grade 01 brake Iluid. 6 Оп models with the dual master cylinder the primaгy (Iront) and secondaгy (геаг) hydraulic brake systems аге individual systems and аге therefore bled separately. Always bleed the longest line first. 7 ТО bIeed the secondaгy system (геаг) clean the агеа around the bleed valves and start at the геаг right-hand wheel cylinder Ьу lirst removing the сар оуег the end 01 the bIeed valve. 8 Place the end 01 the tube in the clean jar which should contain sullicient fluid to keep the end 01 the tube submerged during the орега­ tion. 9 Ореп the bIeed valve арргох t turn with а wrench and depress the brake pedal s!owly through its ful l travel. 1О Close the bleed valve and allow the pedal to return to the released position. 11 Continue this sequence until по more air bubbtes issue from the bIeed tube. Give the brake pedal two тоге strokes to ensure that the line is completely free 01 air, and then tighten the bIeed valve. ensuring that the bleed tube remains submerged unti l the valve is cJosed. 12 At regular inteгvals during the bIeeding sequence. make sure that the reservoir is kept topped-up, otherwise air will enter again at this point. Note: 00 not re-use fluid bIed 'гот the system. 13 Aepeat the whole procedure оп the геаг left-hand brake line. 14 То bIeed the primaгy system (Iront), start with the front right-hand side and linish with the Iront left-hand side cylinder. The procedure is identical to that previous!y described. 1 5 Some models have а bIeed valve incorporated in the master cylinder. Where this is the сазе, the master cylinder should Ье bled before the brake liпез. The bteeding procedure is identical to that already described. 16 Top-up the master cylinder to within 0.25 inch (6 тт) of the top 01 the reservoirs; check that the diaphragm type gasket is correctly located ,п the соуег Ье1оге the соуег is installed.

3 2

Bleeding the hydraulic system

1 Aemoval 01 all the air 1гот the hydraulic fluid in the braking system is essential to the co rrect working of the braking system. Веlоге undertaking this task, examine the fluid reseгvoir сар to ensure that the vent hole is clear; also check the level 01 fluid in the reservoir

Pressure differentia! valve - centralization

Models with the dual master cylinder аге also equipped with а рге­ ssure differential valve. Апег апу repair ог bleed operations it is possibIe that the dual brake warning light will il luminate due to the pressuгe differential valve remaining in ап off-center position. 1 То centralize the valve, first turn the ignition switch to the ON оГ АСС position.

9

•

Chapter 9 Braking system

140

2 Oepress the brake pedal several times and the piston should center itself again causing the warning tight to 90 out.

3

Тиг"

CALIPER ASSEMBLY

EXТERNAL

TRANSFER TUBE

the i9nitl0" switch off.

Note: If difficulty is experienced in getting che va/ve Со сепСег, slacken the bIeed уа/уе ОП the brake opposite the опе repaired and press the brake pedal уегу s/ow/y uпtil the waгning fight goe5 оие. Тighten the

CLIP

BLEEDER SCREW •

bIeed уа/уе and Сор-ир the brake fluid /еув!.

4

FlexibIe hoses - inspection, removal and i"8t8118tio"

1

'"speet the condition of the flexibIe hydraulic hoses leading to

8ach of the front brakes and the

опе а1

the front 01 the

геаг

axle. 11 they

аге

swollen, damaged ог chafed, they must Ье renewed. 2 Wipe the top of the brake master cylinder reservoir and unscrew the сар. Place а piece of polythene 5heet over the top of the re5eгvoir and in5tall the cap.This i5 to 5top hydraulic fluid syphoning out during 5ubsequent operation5. 3 ТО гетоуе а flexibIe hose wipe the union and апу supports free fгom dust, and undo lhe union nut5 from the metal pipe end5. 4 Remove the locknut5 and wa5her5 5ecuring each flexibIe h05e end to the 5upport and lift away the flexibIe hose. 5 In5tallation 15 the reverse 5equence 10 removal. 11 wilt Ье neces5aгy to bIeed the brake hydraulic sY5tem as described in Section 2. Оп models with lhe dual ma5ter cyllnder It is only necessaгy to bIeed either the front ог геаг hydraulic 5Y5tem if опе hose has Ьееп renewed.

HUB AND RDТER ASSEMBLY Fig. 9 . 1 Four-piston. fjxed caliper type disc brake (Sec. 5)

5 Fron1 disc brake pads (1964 1hrough 1967 modelsl - remov81. inspectio" and Ёпа1811811оп ТАВ

1 The optional disc brakes оп рге-1968 Mustang5 аге the fourpiston fixed caliper type (see Flg. 9.11. 2 Jack-up the fгont of the саг and support it оп suitabIe jack stands. Remove the roadwheel. Аетоуе the two securing screws and withdraw the pad retaining 3 clips and/or splash shield (see Fig. 9.1 J. 4 Using а targe screwdriver ог tire lever Inserted between the pad shoe and lining. apply а 5teady pressure against the pad 5hoe and force the p1ston5 10 retract into the caliper Ьоге5 . 5 Grip lhe metal flange оп the outer end of each 5hoe using two palrs of pliers and pull the shoes straight out of the caliper a5sembIy

ТАВ

IF;g. 9 .21. 6 ТО install the new pads. ensure that the pistons аге fully retracted into the саНрег Ьогеs and insert the pad5 into the саliрег with the lining surfaces facing the rotor (di5C). Ensure that the shoe flanges seat fully against the caliper bridges. 7 Install the pad retaining clips and/or splash shield and tighten the two securing screW5. Pump the brake pedal 5everal t1me5 to seal the brake pads and 8 check the brake master cylinder fluid level. 9 Install the roadwheel. lower the саг and take It for а short road te5t to check the орегаНоп of the brake5.

Front disc br8ke callpers (1964 through 1967 modelsl 6 remov81. overh8ul8nd l"st8118tio" 1 Apply the parking brake. remove the front wheel trim. slacken the wheel nuts, jack up the front of the саг and place оп flrmly based jack stands. Remove the front wheel. 2 Wipe the top of the ma5ter cylinder reservoi r and unscrew the сар. Place а рЁесе of polythene sheet over the top of the reservoir and ге­ in5tall the сар. 3 Reтove the friction pads as described in Section 5. If It 15 intended (о install new caliper pistons and/or the seals. 4 depre5s the brake pedal to bring the pistons into contact with the di5C and 50 assis't subsequent removat of the pistons. 5 Wipe the агеа clean around·the flexibIe h05e brscket and detach the pipe as described in Section 4 . Таре up the end of the рфе to stop the pos5ibility of dlrt Ingre55. 6 U51ng а screwdriver ог chisel . bend back the tabs оп the locking plste and undo the two caliper ЬodУ mounting bolts. 7 Slide the caliper a5sembIy off the disc and clamp the caliper mounting lugs in а soft-jawed vise. 8 Aemove the hydraulic tran5fer pipe and bIeed vslve.

USE SECOND PAIR OF PLIERS HERE

Fig. 9.2 Removing the brake p8ds - fixed caliper type (Sec. 5) 9 Remove the bridge bolts holding the саНрег a5sembIy together and separate the two halves (see Fig . 9.31. 1О Carefully ргу the four dU5t boots fгom the grooves 1п the pistons and calipers. and remove the boots. 11 Тар the pistons out of the саliрег bores and remove the piston seats using а small bIunt 5crewdriver. Take great саге not to scratch the surface of the callper bores. 12 Thoroughly wash аll parts in alcohol ог clean hydraulic fluid. During reassembIy new seals must Ье fitted ; these should Ье well lubrlcated wlth clean hydraulic fluid. 13 Inspect the piston5 and Ьоге5 for signs of wear, score marks ог damage ; If evident new parts should Ье obtained ог а new caliper obtained. 14 То reassembIe . install опе of the piston 5eals Into the annulus groove in the cylinder Ьоге. " 15 Install the rubber boot in the cylinder Ьоге groove 50 that the lip Is turned outward. 16 Lubricate the seal and rubber boot with correct hydrautic fluid. Push the piston . crown f;rst. through the rubber sealing boot and then into the cylinder Ьоге. Take саге as it i5 еа5У for the pislon to daтage the rubber boot. 17 With the pi5ton half Inserted into the cylinder Ьоге. in5tall the inner edge of the boot into the annular groove in the piston skirt. 18 Push the piston down the Ьоге as far а5 it will go. Secure the rubber boot 10 the caliper with the ci rclip. 19 Install the remaining three pistons and boots u5ing the same procedure. then make а finat check to en5ure that all the boots аге

, Chapter 9 Braking system

141

•

OUTBOAR D CALIPER

DUS T ВООТ RETAIN ING GROQVE _ _ _ _ _~

_ - - - - PISTON SE AL (4)

EXTERNAl OUS T

600Т

,

: . . . _ - - - TRANSFER TUBE

(4 ) - -....~

•

SCREW

P1S1rON (4)

SHOE

дно

LINING ASSEMBLIES

!

I

- - - - - - INO'OAI'O CAllPER HQUSING

1

I

FLEXIBLE

Fig. 9.3 Exploded

CA!.LPER ТО АОТОА

viвw о' fixвd

caliper type brake (Sec. 6)

I_- T",""'" TUB E

PISTQN DUSТ 600Т АЕ Т Д 11'1 IN(; (';АОУ Е

CALlPER """",... .....

P!iTQ<4 _ _ _~

""... --PLSТOН

~

МТ

8001

;:::;::::::}.~

CALIPER: DUST ВО01 АЕТ "IHEP

I Fig . 9 .4 Cross-sвctional viвw о, fixed caliper type brake ISec. 6)

I

correctly located in the piston and caliper grOQves. 20 AssembIe the two c aliper halves together and secu re them with the tWQ bridge bolts. Tighten the bolts to а torque wrench 5ett 1ng of 75 10 105 IЫ ft 110.2 10 14.7 kgf m) . 21 Соппе с ! the hydraulic transfer pipe and bIeed valve to the cal iper, and slide the саliрег i"to position оп the brake disc. Instal l the two caliper retaining bolts a"d tighten them to а torque wrench setti ng of 451060 IЫ ft 16.2 10 8.4 kgf m ). 22 Re con nect the brake hose and instal l the brake pads as described in Section 5. 23 Bleed the braking system as described in Section 2, install the roadwheel and check the brakes for correct operation.

Fig. 9 .5 Single-piston. floati"g caliper type disc brake {Sec. 71

7 Front disc brake pads (1968 through 1973 models) - removal. inspectio n and installation 1 The optional disc brakes insta lled оп 1968 through 1973 Mustangs аге the single-pislon floaling ca liper type (see Fig. 9.5). 2 То remove the brake pads, jack-up lhe front of the саг , support it оп suitabIe jack stands and remove the ro adwheel. 3 Aemove the two bolts securing the caliper assembIy to the anchor plate and lift away the caliper. Support the caliper to avoid straining the flexibIe brake hose (photos). 4 Aemove the two spring retaining clips using а screwdriver. and

9

Chapter 9 Braking system

142

7.ЗА

7.38 lifting away the caliper and Quter brake

Aemoving the caliper securing bolts

7.5 Aemoving the inner brake pad

pad

OUТER SHOE R:EТAINING CLIP5

INN ER BRA KE SHOE AND LINING У O\.JТER

BRAKE

SHOE AND llNING

ASSEMBL '(

PIHON

STABILIZER

~

I

,

OUST

SEAL LOCA TING PIN

~ OUTER SHOE RETA\NING PIN

,

.'. /

MOVABlE CAllPER

, •

ANCHOR PLA ТЕ

~~

('"

IN$ULATQR

~,

CllP

Fig. 9.6 Exploded view of 1108ti"g caliper type brake (Sae. 8) гетоуе

the outer brake pad and retaining pins from the ca liper.

5 Remove the two retaining clips and lift out the in ner brake pad (photoJ, 6 Examine the brake pad lining ; if it has woгn down close to the rivet head а replacement brake pad kit should Ье obta ined from youг Ford dealer. Important: The brake pad kit will also contain new retaining cl ips . insu lator pins. and а stabltizer; these items must Ье used when insta lllng new pads. 7 Push the retaining pins throu9h the outer pad and ca lipe r. and secure [п place with' new spring cJips. 8 Slide the [ппег pad Into position оп the anchor plate and install the two spring retaining clips. 9 Slide the ca liper into posltion over the disc and inner pad; and ali9n the two mounting bolt holes. 1О Install and tlghten both bolts finger-tight, then fully tighten the upper bolt to the speci1ied torque wrench setting followed Ьу the lower bolt . Secure both bolts with locking wire. 11 Check the brake fluid level in the master cyJinder and pump the brake pedal several times to seat the brake pads. 12 Install the roadwheels. lower the са г and take it for а short road test to check the operation 01 the brakes.

8 Front disc brake calipers (1968 through 1973 models) haul

оуег-

1 Refer to Section 7 and remove the caliper, and remove the flexibIe hose as described in Section 4. 2 Wrap а cloth around the саliрег and using compressed air at the hydraulic fluid port carefully eject the pistons. If the piston has seized in the Ьоге carefull y tap around the piston 3 whllst applying air pressure. Remember the piston may come out with some force. 4 Remove the rubber dust Ьоо! from the caliper assembIy. 5 Carefully remove the rubber piston seal from the cylinder Ьоге with ап old plastlc knitting needle ог something similar. 6 Thoroughly wash all parts [п alcohol ог clean hydraulic fluid. During reassembIy new гиЬЬег seals must Ье Installed and these should Ье welllubricated with clean hydraulic 11u1d before Installation. 7 Inspect the piston and Ьоге for signs of wear, score marks ог other damage; if evident а new caliper assembIy will Ье necessary. 8 То reassembIe. first place the new caliper piston seal into its groove in the cylinder Ьоге. The seal must по! Ьесоmе twisted.

Chaptar 9 Braking system

143

оп

jack stands. Аеmоуе the roadwheel. 2 Аетоуе the disc caliper and pads as described Ёп Section 7. 3 Аетоуе the upper and lower anchor plate bolts, and геmоуе the anchor plate. 4 Before instaJting the anchor plate ensure that the mating surfaces of the plate and suspension spindJe аге clean and free from grit. 5 Because of the sheer force they аге subject to, the old anchor plate retaining bolts should Ье discarded and new ones installed. 6 То avoid distorting the anchor plate, the upper bolts sh.ould Ье tightened to the specified torque figure' followed Ьу the lower bolts. Note that different torque figures аге used for the upper and fower bolts (see Specifications).

CALIPfR

,

1 О Front brake disc

~ )" '"'Т Воот , ! - - ANCHOR PLA ТЕ"

Fig. 9.7 Cross-sectional view of flo8ting caliper type brake (Sec. 8) 9 In5t811 а new dust boot and ensure that the flange seats correctly in the outer groove of the caliper Ьоге. 1О Carefulty insert the piston into the Ьоге. When it is about three-

quarters of the way in, spread the dust boot оуег the piston. Seat the dust boot Ё п the piston groove and push the piston fully into the Ьоге. 1 1 ReassembIy is now complete and the unit is ready for installing to the саг . •

9

Ca liper anchor plate - removal and installation

1 Place chocks behind the геаг wheels, apply the parking brake , loosen the front wheel nuts, jack~up the front of the саг and support it

апd

hub - removaf

8пd

inst8118tion

1 Refer to the appropriate Sections, and гетоуе the caliper and anchor plate assembIy. То save extra work and time, if the caliper and anchor plate аге not requiring attention, it is not necessary to disconnect the flexibIe brake hose from the caliper. Suspend the assembIy with string ог wire from the upper suspension агт. 2 Carefully гетоуе the grease сар from the wheel spindle. 3 Withdraw the cotter рЁп and nut lock fгom the wheel bearing adjusting nut. 4 Undo and гетоуе the wheel bearing adjusting nut from the spindle. 5 Grip the hub and disc assembIy and pull it outwards far enough to loosen the washer and outer wheel bearing. 6 Push the hub and disc O"to the spindle, and гетоуе the washer and outer wheel bearing . 7 Grip the hub and disc assembIy and pull it from the whee l spindle. 8 Carefully ргу out the grease seal and lift away the Ёппег tapered bearing from the back of the hub assembIy. 9 Clean out the hub and wash the bearings with gasoline maki"g sure that по grease ог oil is allowed to get onto the brake disc.

1

3

•

I

,,

~ ~

•

15

16 _ - - -17

9 Fig. 9.8 Exploded view 01 fixed caliper disc brake and hub 8ssembIy {Sec. 101

1 2 3 4 5 6 7 8 9 10 11

Spind/e

Gasket Rotor sp/ash shield

Grease sea! 'ппег bearing сапе and roller Rotor Сир НиЬ Сир

Сапе

and roller bearing

Flat washer

12 13 14 15 16 17 18 19 21 22 23

Adjusting nut Lock nut Grease сар Transfer tube /nboard housing

Outboard hоusiпg Саliрег sp/ash

sMeld Shoe and Iining 8ssemb/ies

Dust boots Pistons Piston seals

-

•

Chapter 9 Braking system

144

CALIPER

РДIПS

•

CALIPER

FAIRLANE, MONTEGO, MUSТANG A.НD

Д55'У

FALCOН,

COUGAR

CLIt.,,_.....~

IHNER BEARING СОНЕ АНО ROLLER

ее.

дNCHOA

PlATE

СОНЕ АНО

HUT LOCK

GASI(EТ .......~

АОТОА

ROLLER NUT

~

SPLASH SEAL

WASHER

"DJUSTING NUT

Fig. 9.9 Exploded view offloating caliper disc brake and hub BssembIv ISec.101 1О Thoroughly clean the disc and inspect 10г signs of deep scoring ог excessive corrosion . 11 these аге evident the disc may Ье reground but the minimum thickness 01 the disc must not Ье less than the figure given in the Specifications. It is desirabIe however, to install а new disc

jl at аВ possibIe. 11 ТО reassembIe, first work а suitabIe grease well into the bearings; fully pack the bearing cages and roller5. 12 То reassembIe the hub install the 1ппег bearing and then gently tap the grease seal back Into the hub. А new seal must always Ье used as, during removal, the other опе was ргоЬаЫу damaged. The tip must face inward to the hub. 13 Install the hub and disc assembIy onto the spindle keeping the assembly centered оп the spindle 10 ргеуеп! damage to the inner grease seal ог the spindle threads. 14 Place the outer wheel bearing and flat washer оп the spindle. 15 Screw the wheel bearing adjusting nut onto the spindle and tighten finger-tight so that the hub and disc will still rotate freely. 16 Now tighten the nut using the method described in Chapter 11 . and secure it with а new cotter pin and locknut. 17 Install the brake саliрег and pads using the reverse procedure 10 removal.

11 Front a"d i"st8118tion

гваг

drum brake shoes - inspection, removal 8nd

The front and геаг drum brakes аге basically the same design with the exception that the геаг brakes аге equipped with а parking brake mechanism. The following procedures apply to both the front and геаг brakes, but references to the parking brake linkage obviously apply to the геаг brakes only. 1 Chock the front ог геаг wheels as appropriate. jack-up the саг and support оп firmly based jack stands. Aemove the roadwheel. 2 Аетоуе the three Tinnerman nuts and remove the brake drum (photos). 3 If the drum wil l not соте off, remove the гиЬЬег соуег from the brake backplate and insert а narrow screwdriver through the slot. Oisengage the adjusting levBt from the adjusting screw. 4 Whilst holding the adjusting lever away from the screw, back off the adjusting screw with either а second screwdriver ог shaped piece of metal as shown in Fig. 9.1 1. Take саге not to Ьигг . chip ог damage the notches in the adjusting screw. 5 The brake linings should Ье renewed if they аге so worn that the lining is only proud of the rivets Ьу about 0.03 in (0.8 mm) ог will Ье before the next routine check. If bonded linings аге used they must Ье renewed when the lining material has worn down to 0.06 in (1.6 mm)

СОУЕА

at its thinnest part. 6 ТО remove the brake shoes detach and гетоуе the secondary shoe-to-anchor spring and 11ft away the spring. 7 Detach the primary shoe-to-Bnchor spring and lift away the spring. 8 Unhook the adjusting саЫе еуе from the anchor pin. 9 Aemove the shoe hold-down springs (photo) followed Ьу the shoes. adjusting screw, pivot nut, socket and automatic adjustment parts. 1 О Аетоуе the parking brake link and spring. Oisconnect the parking brake саЫе from the parking brake lever. 11 After the secondary shoe has Ьееп removed, the parking brake lever should Ье detached from the shoe. 12 1I is recommended that only опе brake assembIy is overhauled at а time untess the paгts аге kept welf apart. This is because the brake shoe adjusting screw assembties аге not interchangeabIe and, il interchanged, woufd in fact operate n reverse, thereby Increasing the drum-to-tining clearance еуегу time the саг is backed ир . 13 То prevent апу mix ир the socket end of the adjusting screw is stamped with ап ' А ' ог ' l '. The adjusting pivot nuts сап Ье identified Ьу the number of grooves machined around the body of the nut. Two grooves оп the nut indicate а right-hand thread and опе groove indicates а left-hand thread. 14 If the shoes аге 10 Ье left оН for а while, place а warning оп the steering wheel as accidental depression 01 the brake pedal will eject the pistons from the wheel cylinder. 15 Thoroughly clean all traces of dust from the shoes, backplate and brake drums using а stift brush . Excessive amounts of brake dust сап cause judder ог squeal and it is therefoгe important to remove afl traces. It is recommended that compressed air is not used for this operation as this increases Ihe possibility of the dust being inhaled. 16 Check that the pistons аге free in the cylinder, that the rubber dust covers аге undamaged and in position . and that there аге по hydraulic fluid leaks. 17 Prior 10 reassembIy smear а trace of brake grease оп the shee support pads, brake shoe pivots and оп the ratchet wheel face and threads. 18 То reassembIe just insta1l the parking brake lever to the secondary shoe, and secure with the spring washer and retaining clip, 19 Place Ihe brake shoes оп the backplate and retain with the holddown springs. 20 Install the parking brake link and spring. Slacken оН the parking brake adjustment and connect the саЫе to the parking brake lever. 21 Install the shoe guide (a nchor pinJ plate оп the anchor pin (where applicabIe). 22 Place the саЫе еуе оуег the anchor pin with the crimped side towards the backplate.

,-----------------------------------------------------------------,45 SНO E

РА~( I!'К;

SНOE

GUI DE (ANCHQR PIN ) PLATE

GUIDE (ANCHOR PI

PLATE

PRIMARY SHOE· TO.ANCHOR

CABLE ANCHOR

PARKING BRAKE

FIТТING

ANCHOR PIN

BRAJ<E LEVER RE1'A . -rнe

..

FORWARD

..

FORWARD

SECONDARY ::ОНОЕ. TO.ANCHOR

BRAKE

SHOE HOLD·QOWN

i,

PRIMARY $НОЕ

SHQE

PARКlNG

BRAKE

PARK ING

C';BlE ' HOUSING

LE VER

RETAINER

CABl E НОО К

REAR ВRЛКЕ

CABL'i: ANO HOUS ING

BRAKE

ADJUSTER SPRING

FRONT BRAKE

ADJUSТER

SPR\NG

SCREW

Fig. 9.1 О Front and геаг drum brakes (Sec. 11 J

-.•

HANDLE UP WARD

RETRACT BRAKE SHOES

11 . 2А Опе

of the Tinnerman type nuts securing the brake drum

11.28 Front brake drum removed; note that the hub assembIy has al50

Ьееп

easier access to the shoes

removed to provide

Fig . 9.11 Method of slackening the fro"t and

гваг

brake shoes (Sec. 11)

AOJVS TIN G LEVE R

~()~

IDENTIFICATIQN LINES

11.9 Removing

а

shoe retainer

Fig. 9.12 Component parts of brake shoe adjuster (Sec. 11)

9

•

Chapter 9 Braking system

146 23 Ins1stl the

primaгy

24 Inslatl the

саЫе

shoe 10 anchor spring.

38 InstaH the brake drum and roadwheel , lower the

guide inlo the secondary shoe web with the

f1anged hole fitted 1nlo the hole in the secondary shoe web. Thread the саЫе

around the

саЫе

guide groove. 1I i5 уегу important that the

саг

to the ground ам take it for а short road test to check the operation of the parking brake and/or footbrake .

саЫе

i5 positioned in this groove and not between the guide and the shoe

12 Front and гв8Г drum brake wheel cylindars - гетоуаl and inst8118tion

web. 25 Inslstl the secondary shoe 10 anchor spring.

26 Check that the

саЫе еуе

i5 not twisted

pin when installed. Atl parts must

27 Apply

зоте

Ье

flat

оп

ог

blnding

оп

the anchor

the anchor pin.

brake grease 10 the threads and socket end of the

adjusting screw. Тигп the adjusting screw inlO the adjusting pivot nut fully and then back off t tuгп. 28 Рlэсе the adjusting socket оп the screw and install this assembIy between the shoe ends with the adjusting serew toothed wheel nearest to the seeondaгy shoe. 29 Hook the саЫе hook into the hole (п the adjusting lever. The adjusting levers аге stamped with ап 'R' ог 'L' to show their correct position оп the left ог right brake assembIy (photo), 30 Position the hooked end of the adjuster spring completely into the large hole in the primary shoe web. The last соВ of the spring must Ье at the edge of the hole. 31 Connect the 'оор end of the spring to the adjuster lever holes. 32 РиН the adjuster lever, саЫе and automatic adjuster spring down and towards the геаг to engage the pivot hook (п the large hole (п the secondary shoe web (photos). 33 After геаззетЫу check the action of the adjuster Ьу pulling the seetion of the саЫе between the саЫе guide and the anehor pin towards the seeondary shoe web far enough (о lift the lever past а tooth оп the adjusting serew wheel. 34 The lever shou ld snap into position behind the next tooth, and releasin g the саЫе should cause the adjuster spring 10 геlигп the lever to its original position. This return motion of the lever will turn the adjusting serew опе tooth. 35 If pulling the саЫе does not produca the desired action, ог if the lever action is sluggish instead of positive and sharp, check the position of the lever оп the adjusting serew toothed wheel. With the brake unit (п а vertica l position (the anchor pin at the top), the lever should con ta ct the ad justing wheel 0.1875 in (4.763 mm ) + 0 .0313 in (0.794 mm ) above the center 11пе of the screw. 36 Should the conta ct point Ье betow this centerline lever will not lock оп the teeth (п the adjusting screw wheel, and the screw will not Ье turned as the leve r is actuated Ьу the саЫе. 37 Ineorrect action should Ье checked as follows : (а) Inspect the саЬ!е and fittings. They should completely (iII ог extend slightly beyond the crimped section о( the fittings. If rhis is not so, the саЫе assemb!y should Ье renewed (ь) Check the саЫе length. The саЫе should measure 8.41 in(213. 5 тт) (гот the end о( the саЬ!е anchor to the end о( the саЫе hook (с) Inspect the саЫе guide (ог damage. The саЬ!е groove should Ье parallel со the shoe web, and the body о( the guide shoufd lie Паl against the web. Renew the guide i( it is damaged (d) Inspecr the pivot hook оп the Jever. The hook suгfaces should Ье square to the body о! the Jever {ог correct pivoting action. Renew the lever if the hook shows signs о( damage (е) Check that the adjustment screw socket is correctly seated in the notch ,"п the shoe web

11.29 СаЫе cortectly hooked onto the adjusting lever

.

1 Refer to the previous Section and remove the brake shoes as described (п paragraph 1 through 11 . If working оп the геаг brakes. slaeken the brake pipe union from 2 the геаг of the wheel cyllnder. Do not pull the pipe away from the cylinder as It will bend, making Installation dlffieult. 3 Оп the front brakes, disconnect the (ппаг end of the flexibIe brake hose аз described (п Section 4 . then unscrew the other end of the hose from the wheel cylinder. 4 Undo and remove the two bolts securing the wheel cylinder to the brake backplate assembIy. 5 Lift away the ге аг wheel cylinder assembIy. Plug the end 01 the hydraulic pipe to stop loss of too much 6 hydraulic fluid. 7 Installatlon of the wheel cylinder is the reverse sequence to removal. It will Ье neeessary to bIeed the brake hydraulic system as deserlbed in Section 2.

1 3 Wheel eylinders - inspection and overhaul 1 Aemove the wheel cylinder as described in the previous Section. 2 То dismantle the wheet cylinder, first remove the rubber boot from each end of the cyHnder and push out the two pistons. сир seals and return spring (see Fig. 9 . 1 3) . Inspeet the pistons for signs of sco ring ог scuff marks; If thesa аге 3 present the pistons should Ье renewed. 4 Examine the inside of the cylinder Ьоге for score marks ог соггоslon. If these eonditions аге present the cylinder should Ье renewed. If the eylinder is sound , thoroughly clean It out with alcohol ог 5 fresh hydraulic fluid. 6 Remove the bIeed screw and check that the hole (з clean. 7 The old rubber cups will ргоЬаЫу Ье swollen and visibIy worn. Smear the new rubber cups with clean brake ftuid and insert опе Into the Ьоге followed Ьу опе piston. 8 Place the return spring (п the Ьоге and push it until it contaets the (еаг of the first seal. 9 Install the second seal and piston into the cylinder Ьоге. 1О Install the two rubber boots. 11 The wheel cylinder Is now ready for installation to the brake backplate.

14

Аваг

drum br8ke b8ckplate - ramoval and inst8118tion

1 Refer to Section 11 , and remove the brake shoes and wheel cylinder from the backplate. 2 Dlsconnect the parking brake lever 1rom the саЫе. 3 Refer to Chapter 8 and remove the axleshaft. 4 Disconnect the parking brake саЫе retainer 1гот the backplate.

11.32А Correct installation 01 adjusting lever.

spring and

саЫе

11.328 Loeation of lever оп adjusting screw

Chapter 9 Braking system

147 ВООТ

cup

•

BLEEDER

PIS,.ON

SlREW

RE TURN SPRING AND cUP EXPANDER A$SY.

Fig. 9.13 Drum brake wheel cylinder components (Sec. 1 З) 5 The bach.pl,·te and gasket тау now Ье lifted away from the end of the axle housing. 6 Insta llation of the brake backplate is the reverse sequence 10 removal. It will Ье necessary 10 bIeed the brake hydraulic system as

described in Section 2. Do not forgel 10 top-up the necessary.

геаг

axle oillevel if

15 Front drum brake backplate - removaJ and installation 1 Remove the brake shoes аз described in Section 11 and the wheel cylinder as described in Section 12. , 2 Remove the bolts securing the ЬаСkрlзtе 10 the wheel spindle assembIy, and lift оН the backplate and gasket. 3 Installation of the brake backplate is the reverse sequence to removal. 1I will Ье necessary to bIeed the brake hydraulic system as described in Section 2.

16 Front and

Г8аг

drum brake Sh08S - adjustment

Automatic adjusters аге used оп drum brakes and these орегасе when the саг is backed-up and stopped. Shoufd саг use Ье such that it is пос backed-up уегу ofcen and the pedal mоуеmепС has increased, then i t wiIJ Ье necessary (о adjust the brakes as follows: 1 Drive Ihe саг rearward and apply the brake pedal firmly. Now drive il forward . and again аррlу the brake pedal firmly. 2 Repeat the сус lе until а desirabIe pedal movement is obtained. Shou ld this not happen, however, it will Ье necessary to гетоуе the drum and hub assembIies and inspect the adjuster mechanism as described in Section 11, paragraph ЗЗ thгough 37.

17 Brake master cylinder -

гетоуаl

and installation

1 For safety reasons, disconnect the battery. 2 W ithdraw the hairpin retainer and slide the stoplight switch off the brake pedal pin just sufficently for the switch outer hole tQ clear the pin . Lower the switch away 1гот the pin. Lift the switch straight ир fгom the pin laking great саге поl to damage the switch. 3 Slide the master cy linder pushrod, and the nylon washers and bushes fгom the brake pedal pin. Note : Оп earlier models w;ch the single master cylinder it is пос necessary СО гетоуе the pushrod (гот the brake pedal; simply гетоуе the гиЬЬег Ьоос (гот the геаг о( the masCer c ylinder со епаЫе the pushrod Со slide !гее when the cylinder is removed. This procedure a/so applies (о а" models with а brake servo

18 Brake

master

cylinder

-

dismantling,

examination

and

reass8mbIy The !ollowing overhaul procedures аге app!icabIe со boch s;ngle and dual masler cy!inders; however оп che single Суре master cylinder there is по slop screw and оп/у опе piston assembIy. 11 а reptacement master cylinder is to Ье instalted. it will Ье necessary to lubricate the seals before installing to the саг as they have а protective coating when originally assembIed. Аетоуе the blвnking plugs from the hydrauli c pipe union seatings. Inject some clean hydraulic fluid into the master cylinder and operate the pushrod several times so that the fluid spreads оуег а" the internal working surfaces. If the master cylinder is to Ье dismantled after гетоуаl proceed as follows: 1 Clean the exterior of the master cylinde r and wipe dry with а lintfree cloth. Аетоуе the filler соуег and diaphragm (gasket) 1гот the top 01 the 2 reservoir and pour out апу remaining hydraulic fluid. 3 Undo and геmоуе the secondaгy piston stop bolt from the ЬоНот of the master cylinder body. 4 Undo and гетоуе the bIeed screw. 5 Depress the primary piston and гетоуе the snap-ring from the groove at the геаг of the master cylinder Ьоге (Fig. 9.14). 6 Аеmоуе the pushrod and the primaгy piston assembIy. Оо по! remove the screw that reCa;ns the primary return spring геСа;пег, геСиrn spring, primary сир and protector оп che primary piston. This is !actory set and mUSl not Ье disturbed. 7 Аеmоуе the secondary piston assembIy. ОО поС гетоуе the outlet pipe seats, outlet check valves and outlet check уа/уе spr;ngs (гот the master cyfinder body. В Examine the Ьоге of the cylinder carefully for апу signs of scores ог ridges. If this is found 10 Ье smooth all оуег new seals сап Ье installed. If however. there i5 апу doubt of the condi tion 01 the Ьоге then а new ma5ter cylinder must Ье obtained. 9 If examination of the seal5 shows them to Ье apparently swollen о г уегу loose оп the pistons. suspect oil contamination in the system. ОН will swell these rubber 5eals and if опе i5 found {о Ье swollen it is геа50паЫе to assume that а" 5eals in the braking system will need attention. 1О Thoroughly clean all part5 in clean hydraulic Iluid ог alcohol. So""

P/iers

9 SNДP

ип;С.

Unscrew the brake pipe fгom the master cylinder outlet port (two оп the dual master cylinder). Plug the end of the pipe(s) to prevent diгt ingress and take suitabIe pr8cautions 10 catch the hydrauHc l1uid as the pipe(s) is ( аге ) removed from the master cylinder. 5 Undo and гетоуе the two screws securing the master cylinder to the dashpanel (ог servo unil). 6 Pu ll the master cyl inder forwards and lift it upward lгот the саг. 00 ПОl allow brake fluid to contact апу paintwork as it acts as а solvent . tnstall the master cylinder using the reverse procedure to rem oval. 7 Jt will Ье necessary to bIeed the hydraulic system as described in Section 2. 4

Fig. 9.14 Removing the master cylinder snap-ring (50С. 18)

•

•

1~ ----------------------------------------------------------------~

FI~~

SECONOARY CUP /

GASKET OUТLET

PISTON

,

СНЕСК

I

PRIMARY CUP

VALVE VALVE

FIТТING

,

LOCKWASHER

Fig. 9.15 Exploded view of single master cylindef (Sec. 18)

СОУЕА

/ ' RETAINER

·PRIMARY PISTON ASSEMBLY SPRING RETURN R NER RETURN SPRING

РАОТЕСТОА

FRONT ВААКЕ SYSTEM OUTLETr

\

,

MASTER CYLINOER

\ RETURN SPRING

CUP SNAP

R

O-RING

АЕАА ВААКЕ

SYSTEM

CUP

OUТLET

BOLT SECONOARY PISTON STOP

·seCONDARY PI ASSEMBLY

Fig. 9 .16 Exploded view 01 dual master cv1inder (Sec. 18)

'REPLACE AS ASSEMBLY ONL У

SNAP RING

Chapter 9 Braking system

,

Ensure that the ports аге cleat. 11 All components should Ье assembIed wet after dipping 'п fresh brake fluid. 12 Carefully inseгt the complete secondary piston and return spгing assembIy inlo the master cylinder Ьоге, easing the seals inlo the Ьоге .

taking

саге

tnat they do not roll

оуег.

149

ВRАКЕ

WARNING LIGHT SWITCH

Push the assembIy fully home.

13 Insert the primary piston assembIy inlo the master cylinder Ьоге. 14 Depress the primaгy piston and install the snap-ring inlo the cylinder Ьоге groove. 15 Inslall the pushrod, boot and retainer onlo the pushrod and push the assembIy ,ПlО the end of the primary piston. Check lhal the retainer correctly seated and holding the pushrod securely. 16 Place the ,ппег end of the pushrod Ьоо! ,п the master cylinder body retaining groove. 17 In5tall the secondary piston stop bolt and 0-rin9 into the bottom of the master cyl inder body. 18 In5tall the diaphragm into the filler соуег makin9 5ure that it i5 correctly 5eated , and install the соуег. Secure in position with the 5pring retainer.

RЕАR ВRАКЕ

INLET

FRONT ВААКЕ INLET FROM MASTER CYLINDER

FROM MASТER CYLINDER

'5

OUTLET ТО LEFT FRONT ВRАКЕ

19 8rake pedal - removaland installation Маnиаl tгansmission models 1 Аетоуе the clutch cable retaining clip and

гетоуе

the cable from

the clutch pedal. 2 Oisconnect the 5toplight 5witch wire5 at the connector. 3 Аетоуе the switch retainer and 5lide the stoplight 5witch f,om the brake pedal pin just sufficiently for 1he 5witch outer hole to clear the pin. lower the switch away from the pin. 4 Slide the ma5ter cylinder pushrod . пу10П washers and bush from the brake pedal pin. 5 Аетоуе the self-Iocking nut and washer from the brake and clutch pedalshaft . 6 Аетоуе the clutch pedal and shaft assembIy. Follow this with the brake pedal assembIy and bushes from the pedal support bracket . 7 Installation of the brake pedal is the reverse sequence to rem oval but the following additiona l points should Ье noted: (а) Check and jf necessary adjust the clutch pedal free-play 8S described in Chapter 5 (ь) Check and if necessary adjust the brake pedal free-play 8S described in Section 21 (с) Lubricate а" moving paгts with а littlе grease А utomatic tгansmission

models

8 9

I

Oisconnect the stoplight switch wires at the connectOT. Withdraw the hairpin retainer and slide the stoplight switch off the brake pedal pin just sufficiently for the switch ouler hole 10 clear the pin. lower the switch away fгom the pin. 1О Slide the master cylinder pushrod, nylon washers and bush from the brake pedal pin. . 11 Аетоуе the self-Iocking nut and washer from the brake pedal shaft . 12 Аетоуе the shaft, the brake pedal and the bushes Iгот the pedal suppoгt bracket. 13 Installation 01 lhe brake pedal is the reverse sequence to removal, but the following points should Ье noted: (8) Check and ,-, necessary adjust the brake peda/ free -play as descr'-bed in Section 21 (ь) Lubricate 8/1 mоу'-пу parts with а little grease

ТО RЕАR

BRAKES

ТО

FRONT

RIGHT

ВААКЕ

Fig. 9.17 Cross-sectional view of brake pressure differential valve (S8C. 201 hydraulic system аз described in Section 2, and possibty centralize the ргеззuге differential valve as described in Section З.

21 Brake pedal travel - measurement and

adju5tmвnt

1 When the parking brake 1з fully released measure the brake pedal free height Ьу first inserting а needle through the ca rpet and sound deadening felt until it contacts the metal dashpanel. 2 Measure the d1stance between the brake pedal to the metal dashpanel. This should Ье within the pedal height limits given in Specifications. 3 If the measurement obtained 1s not within the specilied limit check the brake pedal linkage for missing , worn ог damaged bushes, ог loose securing bolts. Rectify аз песеззагу . 4 11 the measurement is still incorrect then the master cylinder should Ье checked to зее 1f it has Ьееп correctly reassembted after overhaul. 5 То check the brake pedal travel measure and record the distance from the pedal free height position to the datum point which is the six o·clock position оп the steering wheel г1т. 6 Оергезз the brake pedal and take а 5econd reading. The d1fferences between the brake pedal free -he1g ht and the depressed

Steering Wheel Rim

-

9

ct.

Steering Column

20 Pressure differential valve - removaland installation 1 Di5connect the ~rake warn ing Hght connector from the warning light switch. 2 Disconnect the frOnl inlel and ге аг outlet pipe unions from the valve assembIy. Plug the ends 01 the pipes 10 prevent loss of hydraulic fluid ог diгt ingress. 3 Undo and гетоуе the two nuts and bolts securing the valve bracket {о the under5ide of the wing аргоп . 4 lift away the valve and bracket taking саге not to allow апу brake fluid to contact paintwork, аз it acts аз а solvent. 5 The valve cannot Ье overhauled ог repa ired. зо if its performance is suspect а new unit will have to Ье obtained and installed. 6 In5talla1ion 01 the pressure differential valve and bracket 1з the reverse sequence to removal. It will Ье песеззагу to bIeed the brake

NORMAL POSIТION ' (CENTEREDI

Chесkiлg

POints

Vertica1

ct.

Steering Column Steel Measuring

Таре

•

Gage Surface Fig. 9.18 Brake pedal free travel and height adjustment (Sec. 21)

!!j

CABLE A ~SE M BL У

PRONGS MUST ВЕ SECUREL У 'LOCKEO IN PLA CE

OUAL EXHA UH

з

----

REQ O.

12-25

,

LB-FТ

CONTR OL

.,-. .........

HAIRPIN

, V""""' " REТAINER

$INGL E eX HAUST

VIEW V

~,

VIEW W

,

V'EW U

"

./

.. ---

,'..Т,jl

"-

-• ./

CABLE BALL RПАINING CL IP

,

I;

IJ-

, CONNE CT QR

VIEW;. 1J

V'EW U

liL:/J

S

--

MUSТANG СЖLУ

:1' 1 ., V 'EW

BOW IN CONOUl"J MUS"J ВЕ IN BOARO

VIEWV

LIN K

I

•

,

V'EW W CONNE C"JOR COUGAR ONLY

HAIRPIN RE1AI NER

VIEW

У

VIEW

CABLE A$SEItIBL У СА &.Е ............

I: VIEW

~

CAB LE A$SE MBL у

CABLE A$SEMB L У ~~

ЕХТЕ Н $IQН SIDE MEMBER

Х

JAM NU"J 7-'0 LB_ fT_

Т

: '; \ j

~"

V'EW Z

,,

CABLE ASSE MBL У

, '

\

.

ADJUSТING NUT

HAIRPIN REТA I HER eQUAL IZER

.'"

I

1:

I

V'EW У

Ь'~, ~ . _ ..

VIEWZ

Fig. 9.19 Layout of parking brake and ,

саЫе.

pedal operated type ISec. 23)

VIEW 11'4 CIRCLE R ТYP'CAL 2 PLACES CQНVERTIBLE OНL У

Chapter 9 Braking system

,

I

ре1 а

,

5рес . fic.atюns. 7 If фе pedal

,

measurem ent shoutd

travel is

Ье

тоге

within the pedal travel figure given in

than that specified . adjust the brakes

85

described in Section 16. Shoukt this stШ not produce the desired results the drums will naУе 10 ье removed 10 check that the linings аге not badly worn and thз! the automatic adjusters аге operating correctly. Rectify апу faults Ioond. 8

the 5econdary brake shoes. 9 Compres5 lhe саЫе retainer prongs and pull the саЫе ends from the backplate5. 1О In51allation of the parking brake саЫе i5 the геуеГ5е 5equence to removal. It will Ье nece5sary to adju5t lhe parking brake as de5cribed in Section 22.

,

24 Vacuum зегуо unit (brake boosterl - descr1ption

22 Perking brake - adjustment

, 965 model Mustangs were equipped with а hand-operated par/(ing Ьгвке while 1966 and later mйdels were equipped with 8 pedaJ-

r

I

operated parking ЬгвКе. 1 То adjusI the brake ОП 811 models, first bIock the front wheels, jackup the (еаг of the саг and su pport it оп firmly-based jack stands. 2 Оп 1965 models. fully Г81еазе the parking brake and then pull the handle up until the third 'cl ick' is heard, Leave the handle in this posilion, 3 Оп laler models equipped with а foot-operated parking brake , fully release the brake pedal and then depress it опе 'cl ick' from the released position. Note that оп уасииm release brakes the firsl click occurs апег approximately 2 in (50 mт) of travel . 4 Оп all models, slacken the locknut оп the brake саЫе equalizer and lurn the adjuster nut untll the brake cabIes аге just taut enough to саи зе Ihe геаг wheels to drag slightly when rotated Ьу hand. 5 Тighten the equalizer locknut, release the parking brake and check that the геаг wheels rotate freely. 6 Lower the с аг and check the operation of the parking brake.

23 Parking brake

саЫе

151

- removaland in5t811at1on

1 Block {he fгo n t wheel5, jack-up the геаг of the саг and support оп firmly-based jack stands. Аетоуе the wheels. 2 Refer 10 Section 9 and гетоуе the brake drums. 3 Release the parking brake and back-off the adju5ting nut. 4 Аетоуе the саЫе from the equatizer. 5 Аеmоуе the hairpin clip5 and pull the саЫе through the chas5i5 bracket5. 6 Оп model5 equipped with а foot-operated parking brake, release the front 5ection of the саЫе fгom the pedal a5sembIy Ьу removing the spring сliр (See Fig. 9.19) 7 АетОУе lhe 5elf-adjuster 5prings and гетоуе the cable retainer5 "от the brake backplate. 8 Oisconnect the ends of the cabIes fгom the park ing brake levers оп

1 Д vacuum servo unit тау Ье in51aHed in the brake hydraulic circuit in series with the master cylinder, 10 provide a5si5tance to the driver when the brake pedal i5 depre55ed. Thi5 reduce5 the effort required Ьу the driver 10 operate the brake5 under all braking condition5. 2 The unit operates Ьу vacuum obtained from the intake manifold and comprise5 basically а booster diaphragm and check valve. The servo unit and hydraullc ma5ter cylinder аге connected together so that lhe servo unit pislon rod acts а5 the master cylinder pU5hrod. The driver'5 braking effort is lransmilted through another pushrod to the 5егуо unit pi5ton and 115 built in control 5Y5tem. The servo unit piston does поl fit tightly into the cylinder, but has а strong diaphragm to keep ап air-tight seat between the two parts. The forward chamber i5 held under lhe vacuum conditions created in the in take manifold of the engine, and during periods vyhen lhe brake pedal i5 not in use, the соп ­ trols оре п а passage 10 the геаг chamber, so placing it under vacuu m condilions as well. When the brake peda l is depre55ed, the vacuum passage 10 the геаг chamber is cut off and lhe chamber opened to atm05pheric pressure . The consequent pressure differenlial pushes the servo piston forward in the vacuum chamber and operates the main pushrod to lhe master cylinder. 3 The controls аге designed 50 that a5sistance i5 given under alt соп­ ditions and , when lhe brakes аге not required, vacu um in the геаг chamber i5 e5tabIi5hed when the brake pedal is released . Atl air from the almosphere entering the геаг cha mber is pas5ed through а smalt air filler. 4 Under погта! operating conditions the vacuum seгvo unit wi ll give tгоubIе-fгее seгvice for а very long time . If however, it i5 suspected that lhe unit is faulty Не increase in foot pressure is required to apply the brakes) it must Ье exchanged for а new unit. No attempt should Ье made 10 repair the old unit as il is not а repairabIe ite m.

25 Vacuum

зегуо

unit (brake boosterl - removal and i"518118tion

1 Ает оуе the stoplight switch and actuating rod from the brake pedal as described in Section 17 .

SPRING

т

СlИТСН ASSIST

I

8USHING

BRAKE PEDAL SHAFT

WAYE WASHER CLIP

ClUTCH

, I

VACUUM HOSE

•

PEOAL 8UMPER STOP

пI BOOSТER

CYLINDER

STOPllGHT SWIТ CH

СШТСН

PEDAL то EQUAllZER ROD

Fig . 9.20 Exploded view 01 уасиит 5вгуо unit (Sec. 24)

9

Chapter 9 Braking 8Y8tem

152

2 Working under the hood, remove the air cleaner from the саг­ buretor and the vacuum hose from the servo unit. 3 Refer to Section 17 and гетОУ8 the master cylinder. 4 From inside the саг, гетоуе the nuts securing the servo unit to the

forward unt;1 the 8ctuating Гod is clear 01 the dаshрапеl , rot8te it through 900 and lift the unit upward until clear 01 the engine compart-

dashpanel.

It will Ье necessaгy to bIeed the brake hydraulic system as described in

5

Working inside the engine compartment,

тоуе

ment. 6 '"st81Iatio" 01 а new servo unit is the

геуегзв sequence

to removal.

Section 2.

the servo unit

26 Fault diagnosi. - braking sy_t8m Before diagnosing faults

'гот

the following chart, check that зпу braking irregularities

аге пос

caus8d Ьу:

1 ипеуеп and incorrect tire pf8ssur8S 2 Incorrect 'mix' о, radisl snd crossply tires 3 Wear in the steer;ng mechsnism 4 De'ects;n the suspension end dampers 5 MisaJignment о, the bodyfrsme

Symptom

Pedal travels

R8.80n!8

а

long way

Ьеlогв

Brake shoes set too

the brakes operate

,

Stopping abllity роог, еуеп though pedal pressure is f1rm

lаг

Irom the drums (auto adjusters seized)

,

Linings, discs ог drums badly worn ог scored Опе ог more wheel hydraulic cylinders seized, resulting in some brake shoes not pressing against the drums (ог pads against di8CS) Brake linings contaminated with oil Wrong type 01 linings litted (too hard) Brake shoes wrongly assembIed Servo unit not lunctioning

Саг

veers to опе side when the brakes

аге

Brake pads ог lining8 оп опе side аге contaminated with оН Hydraulic wheel cylinder(s) оп опе 8ide partially ог fuHy seized Д mixture 01 lining materials litted between sides Brake discs not matched Unequal wear between sides caused Ьу partially seized wheel cylinders

applied

,

Pedal feels spongy when the brakes

аге

applied

Air is present in the hydraulic system

Pedal leels springy when the brakes

аге

applied

Brake linings not bedded into the drums (after fitting new ones) Master cylinder ог brake bacJwIMe mounting bolts 'оозе Severe wear in brake drums causing distortion when brakes аге applied Discs out 01 true

Pedal travels right down with little vi rtual ly non-operative

8 inding, juddering, overheat ing

ог по

resistance and brakes

аге

Leak in hydraulic system resulting in lack 01 pressure for operating whee l cylinders 11 по signs of le8kage аге apparent the master cylinder interna l seals аге 18iling to sustain pressure Опе ог а

comblnation of reasons given in the foregoing Sections

1

I

\

•

Chapter 1 О Electrical syst m Con1ents

l

I

,

A !ternator brushes - removal, inspection and in5tallat1on ...... A!temator - fault diagnosis and repa ir . . . . . . . . . . . . . . . . . . .

11 1О

Alternator - general description . . . . . . . . . . . . . . . . . . . . . . . .

6 7

AJternator - maintenance .. ..... ,. ... . . . .... . . . . .. ... AJternator - гетоуаl and in51allat1on ...... ,.. . .......... Alternator - special procedures ., ....... , . . . . . . . . . . . . . . Вапе гу - cha rging .... .... .... ..... • ........ • . • . •. . Взttе гу - electrolyte replenishment . . ... .• • • .. .. • • • •• .. , Вапе гу - mainte nance and inspection . . . . . . . . . . . . . . . . . . . Batte ry - гетоуаl and Instal18110n ... ...... , ....... ,... . Fau lt diagnosis - electrical system .. ................ ,.,. Front parking and turn 5ignalligh15 - removal and in51alla1ion .•. Front 5ide marker ligh15 - removaland in5tal181ion .........•. • FUse5 and circuil breakers .. ,..... .. . . . . . . . . . . . . . . . . .. F u siЫ е link - lesl1ng, removal and ins1811alion ........... ... Genera l de5criplion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hazard warning lighlS flasher u"il - renewal .... . . ... . . , ... Headlighls-alignmenl ............ .. . . . . . . . . . . . . . . . . Headl ight dimmer 5wi1ch - removal and inslallal10n ......... Headl lght ON Indicalor . . . . . . . . . . . . . . . . . . . . ..... ..... Headl ig ht swilch - removal and inslallation .... ..... ...... Headl ight unil - removal and inslallalion . ..... ....... .... Horns - adju5tmenl .. ,............. . ..... .... ...... Ignillon 5witch lock cylinder (1970 through 73 models) - temoval and in51allal1on ....... ... . . . . . . . . . . . . . . . . . . ....... Ig"il ion 5wilCh - removal and inslallalion .... ,............

9 8 5 4 з

2 48

23 25 38 17 1

32 19 21 22 20 18 37

36 35

In5trumenl panel cluster - removal and Installal10n .....•.... License plale light ....... . ...... .. .... .... . ,... . ... Aadio - removal and in51allalion ..... ........ .. .. ...... Аваг light clusler - removal and in5tallal10n .... ........... Аеаг slde marker Hghts - removal and inslaHation ........... Speedometer саЫе - removal and inSlallatlon . . . . . . . . . • . . .. Slarter motor - dismanlling, overhaul and геаззвтЫу .... . ... Slarter тоlог - general descriplion . . . . . . . . . . . . . . . . . . . . . Slarter motor - гетоуа1 and inslallalion . . . . . . . . . . . . . . . . . . Slarter molor - tesling оп lhe саг ..........•.... .. ..... Starter relay - removal and i"Slallalio" .......... . . . . • . . .. .Stoplight swilch - removal and in5taHation ............ .... Turn signal circuit - fault diagnosi5 8nd rectification . . . . . . . . .. Turn sign81 flasher unit - renewal ... .. .......... . . . . . . .. Turn sign8Vhazard flasher switch - removal and installation .... Windshield washer nozzles - adjustment . . . . . . . . . . . . . . . . . Windshield washer reservoir and ритр - removal and inslallalion Windshield wiper arm - removal and installalion .,.......... Windshield wiper bIades - removal and instal lation .. ... ..... Windshield wiper mechanism - fault diagnosis and reclificatio" . Windshield wiper motor - dismantling, inspeclion and reassembIy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ........ , Windshield wiper тоlог - removal and installation .......... Wind5hield wiper pivot shaft and link assembIy - гетоуаl and inslallation .......... ......... .... ... ............

Specific8tions

! , •

Battery Lead acid Plates рег cel Vcapac ity :

54 .... . . . . . . . . . . . . . . ... . . . . . . I

. ........... .

66 ... ...... ....... .. . • . .. . . . . .. .. .•. ........ . .. 66 . . . . . . . . . . , . . . . . . • . . . . . . . . . . . . . . . . . . . . . . . . . . .

45 amp hr 55 атр hr 70 атр hr

78 ...... ....... ....... ............ . ........... .

80

атр

hr

Alternator Туре

......... .. . . . . ... ' . • . •... . • . .... • • •........ •. Color Сodе ..... .... • ..... . •.•.•.•. • ....•.•.•. . ... . .. Aating ( а! 1 5V ): Purple .. ..............•.•. . . • ........•. • .•.•.•.. Orange ...... ••.•.. . . .• .• .•.. . • ..... .•.• . • . • . •. . Aed ..... .....• •• . • . . .•. • . •....• • •... • .• .•. • ... . Green ........ ............•.•. • .... ..•.•.•.•.•. . Output (st 15V): Purple ........... .......•. • . • .•.... ....• . •.•.•.. Orange ....... .....•. . . ..• . • • •.•••• . ... . • • ••• • •. . А ed . . . . . . . . . . . . . . • . . . . . • . • . . . . . . • . . . . . • . • . • . • . . Green .......... ..........•.• . . ........ •.•.•.•.. Field current (at 12V): Purple .......... .......... • . • . • ........•. •.•. • .. Orange , red , and green ........ • • • . •.. • • •... • . • • • . • . . Cut-in speed . . . . . . . . . . . . . . . . . . ..•.• . . • .• . ... . , .•.•.. Aated output speed tengi ne грт): Hot ... ..... .............. ..•.• .......... ....•.. Cotd .....................•.•••..... . . . . . . . • . •.. Slip ring diameter (minimum) .... . . . •.• .•..• • • . . . . . , .•.•.. Slip ring maximum run-out .......... •.• . . ............•..

Autol ite ог Motorcraft Purple, orange, red ог green

38 amps 42 amps

55 amps 61 amps

570 walts 630 walts 825 watts 915 watts

2 .4 amps 2.9 amps

400

грт

2000 rpm 2900 rpm 1.22 'п I ЗО . 988 mm l 0.0005 in 10.0127 mml

34 27

47 24 26

33 15

12 14 13 16

28 30 31 29

45 46 40 39 41 44 42

43

Chapter 1 О Electrical system

154

Brush length: New length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Minimum length . . . . . . . . . . . . . . . . . . . • . • . . . . . . . . . . . . .

. . .

0.5 in (12.7

тт )

0.3125 in (7.9375 mm)

•

Alternator regulator Туре

. . . . . . . . . . . . . . . . . . . . . •.•..........•.•. . .•.....

Setting .. .... ..... ... .....•.............. . ... ......

Autolite, etectro-mechanical 13.5 to 15.ЗV

FusibIe link identification Color Aed . . . . . . . . . . . . . . . . . . . . . . . . • .•........•.•. •.. .. Orange ... .•• • ....• . . . . . . . • . • . • . . . . . . . . . . . . . . • . . Green ....... •. ... •...... . . . • ... . • ........ . • . •..

Wire gauge 18 16 14

Starter motor Туре

... ... ....... ... ...•.•. . ..•.....•.•.... ... .•. . Oiameter .... . . . . . . . . . . . . • . ... • . •.. . . . . . • . • .... •.•.. Current draw (ndrmalload) ... • .•. . ... .. .....•.•. . .•..... Cranking speed ..... .... .....•.•. ..... ......•...•.• . .. Minimum stall torque .......• . •.• ..• .......• . • ...... •.. Maximum load current ......• . • . .. . •.. . . . . . • . •. .... .... No load current .... ... ......•. • . . ..... .. . •.•. . . . .. . .. Brush length: New length . . . . . . . . . . . . . . .•..........•.•..... . ... Minimum length .... . .......•... . .. .... ~ .• ... . . .... Spring tension . . . . . . . . . . . . . . . • •. . • . • , . . . . • • • .•. •. . . . . Maxiтum comтutator run-out ....•... . ......•.•.•.•... ..

Autolite, positive engagement 4.5 in (11 4.3 тт) 150 to 200 amps 150 to 290 грт •

15.5 Ibf ft 12.13 kgf m) 670 amps 70 amps

0.50 in (12.7 0.25 in (6.35 40 oz

тт) тт)

0.005 in 10.1 27 mml

Fuses and circuit breakers Е arly models Circuits Ashtray light ..... •.... .. . • . • .. . . •.. . .. , .•... . . . . . ... Back- up light . . . . . . . . . . . . . . . • . • . • . . . . . . . . •.• . . .•.• ... Cigar lighter . . . . . . . . . . . . . . . . • . . . . . . . . . . . . • . • .•....... Clock feed ......... ... ...•.•.. . . .. ......•.•. . . . ..•.. ConveгtibIe top feed . .... ...• • • ..• . • • . . . . . • • • • .... • . •.. Con v eгtibIe top motor . . . . . . . . . . . . . . . . . . . . ..•.•. . .•.. . . . Couгtesy lights (C-Pi llar) (Glove Ьох) (Luggage compaгtment) (Мар light) . . . . . . . . . . . . . . . . . . . • . • . • . . . . ... Emergency flashers . . . . . . . . . . . . . . . . . . . . . . . . . . . . • . • . • . . . Emission control and/or throttle solenoid .........•.•. . . • . .... Engine compaгtment light . . . . . . . . . . . . . . . . . . . • . •. ..... • . . Headlights ........ ..... . . . . . . . . . . ... . ..• • • • ......• .. Heater and de1roster . . . . . . . . . . . . . . . . . . . . . ..•.•. . . . ..... Heater and defroster with air conditioning . . . . . . . . . . • . • . . ..... Horns . .... . . ..... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Indicator lights (convenience control panel) . . . . . . . . . . . . . . . . . . . Seat belt (instrument ог convenience control рапеl) indicator ... . . . Instrument panellights (Clock light) (Heater and А/С controls) (Aadio) . . . . . . . . . . . . . .....•.•. •... .. License lights; Marker lights; Parking lights ........ . • • • . • .... . Power seats ..... ...... . . . . . . . . . . . . . . . . . . ..•.• . • .•.. . Power seat motors ...... . . . . . . . . . . . . ... . . . . . . . . . . . . . . . Power window ... ' ..... .. . . . . . . . . . . . . . . . . . . . . . . . . . . . •. Power window motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . • . Power window relay feed; PRNDL (Au to/trans); Radio and/or stereo tape feed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Speed control .. . ...... .. . . . . . . . . . . . . . . . . . . . . . . . . . . . • . Stop lights . . . . . . . . . . . .. ........•. . .. .. ......•.•.•. .. Swing-tilt steering wheel ... . ... .. •.•. . .. . .. . . . • . •.•.• .. . Tail lights . . . . . . . . . . . . . . . . . . ... • • ... . • . ....••• .•..... Transmission selector 1ight .........•. . .. . ..... • .•.•.•... Turn signals; Windshield washers ..... • .•. , ...... • .•.•.•... Windshield wipers . . . . . . . . . . . . . . . • . ...... . ..•.• . • ..... Windshield wiper motor . . . . . . . . . . .. • . •.. . . . . . • • • .• ... . .

Location Fuse рапеl Fuse рапеl Fuse рапеl Fuse рапеl Attached to starter motor relay Integral part of motor

Fuse Fuse Fuse

рапеl рапеl рапеl

Caгtridge

in feed line

In switch Fuse рапеl Fuse рапеl In headlight switch Fuse рапеl Fuse рапеl

Fuse or СВ (Атрз) SFE 4 AGCo,SFE15 SFE 14 SFE 14 20СВ СВ

SFE 14 AGC о, SFE 20 SFE 14 SFE 7.5 12СВ

SFE 14 8AG о, AGX 30 15СВ

AGC AGC

о,

о,

Fuse рапеl 'П headlight switch Оп staгter relay Integral part 01 motor Attached to starter motor relay Integral with motor

SFE 4

Fuse рапеl Fuse рапе' 'П headlight switch Fuse рапеl 'П head light switch

AGC AGC

~use рапеl

AGC AGC

Fuse рапеl Windshield wiper switch Integral paгt of motor

SFE 20 SFE 15

15С8 20С8 С8 20С8 СВ о,

о,

SFE 20 SFE 20

15СВ

AGC

ог

SFE 20

15СВ

6СВ

СВ

о, о,

SFE 20 SFE 20

Chapter 1 О Electrical system

155

I

Later models FUSl!s M d circuU breakers nat located {n fuse рапе/ ('ог fuse раnеl protected circui:s refer to Chapter 1О, Section 37).

1971 models

Circuit protection and Circuit Headlamps . .... ....... ........ ..... ............ ... .

r8ting 12 атр

Location Integr81 with

СВ

lightiпg

switch

Par1ting lamps; Marker lamps; License lamps; Taillamps ; ( АРО

PRN DL lamp) . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . • . Engine compartment lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . •.

I

Stop lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .... • . Power windows; power seat ; power top and heated backlight ..... . Wiper (2~s pd) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Intermittent wiper (АРа) ...... .. ... ..... ... ............ . Front seat~back latch solenoid . .. ........• ..• . • .. . . . . . .. •. Window motor; Seat motor; Тор motor .....•. . . . . . . . . . . . . . •.

I

, 972 models

I

15 . атр СВ

7.5

атр

Integr81with lighting switch

fuse (S FE 7.5)

Cartridge in feed line Оп геlау pane l аЬоуе glovebox

15 атр СВ

20

атр СВ

Оп

7 атр СВ

7

starter relay

In Wiper Switch

атр СВ

СВ

Integral with solenold 'П motor

СВ

•

I

I

CiTcuit Headlights . . . . . . . . . . . . . . . . . . . . .......... . . . . . . . . . . . . Headlights with Grille Lights ........ ........ ......... ..•. Parking lights; Marker lights; Lieense lights; Taillights (АРа PANDL Light ); Headlight ON control ... ... ... .... . . . . •. Engine compartment light .......... .... . . . . . . . . . . . . . . .. . Stop lights ; Hazard flasher ... ... ... ...... . . . . . . . . . . . .... . Power windows; Power seat; Power top; Heated baeklight Automatic seatbaek latch feed ... .... .. . . .... .. ....... • . • . Wiper 12-spd) . ... ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Intermittent wiper ( АРа) . . . . . . . . . . . . . . . • .•.............. Front seat baek latch solenoid . . . . . . . . . . . • . • . . . . . . . . ...... Window motor; 5eat motor; Тор motor .....•. •. ....... ....•.

Circuit prot8ction 8nd rating 9 атр СВ

13

атр СВ

12

атр СВ

7.5 15

атр

!U5. (SFE 7.5)

атр СВ

20 атр СВ 7 amp СВ 7 amp СВ

Loc8tion Jntegral with lighting switeh Integral with lighting switeh

,

Int8gral with lighting switeh Cartridge in feed line Оп relay рапеl above glovebox Оп

starter relay '" wiper switch 'П wiper switch Integral with solenoid 'П motor

СВ СВ

, 973 models

•

I

! I I

I

, I

I

, t

I

Circuit Headl ights . . . . . . . . . . . . . . . .. . . . . . . . . . . . . .• • . . . . . . . . .. Parking lights ; Marker lights ; license lights . . . . . . . . . . . . . . . . . . . Ta illights: PAN21 light; Headlight ON control Stop lights ; Hazard flasher ...... . ..... .... . . . . . . . . . . . . . . . Power windows; Power seat; Power top; Engine eompartment light ; Automatie seatback latch feed .... ..... . . . . . . . . . . . . . . . Wiper (2~spee d) .... .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Intermittent wiper (АРа) ........ .... .... . . . •... ......... Heated back window ... . . . . . . . . . . . . . . • . • . . . . . . . . . . . . . . Window moto r; 5eat motor; Тор motor .....• .••. •.•.. . ......

15

атр СВ

Location Integral with lighting switeh Integral with lighting switeh

15

атр СВ

Оп

СВ

Оп

18атрСВ

20 amp СВ

'" '" '" '"

СВ

Fuse link СВ

relay

рапеl

above glovebox

starter relay windshield wiper switeh windshield wiper switeh harness motor

Light bulb specification (typical) Light description Auto- trans quadrant . . . . . . . . . . . . . . . . . . • . • • . • • ..... . . . .. Back-up lamp ......... • •. . • , . . . . .. • . • .••.• . . . . . . . . . . . Cigar lighter bezel ...... .. , . , .......•.•. . . . . . . . . . . . . . . . Clock .... ............ ..... .... ..... . . ........ .... . . Cluster illuminat ion ........ .. .........•.•.. , ........ . . . Courtesy lamp - dome .............••• .•••• •. . ..... . . . •. Courtesy lamps - under рапе' .....• . •.• . •................ Eleetrical геаг window defroster ..... .• . • . . . . . . . . . . . . . . . . . . Engine compartment . . . . . . . . . . . . .. ..•. •. . . . . . . . . . . . . .• . Front park and {шп si9nal ........ • .•.• . •. . • . . . . . .. • . • .•. Front side marker ........... . ..• . • . • ..• • . . . . . . •.•. ..• . Gauges ., .. ..... " ....... , .. •.• . . . , ..... " ...... .. . Glove compartment . ., .......... ... .•.•.......... '..•.•. Headlamps - hig h!low .... . . .....•.•.• . , .. , .. ...• , • . •.•. Heater/ A ir Conditioner Control .... .• ...•. . . . . . . , .. • .•.•. • . High Ьеат . . . . . . . . . . . . . . .... . •. .. .• . • . .. . , ..•. •.• .•. License plate tamp , ...... , .... . •...... ,." ....•.•.•.•. Lights bezel . .. . . . .. . . . . , ...•.•. • . " . .... . ... • . •. •. • . luggage eompartment ..........•.• '" ....... • . • . • . ... . Мар 'атр

,

Circuit protection and T8ting

. . . . . . . . . . . . . . . . . . . . . . . .. .. . . . . . . . ...... . .

Aadio дм ........ . ... . . . . . ...... . . . .. . . . . .... .... . . Aadio AM/ FM ............ • . • . • ......... , ..•.•.•..... Aadio AM/ tape player ....... • . • .• . . .... .. , ...•.•. . . • . . . Аеаг side markers ........ , . • .• ' . . . .... .. , ...• ....... . .

Candle pow8r

0.75 ер 32 е р 2 ер 2 ер 2 ер 12 ер

6

-

ер

Wattage

Trade No.

1445 1156 1895 194 194 561 631 (»

6 ер 3-32 2 ер 2 ер 2 ер

ер

0.75

ер

2 ер ер

2 ер 6

ер

6 2

ер

631 1157 NA 194 194 1В95

50/ 60 watts

4

ог

ер

6014 1445 194 97 1895 631 212/ 212-1 1893

0 . 75ер

1В92

2 ер 2 ер

1В93

194

10 -.

Chapter 1 О Electrical system

156

Ught description Rear la il, stop and turn signal ......... . . . .. . . . . . . . . . . .•. .. Speedometer . . . . . . . . . . . . . . .. ......•... . ........ • . Spot fight .. .. . . . . . . . . . . . . . .... . . . ... . •.. .. .. . . . . . Tu rn 5i9nal indicators . . . . . . . .. .......... . ..... . W arning lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..... . W iper/ washer bezel .......... .. .... .. .. ... . . ... .. . .

(" ) Bulb and wire assembIy, Ford

Рап

No. 01 ZB +1 8

1

•

·

• •

•

•

•

• • •

·

•

· •

• • • • • • • • •

• • • • ·

· · · · · • . • ·

• • • • • • • • • •

•

•

•

•

. • · • · · • • · • • • • • • •

Wattage

Trade No.

11 57 194 4405 194 194 1895

Ibf ft 60 to 100 551075 15 to 20 of the electrolyte. 3 InstaHation is the

General description

The major compo nents of the 12 volt negative gгound system compгise а 12 volt battery, ап alternator (driven from the crankshaft риllеу), and а starter motor. The battery э иррliеэ а steady amount of сuпепt for the ignition. lighting and other electrical circuits and provides а геэегУе о' electricity when the current consumed Ьу the electгical equipment exceeds that being produced Ьу the alternator. The alternator regulator ensures а high ouput if the batteгy is in а low state of charge and the demand from the electrical equipment is high, and а low o utput if the batteгy is fully charged and there is little demand for the electrical equipment. When f itt ing electrical accessories to сагэ with а negative ground system . ;t is im portant, if they contain siJicone diodes ог transistors, that they аге connected correctly, otherwise serious damage тау result to the components concerned. Items such аэ radios, tape гecorders. electron ic ignition system, electric tachometer, automatic dipping et c, sho uld all Ье cheeked for еопееt polarity. It is important that the battery positive lead is always diseonneeted if th e ba ttery is to Ье boost-charged. A lso , if body repairs аге to Ье eaгried out using electric welding equipment , the alternator тиэ! Ье disconneet ed, ot herwise serious damage сап Ье caused. Whenever the Ьанегу has to Ье diseonneeted, it must always Ье reeonnected with the neg at ive terminal grounded.

2

ог

•

С6 22-АА

Torque wrench settings Alternator pulley nut . .... . . Starter motor through- bofts . . Starter motor mounting bolts

Candle power 3-32 ер 2 ер ЗА watts 2 ер 2 ер 2 ер

Battery - removal and installation

1 The battery is оп а earrier, installed оп the гight-hand side of the engine compartment. '! should Ье removed опее every three months for eJeani n g and test;ng. Diseonneet the positive and then the ground саЫеэ from t he Ьанегу terminals (photo) . 2 Undo th e seeuring nuts and гетоуе the Ьанегу clamp. Careful ly lift the batte ry from its carrier, holding it vertieally t o avoid spilling апу

з

rеуегэе о'

the

rетоуаl

procedure. Note: Attach (о

Battery - maintenance and ;nspection

1 Normal weekly batteгy maintenance consists о' cheeking the electrolyte 'еуеl о' each cell to епэиге that the separators аге covered Ьу t inch of electrolyte. " the lеуеl has fallen. top-up the battery using distil'ed water only. ОО по! overfill. If а batteгy is overfilled ог апу electrolyte spilt. immediately w;pe away and neutralize , аэ electrolyte attacks and corrodes апу metal it сотеэ ;nto contact with уегу rapidly. 2 If the battery has the 'Auto-fit' device f;tted , а special topping-up sequence is required. The white balls in the 'Auto-fil' battery аге part о' the automatic topping-up device which ensures correct electrolyte level. The vent chamber should remain in position а! all t;mes except when topping- up, ог taking specific gravity readings. If the electrolyte lеуе' in апу of the cells is below the bottom of the filling tube, top-up аэ follows: (а) (Ь)

(с)

Lift о" the vent chamber cover With the battery /eve/. роиг distilled water into the trough unti! а/I the filling tubes and trough аге (и" /mmediate/y install the cover to aIJow the water in the trough and tubes (о flow into the cells. Each се/! wifl automaticalJy receive the correct amount о' water

3 Аэ well as keeping the terminals clean and covered with petroleum jelly, the {ор о' the battery, and especially the top of the cells, should Ье kept clean and dгy. This helps prevent corrosion and ensures that the battery does not Ьесоте partially discharged Ьу leakage through dampness and dirt. 4 Опсе every three months, гетоуе the Ьанегу and inspect the battery securing bolts, the battery clamp plate. tray. and Ьанегу саЫеэ for corгosion (white fluffy deposits оп the metal which аге brittle to touch). If апу corrosion is found. clean off the deposits with ammonia and pa int оуег the clean metal with ап anti-rust anti-acid paint. 5 At the same time inspect the battery саэе for cracks. If а crack is found , clean and plug it with опе of the proprietary compounds marketed for this purpose. If leakage through the crack has Ьееп excessive , then it will Ье necessaгy to refill the appropriate се" with fresh electrolyte as detailed later. Cracks аге frequently caused to the {ор of the Ьанегу case Ьу pouring in distilled water in the middle of winter after instead of before а run . This gives the water по chance to mix with the electrolyte and эо the former freezes and splits the batteгy case. 6 If topping- up the battery Ьесотеэ excessive and the саэе has Ьееп inspected for cracks that could саиэе leakage, but попе аге found, the Ьанегу is being overcharged and the voltage regulator will have to Ье checked. 7 With the batteгy оп the bench at the three monthly interval check. measure its specific gravity with а hydrometer to determ;ne the state of charge and condition of the electrolyte. There should Ье уегу little variation between the different cells, and ;f а variation in ехсеээ of 0·025 is present it will Ье due to either :

~

оп

8.3 10 13.8 7.61010.2 2.0 to 2.7

the ground саЫе first and smear the terminals with petroleum jelly prevent corrosion. Never use ordinary grease.

(а)

2.1 The Ьане гу is mounted at the front of the engine eompartment right-hand side

kgf m

(ь)

Loss о' e/ectro/yte (гот the battery, at some time caused Ьу spillage ог а /eak resulting in а drop in the specific gravity о' the electro/yte, when the deficiency was repJaced with distiJIed water instead о' fresh e/ectro/yte Ап inteгnaJ short circuit caused Ьу buck/ing о' the plates ог а simiJar malady pointing to the /ikelihood о' total battery (аНиге in the пеаг future

,

Chapter 1 О Electrical system

i

t

8

The specific gravity of the elect rolyte for fully charged conditions аl the electrolyte t em perat ure indicated . is listed in ТаЫе А. The specific gravity o f а fu tly discharged Ьапегу at different temperatutes

of т е electrolyte is give n in ТаЫе

В.

ТаЫед

Specffic graviry -

8впегу

fully charged

1.2 68 аl 100 ° F ог 38 С electrolyte temperature 1.272 81 9 0 ° F о г 32 0 С electrolyte temperature \ .27 6 а l 80° F ог 27 С electrolyte temperature 1.280 а l 70 0 F от 2 1 о с electrolyte temperature 1.284 аl 600 F о г 1 Б О С electrolyte temperature 1.288 at 50° F от 1О О С electrolyte temperature 1.292 З1 4QoF О Г 4 С electrolyte temperature 1.296 а! ЗО О F ог -1 . 5 0 С electrolyte temperature

0

0

,

0

ТаЫе В $ресiПс

, 1 I

1.0 98 аl 1.102 аl 1. 106 at 1. 11 О at 1. 11 4 аl 1. 118 а l 1. 12 2 at 1. 126 а l

4

! I

\ I

I

gravity - 8attery fully discharged 1 Oo oF ог 38 С electrolyte temperature 90 0 F ог 32 о с electrolyte temperature 80 0 F ог 2 7 0 С electrolyte temperature 700 F ог 21 о с electrolyte temperature 60 0 F оГ 16 0 С electrolyte temperature 500 F ог 1 О О С electrolyte lemperature 4 0 ° F ог 4 0 С electrolyte temperature 30 0 F ог - 1 . 5 0 С electrolyte temperature

0

Battery - electrolyte replenishment

1 If the b attery i5 Ёп а fully charged 5tate and опе of the cells m ainla ins а specific gravity reading whlch Is 0 ·025 ог more lower than the others. and а check of each cell ha5 Ьееп made with а voltmeter to check for short circuits 1а four to seven se cond te5t 5hould give а ste ady reading of between 12 to 18 volts) then It Is 11kely that electrolyte has Ьееп lost from the cell with the low readlng . 2 Top·up the с е" with а solution of 1 part sulphuric acld to 2·5 parts of watef. If th e с е" is already fully topped up . draw some elect(olyte OU l of It w lth а hydrometer. Note: When mixing the su/phuric acid and water пеуег add water to sulphuric acid, a/ways роиг the acid s/ow/y о псо the water "п а gfass container. " water i8 added {О 8ulphur1c acid It wШ explode. 3 Continu e 10 top· up the cell wlth the freshly made electrolyte and lhen recharge the battery and check the hydrometer reedlngs.

outpu1 of the machine to dc for battery charging . and ап outpul СОПlгоl regulator. The rotor i5 belt driven from the engine through а pulley keyed to the rotor shaft. А pre5sed 5teel fan adjacent to the pulley draws cooling air lhrough the unit. This fan forms ап in1egral part of the alternator specification. It ha5 Ьееп designed to provide adequate air flow with minimum noi5e, and to withstand the high 5tresses associated with the maximum 5peed . Aotation 15 clockwise viewed оп the drive end. Maximum cOnlinuous roto( 5peed is 12 500 rpm. Aectification of the alternator output Is achieved Ьу six silicone diodes housed in а rectifier pack and connected а5 а 3·phase full wave bridge. The rectifler pack is attached to the outer face of the slip ring end bracket and contains also three 'field' diodes. At погта' operating 5peeds, rectlfied current from the stator output windings flows through these diode5 to provide the self excitation of the rotor field, via bru5hes bearing оп face type slip rlngs. . The 5liр rings аге carried оп а small diameter moulded drum attached to the rotor shaft . outboard of the sJip (Ing end bearing. The inner rlng i5 centered оп the гotor shaft axle, while the outer ring has а теап diameter o f t inch approximately. Ву keeping the mean diameter of the slip rings to а minimum , relative 5peeds between brushe5 and rlngs, and hence wear, аге also minlmal. The 5liр r1ng5 аге connected to the rotor field windings Ьу wire5 carried in groove5 in the rotor shaft. The brU5h gear Is hou5ed 1п а moulding fitted 10 the inside of the геаг casing. This moulding th)J5 encloses the slip ring and brush gear assembIy, and . together with the 5hielded bearing , protects the assembIy against the entry of dust and moisture . The regulator is located оп the right-hand side of of the engine compartment. It i5 а factory-calibrated unit and is not 10 Ье adjusted. Should i15 operation Ье faulty it must Ье renewed а5 а complete unit.

7

,

I

I

Bsttery - charging

1 ' П wi nter tlme when heavy demand is placed upon the battery, such as w hen sta'ting from cold. and much electrical equipment Is continual lv Ё п U5e , It Is а good idea occasionally to have the battery f uHy charged from ап external source at the rate of 3·5 10 4 amps. 2 Cont inu e 10 charge lhe battery аl th is rate until по further rise Ё п specific gravity is noted оуег а four hour period. 3 A lt ernat ively, а lrickle charger charging а! the rate of about 1·5 amps сап Ь е safely used overnight. 4 Special rapid 'boost' chargers which аге claimed 10 restore the powe r of t he battery in 1 о( 2 hours аге {о Ье avoided as they сап c aU5e serious damage to the battery plates through overheating. 5 While ch arg lng the battery, note that the temperature of the electrolyte shou ld пеуег exceed 1OO ° F (37 ·8 0 С) .

i 6 I

I

Alternator - general descrlption

The m ai n advantage of the alternator lie5 in it5 аЫlilУ to provide а charge at low re volutions. Driving 510wly in heavy traffic with а dynamo invariabIy means по charge is reaching the battery. '" 5imilar conditions е уеп w ith the wiper, heating, lights and perhaps radio 5witched оп the alternator will en5ure а charge reaches the battery. The alte,nator is of the rotatlng field , ventilated design . 11 comprise5 3 · pha5e output winding ; а twelve pole rotor carrying the field wlndings - each end of the rotor shaft runs in Ьа" гасе bearing5 which аге lubricated {ог life ; natural finish aluminium die·cast end brackets incorporaling the mounting lugs; а rectifier pack for converting ас

Alternator - maintenance

1 The equipment has Ьееп designed for the minimum amount of maintenance in 5ervice, the only item5 5ubject to wear being the brushe5 and bearing5. 2 Brushes 5hould Ье examined after about 75000 miles (120 000 km ) and renewed If nece5sary. The bearing5 аге pre-packed with grease for life , and 5hould not require further attention . 3 Check the drive belt at the specified 5ervice intervals for correct adjustment which should Ье 0·5 Inch (13 mm J total movement а! the center of the run between the alternator and water pump pulleys.

8 5

157

Alternator - speci81 procedures

Whenever the e/ectrica/ system 01 the CBr;S being attended to, and exteгna l meBnS о{ staгting the engine аге used, there аге ceгtain рге­ cautions that must Ье (вкеn otherwise serious Bnd expensive damage to the alteгnator сап result. 1 Always make 5ure that lhe negative terminal of the battery is grounded . If the terminal connections аге accidentally reversed ог If the battery has Ьееп reverse charged the alternator diodes will Ье damaged . 2 The output terminal оп the alternator marked ВАТ ог В+ must пеуег Ье grounded but should alwaY5 Ье connected directly to the positive terminal of the ЬаНегу. 3 Whenever the alternal0r i5 to Ье removed ог when di5connecting the terminal5 of the alternator circuit , always disconnect the battery ground tetminal first. 4 The alternator must пеуег Ье operated without the battery to alternator саЫе connected. 10 5 If the battery is to Ье charged Ьу external means always di5СОП- ... - - -.... nect both the battery cabIes before the external charger i5 connected. 6 Should It Ье nece5sary to use а booster cha rger ог booster battery 10 5tart the engine always doubIe·check that the negative саЫе i5 соп· nected to negative terminal and the positive саЫе to positive terminal.

9

Altern8tor -

гетОУ81

8nd inst8118t1on

1 Disconnect the battery с аЫе5 . 2 Loosen the alternator mounting bolts and remove the adju5tment arm-to·alternator attaching bolt. Push the alternator 1 п toward5 the engine and remove the drive belt.

Chaptar 1 О Elactrical system

158

9.2 loosen the alternator adjustment з

Аетоуе

агт

the electrical connectors

9.3 Disconnecting the alternator wiring at the multi-socket

bolt

fгom

tne alternator. The stator

and field connectors аге the push-on type, they should Ье pulled straight off the terminal studs. Оп зате models а multi-socket сап Ье disconnected and the wires left connected to the alternator (photo), 4 Remove the two mounting bolts and carefully 11ft away the alternator. 5 Take саге по1 10 knock ог drop the alternator otherwise this сап

cause irreparabIe damage. 6 7

In5t8111ng the alteгnator i5 the.r8verse sequence to removal. Adjust the drivebelt 50 that it has 0·5 inch (13 тт) 10tal

тОУ8-

ment at the center of the rип between the alternator and water pump pulleys . Note: It mау Ье necessary to геmоуе other accessory drivebelts Ье(оге the alteгnator drivebelt сап Ье removed (see Chapter 2).

,

The ammeter (AL т) gauge оп the instrument panels indicates the charge (С) ог discharge (О) current passing into, ог out of the battery. With the electrical equipment switched оп and the engine idling the gauge needle тау show а discharge condition. However, at fast idle ог погта' driving speeds the needle should stay оп the С side of the gauge; just how far оуег will depend оп the charged state of the battery. If the gauge does not show а charge under these conditions there is а fault in the system and the following points should Ье checked before inspecting the brushes ог, if necessary, renewing the allernalor: (а) (ь) (с)

Check the drivebelt tens;on, 8S de5cribed in Section 7 Check the battery, 85 de5cribed in Section 3 , Check а" electrical С8Ые connection5 (ог cleanline55 and 5ecur;ty

11 Alternator brushes - removal. inspection and installation 1 О Alternator - fault diagnosis and repair Due to the specialist knowledge and equipment required to test ог seгv ic e ап alternator it is recommended that i1 the performance is suspecl the саг Ье taken 10 ап aulomoblle electricfan who will have the facililies for such work. Because of this recommendation , information is limiled 10 the inspeclion and renewal of the brushes.

1 First remove the alternator as described in Section 9. ' 2 Scratch а line across the length of the alternator housing to ensure correct reassembIy. 3 Аетоуе the three housing through-bolts, and the nuts and insulators from the геаг housing. Make а careful note of all insu lator positions.

BRUSH TERMINAL

FAONT 8EAAING

AND INSULATOR ЯЕАА

8EARING

FAN SPACER

8RUSHES

8EARING I

RADID SUРРЯЕSSIDN

8AUSH SPAINGS INSULдTDRS

САРАСПОА

..... ...

THAOUGH BDLТS

HOLDEA FRONT HDUSING

Fig. 10.1 Exploded view 01 alternator

($ес.

11)

'д"

,

Chapter 10 Electrical system

159

А

special holding соН is used 10 maintain the тоуаЫе pole shoe in 1he fully seated position whilst the starter is turnlng the engine. 8RUSH HOLDE R •

TERMINAL

BRUSH

INSULA TQR

ТЕ

Fig . 10.2 l"st81Ii"g the springs and brushes i"to the holder assembIy (See. 11) 4

геаг

Withdraw the

housing section from the 5tatO(, rotor and front

housing assembIy.

5 Аетоуе the brushes and springs from the brush holder assembIy which is located inside the геаг housing. 6 Check the length of the bгushes against the wear dimension given in the Specifications at the beginning of this Chapter and renew if

r

necessary. 7

I"stall the springs and brushes l"to the holder assembIy and retain

them in place Ьу inserting а piece of wire through the геаг housing and brush terminal insulator as shown in Fig. 10.2. Make sure enough wire

I I

I l

; r

I

I

I ,I

protrudes through the геаг of the housing so that it тау Ье withdrawn at а later stage. 8 Refit to the stator the геаг housing rotor and fTont housing assembIy. mak lng sure that the scribed marks line up. 9 Install the three housing through-bolts and геаг end insulators and nuts. but do not tighten. 1О Carefully extract the piece of wire from the геаг housing and ascerta in as far as possibIe that the brushes аге seated оп the s1ip ring. Тighten the through-bolts and геаг houslng nuts. 11 Install the alternator as described in Section 9.

,2

St8гter

motor - general description

Тhe

starter motor system comprises а motor with ап integral positive engagement drive, the battery, а remote control starter switch . а neutral start switch, the starter relay and the necessary wiring. When the 19nition switch Is turned to the start position the starter relay is energised through the starter control circuit. The relay then connects the batteгy to the starter motor. Cars fitted with ап automatic transmission have а neutral start switch 1п the starter control circuit which prevents operation of the start er rf the selector 'еуег Is not in the N ог Р positions. With the starter in its rest positionone of the field coils is соп ­ nected directly to ground through а set of contacts. When the starter Is fjrst connected to the battery, а large cu rrent flows through the grounded field coil and operates а movabIe pole shoe. The pole shoe Is atta ched {о the starter drive plunger 'еуег and so the drive is engaged with the ring gear оп the flywheel. When the тоуаЫе роlе shoe is fully seated, it opens the field coi l grou nding contacts and the starter is in а normal operational condition. ТО

AL ТЕ RN,I. Т ОII OUT f'UT

•

I

~1---I7"""+- - -

.l -. 8АПfltУ •

I STAII:TEII: SWIТCH (ON IGN!ТЮN SWIfCH]

AUTOMATIC пtАNSМISSIОN ONL у STArHflt NfUHAL SWПСН CtOSf O WiTH SfLf CTOIt IN N 011: ,

роsпtQN

С __ !.d.:~ill. SI"pe

,

то 8АПЕRУ

...1 - - -...........

,,I ю

IGNIТЮN COll _ _.'JIti.~с'-J ST AItTH

Fig. '0.3 Staгting circuit (Sec. ,2)

,з

Staгter то1ог

- tes1ing

оп

the

саг

1 If the starter motor fails to operate, then check the condltion of the ba1tery Ьу turning оп the headlights. If they glow brightly for зеуегаl seconds and then gradually dim . the batteгy is in а discharged condl1ion. 2 If the headlights continue to glow brightly and It Is obvious that the battery is in good condition. check the tightness of the ЬаНегу leads and all cabIes relative 10 the starting system. If possibIe. check the wiring with а voltmeter ог test light for breaks ог short circuits. 3 Check that there is current at the relay when the Ignition switch is operated. If there is. then the relay should Ье suspect. 4 If there 1з по current at the relay. then suspect the ignltion swltch. Оп models with automatlc transmission check the neutral start switch. 5 Should the аЬоуе checks ргоуе negative then the starter motor bгushes рroЬаЫу need renewal ог at the worst there is ап internal fault 1п the motor.

14 Starter motor - removal and installation

,

1 Chock the геаг wheels, apply the parking brake. jack- up the front of the саг and support оп firmly based stands. 2 Disconnect the starter саЫе at the starter. 3 Аетоуе the starter motor securing bolts and 11ft the starter out towards the front of the engine. 4 Installation is the reverse of the гетоуаl procedure.

'5 Starter motor - dismantling. overhaul and

гваззетЫу

1 Slacken the brush соуег band retaining screw and гетоуе the brush соуег band and starter drive plunger 'еуег соуег. 2 Note the positlons of the leads to ensure correct reassembIy and then гетоуе the commutator brushes from the brush holder. 3 undo and гетоуе the long through- bolts and 11ft off the drive end housing. 4 Аетоуе the starter drive plunger lever return spring . 5 Аетоуе the pivot pin that retains the starter gear plunger 'еуег. using а suitabIe diameter pin pun ch. • 6 Lift away the 'еуег and withdraw the armature. 7 Аетоуе the S10P ring relainer followed Ьу the stop rlng that retains the starter drive gear onto the end of the armature shaft. The stop г1П9 must Ье discarded and а new опе obtained ready for reassembIy. В Slide the starter drlve assembIy from the end of the armature. 9 Аеmоуе the brush endplate . 1О Unscrew the two screws that secure the ground brushes 'о the frame. 11 Dism antling should now Ье consldered to Ье complete as гетоуаl of the fleld coils re.quires зрес1аl equipment. 12 Clean the field coils, armature, commutatof, armature shaft, brush endplate and dгive end housing using а non-fluffy cloth and brush. Other parts тау Ье washed in а suitabIe solvent. 1 3 Carefully inspect the armature windings for broken ог burnt insulation and unsoldered connections. 14 Test the four field coils for ап ореп circuit. Connect а 12 volt Ьанегу and 12 volt bulb 10 опе o f the leads between the fjeld terminal post and the tapping po;nt of the field coils {о which lhe brushes аге connec1ed. Ап ореп circuit is proved Ьу the bulb not lighting. 1 5 If the bulb lights, it does поl necessarily теап that the field coils аге in order, as there Is а possibility that опе of the coll s could Ье grounded 10 the starter yoke ог pole shoes. То check this, remove the lead from lhe brush connector and place it against а clean portion of the starter yoke. If the bulb lights. the field coils аге grounding. 16 Renewal of the fleld coils calls for the use of а wheel operated screwdriver. а soldering iron. caulking and riveting operations, and i5 considered beyond the scope of the majorilY of owners. The starter yoke should Ье taken to а reputabIe electrical engineering works for new field coils 10 Ье installed . Alternatively purchase ап exchange starter motOT. 17 If the armature is damaged this will Ье evident оп inspection. Look

10

-

Chapter 1 О Electrical system

160

BRUSH

DR1VE

ЕНD PLAТE

FRAME

ЕНD

FIELD

DRIVE

CQVER ВАНО

ARMATURE

,.

/%

~!WA~HER

PLUNGER RETURN SPRING STOP RING

. .

~

sтop R\tЩ

REТAINER

j

Fig. 10.4 Exploded view of starter motor (Sec. 15) for signs of burning, discoloration and for conductors that have lifted away from the commutator. ReassembIy is а straightforward reversal of the dismantling procedure. 1 В If а bearing is WQГn, 50 atlowing excessive side-play 01 the armature shaft, the bearing bush must Ье renewed. Drive out the old bush with а piece of $uitabIe diameter rod, preferabIy with а shoulder оп it to stop the bush col la psing. 19 Soak а new bush in engine oil ' for 24 hours ОГ, if tlme does поt permit, heat in ап oil bath 8! 10О О С (212°FI for two hours prior to installation. 20 As а new bush must по! Ье reamed after in5tallation, it must Ье pressed into position using а small mandrel of the зате internal diameter as the bush and with а shoulder оп it. Place the bush оп the mandrel and ргеЗ5 into position using а bench vi5e. 21 If the brushes аге renewed, their flexibIe connector5 must Ье un50ldered and the connector5 of new brushes 50ldered in their place. Check that the new brU5hes move freely in their holder5 as detailed аЬоуе. If cleaning the commutator with gasoline fails to remove аll the burnt агеа5 and spots, then wrap а piece of glas5 рарег around the commutator and rotate the armature. 22 If the commu tator is уегу badly worn, гетоуе the drive gear. Then mount the armature in а lathe and, with the lathe turning at high 5peed , take а уегу fine cut оН the commutator and finish the suгface Ьу polishing with glass рарег. Do not undercut the miCB insufators

between the commutator segments. 23 Make sure that the drive moves freely оп the armature 5haft splines without blnding ог 5ticking. 24 То reassembIe the starter motor i5 the reverse sequence to dismantli ng. The following additional points shou ld Ье noted:

the drive end housing approximate/y t (u" with grease A/ways use а new stop ring Light/y /ubricate the агmасuге shaft sp/ines with а Lubriplate 777 ог thin оil

(а) FШ (Ь) (с)

16

St8гter

relay - remov81 and in8t811ation

1 For safety геа50ПЗ , disconnect the Ьанеry. 2 Make а note of and then disconnect the battery саЫе5. ignition 5witch and coi l wire from the relay . 3 Undo and геmоуе the two 5crews that secure the relay to the fender аргоп and lift away the relay. 4 Installing the staгter relay is the rever5e sequence to removal.

17

FusiЫе

link - testing, removal and installation

1 А fusibIe link is u5ed to protect the a l teгnator from overload and is located in the wiring harne5S connecting the staгter relay and ВАТ terminal оп the alteгnator. 2 If it is suspected that the alternator is not charging, first check that

SТART ER

ВдТТЕRУ

RELAY

FUSE LINK SPLICE ....... SUPPL У WIRE ТО VEHICLE EQUtPMENT ALTERNATOR

BAHERY TERMINAL

Fig . 10.5 Installing the fusibIe link (Sec. 17)

the Ьанеry is fully charged and the terminals аге clean. 3 U5ing а voltmeter, check that there is voltage at the ВАТ terminal at the геаг of the alternator. No reading indicates that the fusibIe link has ргоЬаЫу burned out. Check the fuse visually. 4 То in5tall а new fusibIe 1ink di5connect the Ьанегу ground terminal fif5t. 5 Di5connect the fusibIe link eyelet terminal from the batteгy terminal of the 5tarter relay. 6 Cut the fU5ibIe link and the splice(5) from the wire(s) to which it i5 attached. 7 Splice and 50lder the new fU5ibIe link to the w ire from which the old link was cut. Protect the splice with in5ulation tape. 8 Securely connect the eyelet terminal to the batteгy 5tud оп the staгter relay. 9 Reconnect the batteгy ground terminal.

18 Headlight unit - removal and in8tallation 1 Undo the headlight door retaining screws and remove the headlight door (photo). 2 Undo the three screws that hold the headlight retainer to the adju5ting r1ng and remove the reta iner (photo) . 3 Pull the headlight sealed Ьеат unit forward and disconnect the wiring a5sembIy connector (photo) . 4 In5tallation i5 the reverse of the removal sequence. Locate the 5ealed Ьеат unit glass tabs in the positioning 510t5. It is recommended that whenever the sea led Ьеат unit is changed. the headlight alignment is checked (see Section 19).

•

;--------------------------------------------------------------------161 ADJUSTING RING •

RI NG

,

•

_./"

'.--'--

IiEADllGIO DOOR 11

/

, , •

W\R ING

у д но

PLUG

Fig . 10.6 Removing the

hвadlight

unit (Sec. 181

•

•

I

18. 1 Removing the headlight door

, 8.2 Undo the 5crews and remove the headlight retainer

18 . ЗА

Pull the headlight unit foгward ...

I ,

, •

•

,

I - - - 1111$1.

18.38 ... and disconnect the wiri ng con nector

Fig . 10.7 Disconnecting the wiring connector (Sae,'"

I

/'

Chapter 1 О Electricalsystem

162

KNOB RELEASE

19 Headlights - alignment

ВUТТОN

/с

is a/ways advisabIe to have the headfights aligned оп ргорег opticaf beam-setting еци/рmепс but if this is not 8vailabIe the follow-

ing procedure mау Ье used: 1

wall

Position the от

board. The wall

line of the 2 Draw

of the

саг оп

level ог

gгound

1 О ft (3 metres! in front of

board must

Ье

а

dark

at right-angles to the center-

саг.

а

verticalline

оп

the board

ог

wall in line with the center-line

саг.

3 Bounce the саг оп its suspension to ensure correct settlement and then measure the height between the ground and the center of the headlights. 4 Draw а horizontal line асгоss the board ог wall а1 this measured height. Оп this horizontal tine mark а cross оп either side of the veгtical center-line, the distance between the centeг of the light unit and the centeг 01 the саг. 5 Remove the headlight doors and switch the headlights onto full

Fig. 10.8 Headlight switch

геmоуаl

(Sec. 201

DlhWE R SWITCH

...sSY.

Ьеат.

careful adjusting of the horizontal and vertical adjusting зсге~з оп each light, align the centers of each Ьеат onto the crosses which were previously maгked оп the horizontalline. 7 Bounce the саг оп its suspension again and check that the beams return to the correct positions. At the same time check the opeгation of the dimmer switch. Install the headlight doors. 6

Ву

20 Headlight switch - removal and installation 1 Disconnect the battery ground саЫе. 2 Working through the access hoJe in the underside of the instrument panel,press the release button using а small screwdriver (Fig. 10.18) and remove the switch knob and shaft. 3 Reтove the bezel nut and lift out the switch body from behind the instrument panel. Disconnect the wiring haгness connector. 4 Install the switch using the reverse procedure to removal.

21 Headlight dimmer switch -

геmоуаl

and installation

1 Disconnect the Ьааегу ground саЫе. 2 Carefully pull back the сагре! from aTound the dimmeг switch, removing the scuff plate and cowl trim screws if necessaгy. 3 Undo and remove the two screws securing the dimmer switch to the mounting bracket. 4 Draw the switch forwards and disconnect the multi-pin connector from the геаг of the switch. 5 Lift away the dimmer switch. 6 Insta l1ing the dimmer switch is the reverse sequence to removal.

22 Headlight ON indicator Later modeJs have а headlight ON indicator and buzzer system to warn the driver that the lights have Ьееп left оп. Ап indicator light, wh ic h conta ins а built-in flasheT, and а buzzer аге connected (п parallel between the headlight switch and а relay. The buzzer and relay аге mounted о п а гelay panel above the glovebox.

Fig. 10.9 Removing the dimmer switch ISec. 211

Later models 5 The parking lights аге located in the гadiator grille. То renew the bulb, twist the bulb socket then pull the socket and bulb from the light body. 6 То remove the light body undo the two screws attaching the parking light and door to the grille and lift away the 1ight body. 7 Installation is the reverse of the removal procedure.

24

Аеаг

light cluster -

гетоуаl

1 Renew the bulbs Ьу disengaging the sockets from the light body inside the luggage compartment. 2 То remove the light body, move the spare tire to one side and then withdraw the three light sockets from the light body. 3 Remove the two nuts attaching the wlre harness clips to the light body. 4 Undo the four nuts securing the light body to the геаг panel and remove the light body assembIy fгom the outside. 5 The light body сап now Ье separated from the bezel and lens Ьу removing the attaching screws. 6 Installatlon is the reverse of the removal proceduгe.

25 Front side marker lights 23 Front parking and turn signallights -

гетоуаl

and installation

гетоуаl

and installation

and installation

Early models 1 The frOn1 parking lights аге located (п two openings in the front bum per, and the bulb сап Ье renewed Ьу undoing the lens securing screws and removing the bulb. 2 The wire to the light unit connects to а plug behind the light body. The light body is mounted Ьу а bracket to the upper side of the bumper opening, 3 The light body and lead wire аге removed from underneath the саг after disconnecting the wire at the pJug and disengaging it from the retaining clips. 4 Installation is the reverse of the removal sequence.

1 То renew the bulb, reach behind the fender and disengage the bulb socket from the light body Ьу turning the sock"'et counterclockwise. Remove the bulb from the socket. 2 Undo the light body securing nuts and the wire retaining clip, then reтove the light body and the retainer. 3 Installation is the reverse of the removal procedure.

26

Аеаг

side marker lights -

геmоуаl

and installation

,

1 Remove the lower геаг согпег of the trim panel in the luggage compartment. 2 Remove the bulb socket from the light body Ьу turning it

Chapter 1 О Electrical system

163

•

,\ \

FENDER

Fig. 10.1 О Removing the fro"t side marker lights {See. 261

, REAR SIDE MARKER HQUSING

i

\\.:

1-

•

•

-

SOCK ET AND 8UlB (INSID E TRUNK) -

....

Fig. 10.11 Removing the гваг side marker lights (Sec. 26) counterclockwise and putling it out, then remove the bulb. 3 Undo the nuts from the bezel studs (inside the tuggage compartment) and remave the bezel . lens and light body from the outside. 4 Installation is the reverse of the гетоуаl procedure.

27 Ucense pl8t8 light Тhe

license plate light is removed Ьу disconnecting the connector plug fгom inside the luggage compartment , undoing the two light body

• I

retaining screws and tifting out the light body assembIy .

28 Stopl ight switch -

гвтоуаl

and installetion

1 Discon nect the battery. 2 Disconnect the wires at the switch con nector. 3 Withdraw the hairpin retainer, slide the stoplight switch , the pushrod , nylon washers and bushing away from the brake pedal and rem o"e the switch (Fig. 10.12). 4 Installing the switch Is the re"erse of the remo"al pгoceduгe.

29 Тuгп sign81/ h8z8rd flasher switch - гетОУ81 8nd inst8118tio"

1

I

I

screwdri"er ог а piece of wire (Fig. 10.13). 5 Аетоуе the wire соуег plastic sleeve. 11 equipped with а t1l1 steerin9 colu m n, l аре lhe wire ends together and atlach а piece of stron9 cord 10 the wires 10 help pull the wires through the steering column when installing the switch . 6 Unscrew the turn slgnal switch 'еуег. 7 Оп 111t steering columns remo"e th~ lwo steering column upper collar retai ning screW$ and гето"е the соВаг. Push the $teering colu mn upper collar down and гетоуе the wiring retaining clip from the column jacket. 8 Undo the two switch secuгing screws and гетоуе the switch and wire assembIy. 9 Installing the switch is the re"erse 01 the гетоуа' procedure ,

Disconnect the batteгy ground terminal. 2 Aemo" e the steerlng wheel as described '" Chapter 11 . 3 Аето"е the wirmg со"ег from the steering column, If equipped with а fixed steering column. Disconnect the multi-conneclor at the base of the sleering colu mn. 4 Make а note of the cotor Сodе and localion of each wire, then disconnect the wires from the connector plug, using а уегу small

30 Turn 8ign81 circuit - fault diagn08is and rectification Should the flasher unit fail (о operate, ог work уегу slowly ог rapidly, check out the tuгn signal ciгcuit before assuming that there is в fault "n the unit. 1 Examine the lurn $ignallight bulbs, both lгопl and геаг, for broken ... filaments. 2 If the external 11ashers аге working, but either of the internal flasher warning lights ha"e ceased to function , check the filaments in the warning light bulbs and renew if necessary. 3 If а flasher bulb i$ sound but does not work check all the llasher circuit co nnections with the aid of the relevant wiring diagram at the end of this Chapler. 4 With l he Ignltion switched оп check that the correct ,,0lt8ge Is rea ching the fla5her unit Ьу connecting 8 voltmeter between the 'ptU5' termin81 8nd ground. 11 it '5 found th8t ,,0118ge i5 correct 8t the unit, connect the two flasher unit terminals together and operate the lurn $i9nal 5witch. If опе of the fl8sher warning lig hts comes оп this proves

1О

$WITCH ASS EM Bl

У

--

::~~ •

BR A KE PED AL N YLON

,

НОР

LIGIO S.... ITCH

АSSЕ М8 LУ

,

' - HAIRPIN ЯН

NYLQN

AI NER

" " Н'Е '

ASSE MBL У

NYL O'>I WA SHE R - - - - - - '

Fig. 10.12 Stoplight switch removal (Sec. 28)

L IFT

REТAIH I NG

TABS 10

Sp·"AТE

ССЖNЕСТОRS

SLEEVE V IE W

VIEW

FEMAlE

V IE W С

В

'O.E~. RETA I N I NG LANCE то

СОННЕСТОЯ

А

МдlE дно FEМAlE

SLEEVE SPACERS R 'Н

дно UP Т О FROМ тор USING д

ЯЕМОУЕ ОЯ INSTALL ТERM I NAL 5

CLIP

I

SIiOWN

ОЯ

SIMILAR TOOL

'Н МALE

;,AL.CONNECTOR-INSТАllАТ I ОN '~

FOR MALE TERMINAL 11'1 FEMALE SlEEVE CONNECTOR SECT ION

А_ А

Fig. 10.13 Removing the wire terminals from the connector (Sec,

ЗЗ)

•

Chapter 1 О Electrical system that t е

asher unit itself is аl fault and must Ье renewed as it is поl possiЫe 10 dismantle and repair it.

з1

Tum signal flasher unit - renewal

1

Тhe

turn signal flasher unit is located

оп

the steering column

bracket behind the instrument panel оп early models. Оп lateT models it is attached to the bracket above the glovebox under the instrument

panel. 2 ТО renew the ftasher unit , disconnect the wiring connector from the unit and remove it from the mounting clip. Tab-and-slot mounted flashers аге removed Ьу rotating the unit 90 degrees counterclockwise 10 disengage it from the mounting 510t. 3 Ensuгe that the new flasher unit has the 5ате color code and part

number

аз

the old unit.

32 Hazard warning lights flasher unit - renewal 1 The hazard warning light5 fla5her unit i5 in5talled behind the 1П5trument panel пеаг the ashtray оп early models. Оп later models It i5 taped to the wlring harne5s above the fuse panel . 2 Aem oval proceduгe is the same as that described in Section 31.

165

4 Aemove the speedometer саЫе 5haft and driven gear from the tran5mission. 5 Aemove the driven gear retainer and the driven gear and shaft from the саЫе. 6 Aemove the lower рап of the broken inner саЫе from the end of the outer casi ng . In5tall1ng the new speedometer inner саЫе i5 the reverse 7 sequence to removal. 8 Lightly lubricate the inner саЫе and in5ert Into the outer ca5ing. When the саЫе has nearly all Ьееп in5erted turn the end to en5ure that the squared end i5 engaged with the speedometer driven gear.

саЫе 9 Working behind the instrument panel, disconnect the 5peedometer саЫе from the геаг of the 5peedometer head. 1О Push the outer саЫе and grommet through the opening in the dashboard panel. 11 Aai5e the саг and , working underneath . detach the саЫе from all it5 retaining clip5. 12 Disconnect the саЫе from the tran5mi5sion as described earlier in this Section and withdraw from under the саг. 13 In5tall the speedometer саЫе uslng the reverse procedure 'о removal .

Outer

, 34 Instrument ЗЗ

!

Speedometer

саЫе

рапеl

cluster - removal and in5t8118tion

- removal and installation 1

IппегсаЫе 1 Working behind the instrument рапе! disconnect the speedometer саЫе from the геаг of the speedometer head (see Fig. 10.14). 2 Careful!y pu!1 the 5peedometer inner саЫе out from the upper end of the 5peedometer саЫе outer casing. 3 If the inner саЫе is broken, raise the саг and. working underneath , undo and remove the bolt that secure5 the 5peedometer саЫе mounting clip to the tran5mission (see Fig. 10.15).

Disconnect the battery ground terminal.

1965/66 models 2 Di5connect the 5peedometer саЫе at the геаг of the panel . 3 Aemove the 5ix atta ching screW5 and tllt the cluster forward , jU5t enough to disconnect the wiring and the bulb 50ckets, then remove the clu5ter а55етЫу (photos). 4 The instrument5 and gauge5 сап now Ье removed, if necessary, for servicing ог renewal . 5 In5talling the cluster 15 the rever5e of the removal procedure .

. / CABLE ASSEMBL У

SPHOCNE1ER

ORIV E~

,

_ _ _ __

GEA~ REТAINER

,

"'-. ,

_-®

MaJNТI~G

SНAFT

\

)

CLIP

-

.... aJ~T ... G

/

SPEEOCNeТER

PRES,S FLAT FACE AND PULL CABLE AWAY FRQМ HEAD

Fig . 10 .1 4 Speedometer

,

SРЕЕоа..еПR

DRIVE~

Ge"'R

CA8LE

cabIe-tо-sрееdоmеtег

ISoc.

head connection

Fig.

10.15 Speedometer

ЗЗJ

cabIe-tо-tгапsmissiоп

ISoc.

connection

ЗЗJ

10

34 .3А

Aemoving the instrument рапеl bottom attaching screW5

34.3В ... and the top attaching screW5

З4.3С Аеаг

view of the instrument рапеl

•

1~ ------------------------------------------------------------~

PRINTED CIRCUIT PLUG R ACLE

ВДСК

VIEW ДММЕТЕА

CIRCUIT

• •

о о

01 L PRESSURE GAUGE NUTS 1 BULBS

. о

~

о

о

FUEL О TEMPGAUGE ASSEMBLY NUTS

о

SPEEDOMETER VOL

REGULATOR

'::=== __----:;7 CLUSТER

'-

_

HOUSING

о ТДСНОМЕТЕА

SPEEDOMEТER

ТЕМР

1-

GAUGE LENS

FUEL GAUGE

ASS

_CLUSTER TRIM COVER

DISASSEMBLED VIEW •

•

ASSEMBLED VIEW

Fig. 10.16 Instrument cluster -1969/70 (Sec. 34)

•

Chapter 1 О Electrical system 1967/ 68 models 6 7

Аетovе Rеnюvе

con~

1969/ 70 models

the instru ment рапе' pad assembIy. the heater control attaching screws and withdraw the

8ssembly.

8 Oi.sconnect the speedometer саЫе from the speedometer head. 9 Oisconnect the cigar lighter wiring connector, undo the зshtгау anaching screws and гетоУв the ashtray.

10 Working through the ashtray opening , undo the nut attaching the instrument clu ster 10 the panel. 11 А етоуе the seven attaching screws and withdtaw the cluster Юrwагd ;

167

disconnect the two multi·connectors and

гетоуе

the instru-

ment clustet. 12 1"5t8111 " g the instrument cluster i5 the

procedure.

С ШSТ ЕR

геУегзе

of the

гетоуаl

1 3 Remove the instrument

рапе'

pad

аз

described in Chapter 12 ,

Section 29. 14 Remove the six attaching screws and withdraw the cluster, just enough to provide access, and disconnect the multiple plug to the printed circuit and, if so equipped, the tachometer plug. Аетоуе the instrument cluster. 15 Instatling the instrument cluster is the reverse of the гетоуа' procedure.

1971/73 models 16 Remove the instrument panel end-finish pane l and the cluster opening finish panel. 17 Remove the fouг cluster atta ching screws and pull the cluster

BACKS FRONT VIEW LIGHT

Т ЕМР

FUEL GAUGE

INSTRUMENT VOLTAGE REGULA Т ОО AND RADIO OI L

PRINTE D CI R CU IТ FUE L GдlJG E

LIG HTS HIGH а ЕА М LIGHT

BRAKES LIGHT ВАСК

ALT. LIGHT

VIEW

Fig. 10.17 Instrument cluster - 1971 / 73 ISec. 34) ВАСК

-

VIEW

.

GAUC;E TERM INALS

ТЕМ ?

ALT С А исЕ TERMINALS

•

~,~~ =:::

DIL GAUGE TERMI NA LS

10

I

I • I

FROHT VIEW

Fig. 10.18 Auxiliary cluster -1971/73 (Sec. 34)

I

•

Chapter 1 О Electrical system

168

away from the instrument panel. 18 Oisconnect the wiring connectors апd the speedometer саЫе,

then

гетоуе

the cluster.

19 ТО remOV8 the аuхШагу cluster, undo the instrument рапеl center

finish рапеl attaching screws (4) and disconnect the wiring. Аетоуе the four screws attaching the cluster to the finish рапеl and lift away the auxiliary cluster. 20 In5t811ing the instrument cluster and auxiliary cluster is the reverse of the гетоуаl procedure.

35

Igпitiоп

switch -

поl

tighten them. 15 Моуе the switch

ир

and down оп the column to locate the middle position of rod lash and then tighten the secuгing nuts. 16 Аетоуе the plastic locking pin ог wire. 17 Connect the battery ground саЫе and check the operation of the switch in all роsitiопs. 18 Attach the stеегiпg соlumп to the brake support апd install the shrouds.

36 Ignition switch lock суliпdег (1970 through 1973 modelslremoval and iпst8118tiоп

геmОV818пd iП8t8118tiоп

1965/69 models

Fixed steering column

1 Disconnect the batteгy ground саЫе. 2 1П5е" the ignition key into the switch and turn to theACC position. In5ert а рlесе of wire Into the hole of the lock cylinder. Push the 3 wlre inw8rd, 10 depress the lock pin. then turn the key counterclockwise and withdraw the lock суliпdег. 4 Press the геаг of the switch and rotate It counterclockwise. Remove the bezel . switch and sрасег. 5 Disconnect the wiring and plug from the геаг of the 5witch. 6 In5tallation i5 the reverse of the removal procedure.

10.191.

1970/73 models Di5connect the batteгy ground саЫе. 8 Remove the 5teering column 5hroud and detach the 5teering column from the brake support bracket (зее Chap1er 11 ). 9 Di5connect the switch wiring at the multiple plug. 10 Undo the two nuts securing the 5witch to 1he 51eering column, then remove the pin connecting 1he switch plunger directly 10 the actuator and remove the switch. 11 When Installing 1he ignition switch, both the locking mесhапiзm а1 the (ор of the column and the 5witch i15elf mU5t Ье in the [ОСК p05i1ion for correct аdjustmепt. 12 То hold the mechanical parts of the column in the [ОСК position. move the shift 'еуег to Р (automatic transmission) ог reverse gear (manual transmis5ion), turn the key to 1he [ОСК p05ition and remove the key. New 5witches аге 5upplied already pinned in the [ОСК position Ьу а pla5tic pin Inserted in а locking hole оп top of the 5wltch . То pin ап exi51ing 5witch. pull the switch plunger out аз far а5 it wil1 go and then move it in опе detent.lnsert а 0·090 in (2·38 mm) diameter wire in the locking hole оп top of the switch. 13 Connect the switch plunger 10 the switch actuator rod. 14 In5tall the switch оп the column. Install the securing nut5 but do 7

!=IXED STEERltotG

1 Disconnect the batteгy ground саЫе. 2 Аетоуе the steeгing wheel а5 de5cribed in Chapter 11. ' 3 In5ert а wire pin. 0·09 in (2·38 mm) diameter in the hole located in5ide the соlumп halfway down the lock cylinder hou51ng (see Fig. Place the gearshift leveг 1п the Р p05ition (automatic tгаП5missiоп) ог гeverse gear (manual tгansmission) position. and turn the lock cylindeг with the Ignition key to the RUN position. 5 Depress the wire р1п and pull 1he lock cytinder out. Remove the • • wlre pln. • 6 When Installing the lock cyl inder. make sure the locking pin is depressed. thеп Iпsеrt the cylinder into Its houslng and turn the key to the OFF p05itlon. The cylinder mU5t Ье fully inserted before turning the key 10 OFF p05ition as this action extends the cylinder retaining pin into the cylinder housing. Reconnect the batteгy. 7 Check for correct operation in all positions and in5tall the steering wheel. 4

Тilt

steering column

11 is по1 neceS5aгy to гетоуе the s1eering wheel. Insert the wire р1п in the hole located оп the out5ide of 1he column (зее Fig. 10.19) and proceed а5 for the fixed steering column. 8

37

Ногпз

-

8djustmепt

1 If the hOГn5 аге faulty ог fail completely, check the wiring and the connections at the terminals and the switch . 2 Connect а voltmeter and ammeter 10 the horn and to а voltage supply as 5hown in Fig. 10.21 and check the cu rrent draw which 5hould Ье 4 10 5 amperes at 12 volt5.

COLU~

lOCK CYLINDER lOCK CYLINDER HOUSING lOCK CYllNDER HOUS"lNG LOCK

-

HOLE CYLINDER RELEASE

•

•

EMERGENCY FLASHER ВUТТON LOCK CYLIHDER OPERATIHG

PATTERН

Fig. 10.19 Removing the ignition switch lock cylinder (1970/73 models) (Sec. 36)

•

•

Chapter 1 О Electrical system

•

169

HOLE FQR WIRES

--НORН

$WITCH INDEN T

SWITCH

TRIM COVER ASSEMBLY МЕDд LЮ N РДО

ASSEMBL У

HDRN WIRES

HORN

ТERMINAL ДТТДСНМЕНТ

•

Fig. 10.20 Exploded view of horn switch {Sec. 371

з

Adjust, jf песеssагу, Ьу turning the self~lockjng adjusting screw to change the contact tension. If the current cannot Ье adjusted to within

POSITIVE LEAD

NEGATIVE LEAD

the specified limits. the horn must Ье renewed.

NEG. _ LEAD

38 Fuses and circuit breakers

::..- POS.

1 The fuse panel (s located оп а bracket atta ched to the lower right flange of the brake pedal support оп later тodels . Оп earlier models the fuse pan el is located оп the 'е" side dash pane l. 2 Mast of the electrical circuits аге protected Ьу fuses and ci rcuit breakers. Fuse identification is given in Figs. 10.22 , 10.2 3 and 10.24, and in the Specifications at the beginning of this Chapter. 3 If а fuse bIows always trace the cause and rectify before renewing the fuse. Always install а fuse of the correct amperage.

LEAD HORN WIRE

+

Fig. 10.21 Checking the horn сuпепt dr8w (Sec. 37) •

PQST EMERGENCY

(NEW

Flд5HER

I

Fig . 10.22 Fuse penel- 1971 models (Sec. 38)

1 2

20атр

1 4атр

•

2

4атр

4

14 amp

5

14 amp

Horns Courtesy lamps: Instrument panel , door, С - рillаг , glovebox, тар lamp, luggage compartment 'атр, dome lamp, cigar tighter feed , ignition key buzzer and automatic seat back latch and clock feed tnstrument рапеl itlum ination: Heater switch, headlight switch, wiper/ washer switch , ashtray, radio, clock and gauge itlumination Indicator lamps: Seat be lt and emission controt, door ajar, parking brake, dual brake Heater defroster: NOTE : 30 дmр required !ог 8;'

6 7

15атр

20атр

10

conditioner

Back-up lamps, radio, wipers, tow fuet and turn signal indicator Accessory feed

ТО

FUSE PANEL LOC.t.TED он PL.t.TE АТТАСНЕО LOWER RIGHT НАНО FLANGE OF BR.t.KE PED.t.L SUPPORT

•

•

Chapter 1 О Electrical system

170

FUSE PANEL LOCATED АТ RIGHT OF SТEERING COLUMN АТТАСНЕD то LOWER RIGHT

Fig. 10.23 Fuse panel - 1972 models (Sec. 38)

FLANGE OF BRAKE PEDAL SUPPORT

1 2

НЕО

3

20 14

атр атр

4атр

4

14

атр

5

14

атр

6

15атр

7

20

атр

Horns and cigar lighter Cou rtesy : Ооте ог C-pillar, тар , luggage and glove compaгtment lights, automatic seat back latch release соВ feed, clock feed , ignition key and headlights ОМ buzzer Instrum ent рапеl illumination: Heater switch, headlight switch, wiper/ washer switch, ashtray, radio and gauge illumination, clock illumination, cigar light and instrument cluster illumination Indi cato r lights: Oil prв ss ure , seat belt. emission control ог throttle solenoid positioner, door ajar and parking brake, seat belt ti me delay relay Heater defroster: NOTE : 30 8mр required (аг 8;Г canditianer Back-up lights, radio, windshield washer, and turn signal flasher Accessory feed: Parking brake indicator light, power window and back light safety relay соН feed

Fig. 10.24 Fuse panel - 1973 models (Sec . 38) ,

ACCESSORV

1 2

20атр

Horns and cigar lighter

14

Couгtesy :

3

4 атр

атр

НЕО

• •

FUSE PANEL LOCAТEOON А ВАдСКЕТ ДТТАСН Е D то

LOWEA RIGHT FLANGE

4

14

атр

5

14

атр

6

15атр

7

20атр

QF ВААКЕ PEDAL SUPPORT

Ооте

ог C-piНa г .

тар ,

luggage and glove соmрагtmеп! lights, auta:matic seat back latch relay соВ feed, clock feed, ig nit ion key waгning and headlights ON buzzer Instrument рапе' and cluster illumination: Ashtray. clock, radio, wiper/washer switch. heater cont rol. headlight swltch, cigar lighter and gauge iIIumination Indicator lights: 011 pressure , engine water temperature, dual brake syste m, seat bel1 warning 'атр and buzzer, emission control throttle solenoid positioner. solenoids, electronic spark control Heater defroster: NOTE : 30 аmр required (аг air canditianer Back-up lights. radio and stereo tape player, windshield washer and turn signal system Accessory feed: Parking brake warning 'атр , power wlndow and heated геаг window relay coi! feed

• 39 Windshield wiper bIades -

гетоуаl

The windshield wiper b/ades

40 Windshield wiper

and installation

сап Ье опе о'

two types. With the

Ьауопе! {уре

the b/ade saddle sfides over the end о' the агm and is engaged Ьу 8 locking stud. With the b/ade sadd/e pin Суре, д pin оп the дгm indexes into the side 01 the bIade saddle and engages д spring

loaded cJip in the sadd/e. 8ауопе! (уре

1

- Trico

ТО гетоуе а

Trico bIade press down

tap stud . 2 Depress the {аЬ bIade from the агт.

8 ayonet

(уре

оп

the saddle

the

агт _о

disengage the

release the tap stud and pull the

- А nсо

То гетоуе ап Апсо

bIade from the

{о

оп

bIade press inwards

оп

the

{аЬ

and pull the

агт.

(уре - Trico То гетоуе а pin {уре Trico bIade insert а screwd river into the spring release opening of the bIade saddle, depress the spгing clip and pu ll the bIade from the агт.

Sadd/e pin

агт

- removal8nd In5t8118tion

1 Swing the агт away from the windshield and inseгt а 0·09 in (2·38 тт) pin (drill ог рор rivet) through the pin hole, as shown in Fig. 10.25. {о release the агm which сап now Ье putled off. 0 0 not ргу it off with а screwdriver. 2 leave the pin in position unt il the агт is installed. With the pivot shaft in the park position, push the агт оп and гетоуе the pin.

41 Windshield wlper mechanism - fault diagn05is and rectifica1ion 1 Should the windshleld wiper fail , ог work уегу slowly. then check the terminals оп the motor for loose connections, and make sure that the insulation of аll the w iri ng is not cracked ог broken , thus ca using а short circuit. If thi5 i5 in order then check the current the motor is taking Ьу connecti ng ап ammeter in the circuit and tu rni ng оп the wiper switch. Consumption should Ье between 2· 3 to 3·1 А трз. 2 If по current is passing through the motor, check that the switch is operating correctly. 3 If the wipe r motor takes а уе гу high current check the wiper bIade5

-

I

Chapter 1 О Electrical system

171

so that the motor is in the park position.

1971 / 73 models KNURLEO ROUND

;>IVOT

"'ОТЕ : то

$НAFT

17 Disconnect the wiper motor wiring connectoT. 18 Аетоуе the cowl top left vent зсгееп. 19 Disconnect the wiper link 1гот the wiper motor агт Ьу removing the retaining clip. 20 Undo the three wiper motor securing bolts and remove the wiper motor and mounting bracket. 21 Installing the wiper motor is the reverse of the removal procedure. Ensure that the connecting сliр locking flange is forced into the locked position (see Fig. 10.26). Check the motor operation .

р!уот НЕ"О

A$SEMB LY

PREvENT GLIIoSS ... NO/OR P"'INT

DАМАСЕ.

00 НОТ РАУ дАМ FRQM PIV01 WПН МЕТ AL ОА

SHARP TOOL .

43 Windshield wiper pivot shaft and link assembIy - removal and installation C~ SН"PED

REMQvE PIN

PIVOT

НЕАО

AFТER

I~T"'lLATIOO

INSi ALLA TIOO QF NEW ARM

Fig. 10.25 I"stalli"g windshield wiper (Sec. 401

REMQVAL OR INSТALLATIOO QF EXISTINGARM

агт

to pivot shaft

far freedom of movement. If this is satisfactoгy, check t~e gearbox соуег ahd gear assembIy for damage. 4 If the motor takes а уегу low cuгre"t ensure that the batteгy is fully charged. Check the brush gear and ensure the brushes аге bearing оп the commu tator. If not, check the bгushes far freedom of movement and . jf necessary, renew the tension springs. If the brushes аге уегу warn they should Ье renewed. Check the armature Ьу substitution if this unit is suspect .

42 Windshield wiper motor - гвmоуа' and installation

1965/ 66 models 1 Disconnect the batteгy ground саЫе. 2 Disconnect the wiring from the wiper motor. 3 Аетоуе the three bolts securing the wiper motor bracket 10 the dash panel , lower the wiper and bracket assembIy, and disconnect the wiper linkag e fTom the motor. 4 Lift out the wiper motor and bracket assembIy. 5 Insta lling the wiper motor is the reverse of the removal procedure.

1967/ 68 models 6 Disconnect the wiper motor wiring connector. 7 Undo the attaching nut and disconnect the pivot агт and wipeг arms from the motoT. В Remove the bolts securing the motor to the mounting bracket and w ithdraw the wiper motor. 9 Insla lling the motor is the reverse of the removal procedure.

1 Remove the wiper агтs and bIades as described in Section 40. 2 Remove the four retaining drive pins and lift off the cowl top left vent . 3 Remove the drive arm-to-pivot retaining clip. 4 Undo the three retaining screws 1гот each pivot , and remove the pivot shaft and link assembIy. 5 Installing the wiper pivot shafts and linkage is the reverse of the removal procedure. Ensure that the retaining clips аге in the !ocked position (зее Fig. 10.26).

44 Windshield reassembIy

wlper

motor

-

dismantling,

inspection

Bnd

1 Undo the securing screws and remove the ground terminal and cover (Fig. 10.27). 2 Carefu lly remove the idler gear and pinion retainer. 3 Lift away the idler gear and pinion. 4 Undo and remove the two long motor through-bolts, and separate the houSin9, switch terminal insulator sleeve and armature. 5 SuitabIy mark the position of the output агт relative to the shaft, to ensure correct reassembIy . 6 Undo and remove the output arm retaining nut, output агт, spring washer, зрасег washer, 0-rin9, output gearshaft assembIy, parking switch lever and washer, in that order. 7 Remove the brushes and brush springs. 8 Remove the brushplate and switch assembIy and finally remo ve the switch contact to parking lever pin from the gear housing. 9 Thoroughly clean all parts and then inspect the gear housing 1ог signs of cracks, distortion, ог damage. 1 О Carefully check all shafts, bushes and gears for signs 01 scoring ог damage. 11 If the brushes аге worn they should Ье renewed. 12 Апу serious fault with the armature such as а breakdown in insulation necessitates а new motor аззетЫу. 13 АеаззетЫу of the windshield wiper motor is the reverse sequence to dismantling and will present по ргоЫетз provided that саге is taken .

45 Windshield washer nozzles - adjustment

1969/ 70 models 10 Remove the wiper агт and bIade assembIies from the pivot shafts, and disconnect the washer hose at the Т -fitting оп the cowl grille. 11 Аетоуе the eight securing scгews and lift off the cowl top grHle. 12 The motor is located in the left side fresh air plenum chamber. Disconnect the motor"ground wire Ьу removing the attaching screw at the frOnl edge 01 the plenum chamber. 1 3 Disconnect the motor wire harness at the pJug and push it back into t he chamber. 14 Аетоуе the retaining сНр and disconnect the linkage drive агт 1гот the motor output агт crankpin. 1 5 Remove the three bolts securing the motor 10 the mounting bracket , rotate the motor output агт 1 ВО degrees and lift out the motOT. 16 Instal ling the motor is the reverse of the гетоуа' procedure but, before installing, rotate the output агт 180 degrees. Before connecting the linkage drive агm to the motor, turn the ignition switch toACC

То

adjust the washer nozzles use а pair 01 thin-nosed pliers and carefully bend the nozzle in the required direction . 00 not squeeze the nozzle too hard otherwise it will Ье crimped closed.

46 Windshield washer reservoir and pump - removal and installation

Early models 1 The reservoir, pump and motor аге supplied аз а complete assembIy and cannot Ье repaired, ехсерl for the renewal of the screen in the top of the reservoir. I 2 То remove the assembIy, disconnect the wiring connector and hose, remove the retaining screws and lift the complete аззетЫу from the left fender аргоп.

1О

•

17 2--------------------------------------------------------------------~

Р

ll NKAG E ARM

•

Р'"

STEP1·1

ПЕР

ALLCLIP

Fig . 10.26 Installing the

2-

PUSН

windshiвld

STEP 3.

FORW..,RO

LOCКED РОSIТ1ОН

wiper arm retaining clips (Secs. 42 and 43)

SP RING WASHER SPACER WASHER

OUTPUT ARM

"О"

RING

ARMATURE 5HДFТ ЕНО PLAY SPRING

PARK SWITCH ТО PARKING LEVER PIN

, _ _ _ _ _ pARKING SWITCH

..

LEVER GEAR

PARKING lEVER

SWITCH WASHER OUTPUT дно

PLA ТЕ

3

SHAFT

дно РINЮN

дно

SWITCH ASSEMBL У

GeAR РINЮN RETAINER

•

-

ARMArURE

- -_ _ _ MOTOR HOUSING M AGNEТ

дно

ASSEMBL у

Fig . 10.27 Exploded view of windshield wiper motor (Sec . 44)

•

Chapter 1 О Electrical system

Later models з

Аетovе

the w iring connector ptug and washer hose. 4 Undo and гетоуе the retaining screws, and lift the washer and motor assembly away from the left-hand side fender аргоп. 5 То гетovв the pump motor from the reservoir, ргу cut the retaining ring аnd carefully pull the motor out of the reseгvoir recess (see Fig .

10.28). 6 Тhe motor and

риrnр

assembIy cannot

Ье

renewed. 7 When iПSlзlliп g the motor into the reservoir, make sure the projection оп the motor body is lined ир with the 5101 in the reservoir. 8 Press оп the motor retaining ring and insta ll the reservoir assembIy 10 the с аг using the reverse procedure 10 removal.

гетоуа'

and installation

1965/66 models 1

2 Remove the control knobs and the nuts attaching the radio to the instrument panel. 3 Disconnect the antenna and the speaker wire. 4 Disconnect the wire at the fuse panel and the pilot light wire. 5 Undo the radio-to-bracket attaching bolts and remove the radio from the instrument panel. 6 Installation is the reverse of the removal procedure.

repaired , and if faulty

т из! ье

47 Radio -

173

1967/68 models 7 Disconnect the battery ground саЫе. 8 Remove the right and left supports from the support bracket, and remove the console assembIy. 9 Disconnect the wiring connections and the antenna from the radio. , О Remove the radio control knobs. , 1 Remove the nuts from the radio control shafts and lift out the radio. 12 Installation is the reverse of the removal procedure.

1969/70 models

Disconnecl the battery ground

саЫе.

1 3 Disconnect the battery ground

RE5ERVQIR -

саЫе.

..

Fig. 10.28 Removing the windshield washer motor ISec. 46)

DRY lUBE HERE ......, MQTQR AssEM8Ly ........ ...--_

• •

RETAINING RING

HAND PR ESS

COMPOHEHТS

TOGETHER

_ _ RAOIO

INSTRuмENT PANEL

REINFQRC EMENT

Fig. 10.29 Removing the radio - 1969170 model. (Sec. 47)

10

MOUNTING

•

Chapter 1 О Electrical system

174

------- - - --

--

--

-

8EZEL KN08

'--,STEREO ТАРЕ

Fig. 10.30 Removing

radio -1971/73 models (Sec. 471

14 PuH the control knobs, discs and sleeve from the radio contгol shafts. 15 Aemove the radio applique f~om the instrument рапе' (see Fig.

10.291. 16

Аетоуе

the right and left finish panels and the two mounting

plate attaching SGrews, then pull the radio out 01 the instrument and disconnect the wiring. 17 Аетоуе the mounting plate and геаг support from the radio. 18 In5tallin9 the radiQ i5 the reverse of the

гетауа'

procedure.

рапе'

1971 /73 models 19 Disconnect the ЬаНегу ground 20 Discannect the antenna.

саЫе.

21 Remove the four screws securing the bezel and radio to the instrument panel.

22 Pull the radio forward and disconnect the power lead and speaker; then lift away the radio. 23 Installing the radio is the reverse of removal procedure.

,

•

l

Chapter 1 О Electrical system

175

48 Fautt diagnosis - electrical system Symptom

No

Reason/s

vоl tзgе а!

starter motor

Battery discharged Battery defective internally Battery terminalleads 1005e ог ground lead not securely attached to body Loose ог broken connections in staгter motor circuit

Starter motor switch

• Vоlt зgе

at

staгter

motor : faulty motor

ог

solenoid faulty

Starter motor pinion jammed in mesh with flywheel gear ring Starter brushes badly worn, sticking, ог brush wires 10058 Commutator dirty, worn ог burnt Starter motor armature fэultу Fietd coils grounded

Electrical defects

Battery in discharged cOndition Starter brushes badly worn, sticking , от brush wires 10058 Loose wires in starter motor circuit

,

Dirt

ог

oil

оп

drive gear

Starter motor pinion 5ticking

Mechanical damage Lack of attention,

ог

mechanical damage

5crewed 5teeve

ftywheel gear teeth broken

ог

worn

Pinion ог flywheel gear teeth broken Starter drive main 5pring broken Starter motor retaining bolts 1005е

ог

worn

Pinion

ог

оп

Wear ог damage

defective internally Electrolyte level too low ог electrolyte too weak due to leakage Plate separators по longer fully effective Batteгy plates severely sulphated

/nsufficient current flow to keep battery charged

Drivebelt slipping Batteгy terminal connections loose ог сопоdеd Alternator not charging properly Short in lighting circuit cau5ing continual batteгy drain Regulator unit not working correctly

Alternator not charging ..

Drivebelt loose and slipping, ог broken Brushes worn , sticking, broken ог dirty Bгush springs weak ог broken

.. "

а"

appears to

Batteгy

Ье

well but the

a/teгnator is

still not charging, take the

саг (о ап

automoblfe efectrician to check the

alteгnator

and regu/ator

10

•

•

• 176 ----------------------------------------------------------------~

GLOVE CQMPARTMENT llGHT AND 5WIТCH

I

ON/'W ~

STARTER RELAY ТО ВАТТЕАУ

-

( +) TERMINAL

GN/VW

•

•

_ _ _ _ RO/WH _ _ __

..------- .'/ О'" WATER ТЕ"Р

___-;Ro~1~ .K/VW

-':'

MAIN CONNECTQRS

GAUGE

' -_ _ _ WH/ RO _ _

D=:8K/GN

SENDING

QIL PRES5URE

UNП

INDICAТOR

BK/G N

F'UEL GAUGE

.К/ о.

•

WAIER

C~SIANT

TEMPERATURE

VOL TAGE UNIT

SENQING UNIT

llGНТ

-

IGNITION

SWITCH

,w

--8'----

•

.K/OR ""/ON- - -

.К/ 8К

WIND5HIELO WASI1ER PUMP AND

FUSE

МО Т ОА

OR/WH

PANEL

8К/О"

LJGHT

SWtTCH

МОТОА

WINDSH IELO WIPER

(2 SPE;:.E:D):..-_ _-..,

I

)-BK! WH

WINDSHIElO •

WIPER

WASHE R SWITCH

~::::::~=~

__-=

ON _

----------'W--~

~

•

•

I'-_ _ 8К _ _ { • • )

'*•

Fig. WD1A Interior light. wiper and gauge wiring diagram - 1965

•

•

;--------------------------------------------------------------177 --GN/VW - - - - - - - - ' 8L

8K/8L _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __

х

8K/8L SWITCH

LIGHT ТО

CONSOLE

I

r-=»

CDURTESY

8К

COМPARTMENT

LIGHT

GROUND ТО

ТО

воау

CQN50lE COURTESY LIGHT

INSTRUMENT '--' PANEL LIGHT

--

' " ' INSTRUMENT PANEL UGHT

ТRАNSМISSЮN

SELECTOR

OIAL LIGHT

. СООЕ

WIRING CQLOUR

'оо ВК ·

8 Ч ОО

,965

ДНО

1966

-8LACK

-8ROWN АD АЕD ОА -QRANGE YW VELLOW ВН

-•

I I

WH

WINDSHIELD WIPER ~TOA (SINGLE SPEEOJ

8L

I I

GN 8L \/L GY -

GREEN BLUE VIOLET GREV

WH -

WHITE

EXAMPLE

I I

/

I

ОЕ О

I

I

I

WINDSHIELD WIPER SWIrCH ( SINGLE SPEEO)

I rUEL ТАНК SENDING UNI1

8 K/ 8L

OR/WH

WHIТE

SCHEMATIC А

-------

\

._SEE ACCE5S0RIES

I I

RO/ WH

I •

-

- WIRING SEE ACC ESSORIES

BK/SL

SPLICE

8K / 8L

+_ "--

=

CQURTE5Y

GRQUND

llGIO

ТО ВОО'!'

==,::!GN/'VW ~~_ GN/VW..... 8К/8С

8./ 8L;.='1 •

8K/ 8L 8K/ 8L--'

-

8K / 8 L - - - - - - - - - - - - - - - -

•

Fig. WD1

В

Int8rior light. wiper and g_uge wiring diagram - 1965 (continued)

•

-

,

~

.-

INOICдTOR то ВДПЕRV(+) ТЕ

RMINAL

TAILLIGHT- STQP & l'URN 5IGNAL

LIGHTS ВЕАМ

SIGNAL

HEADLIGHT HIGH 8. LOW

ВЕАМ

QR/8L

НА5НЕА

STAR1ER RELAY

BACKUP LIGHT

fI"'/R~K

I Н)

МЛIN

CONNECTOR

I

NAL & TURN PARKING LIGHT

~/OR гс

ВUТТОN

GNjBK

YW/GN

llCENSE PLATE

(i) - '" "

eK~

.к

Вl
.К/ОО-+-

VW WH

IGNIТION

SWtTCH

.:«~

FUSE pANEL

BACKUP LIGHT .к

.к

TURN SIGNAL & PдRKING LIGHT

SWПСН

LIGHT SWITC

HEAOLIGHT DIMMER HEAOLIGHT HIGH & LOW

SWПСН ВЕАМ

•

Fig. WD2 Exterior light. horn and turn sigпаl wiring diagram - 1965 Isee page 177 for Wiring Color CodeJ ,

ТдIШGНТ-SТОР

& TURN SlGNAL

-

•

~-----------------------------------------------------------------------179

R.н.

АЕАА

l

LICENSf PLATE lAMP

510Р & TURN

51GNAl LAMP

Н.

REAR

STOP & TURN

SIGNAl

LдMP

GRQUND

L-_ _ _ _ _ RD / B K - - - - - - . . . J L _ _ _ _ _ _I-+_

АО /

. - - - GN/ RD - - - , TURN 51GNAL SWПСН & НОАН SWITCH

LIGHTING SWliCH S10PLAMP SWI1CH L.H. TURN

INDIC ATOR L AMP

Н, ВЕдМ А ,Н.

TURN 5IGNAL INDICдlQR LAMP IGN ITION SWIT Н

HEADlAMP DIMMER SWIТCH

GN/ рдАТ

OF 5TEERING

•

СОШМN

A5SY. - - GN / WH - - - - - - - - - ' BK/GN

I

I

FUSE PANEL

STARTING

I

\J

I

\J

мотая

RElAV

L .H HORN

Н ОАН

TURN SIGNAl

PITCH

FlASНER

lOW

PIТCH

вк

GN/eK то

'*

R Н

_ FAIRLANE QNLV

TURN SIGNAL &

PARКlNG

LAMP

10

l.H . TUPN SIGNAL & PДAКlHC; lAMP

ВЕАМ

RH HEADL AMP5

l .H.

HEДDLAMP5

Fig. WD3 Exterior light. horn and turn signal wiring diagram - 1966 (see page 177 for Wiring Color Codel

•

,

180------------------------------------------------------------------------'

CA8LE 8АТТЕRУ ТО STARTING "отn. RELAY

CABLE STARTINr.

МОТО.

RELAY

ТО

STARТlNG МОТО.

STARTING МОТО.

RELAY NEUT RAL START SWITCH (AUTOМд Т 1 С TRANSM1SS ION ONLY)

152 SPARK PLUG 6 CVL.

8АТТЕRУ

262 CA8LE 8АТТЕRУ то CROUNO

IGNITION COIL AL TERМATOR

I I

16

С , Р , О,

I I L

,7С

-DISTRIBUTOR 6 CYL .

14'05 ASSY,

I

14290 ASSY, •

SPARK PLUGS

в

AL TERNATOR REGULATOR

С . Р, О,

В

CYL ,

CYL,

'2 •

•

Fig. WD4A 19nition.

staгting ,

c harging and gauges wiring diagram - 1966

•

~-------------------------------------------------------------------181

WIRING COLOR 168 16

'"

1S2д

ЗОС

ЭОВ

1.. 152 21

2.. 26 ЭОА

" зо

31 32. 32

,

Э7С

37В

37д

I

'1--1' -

АЕD·САЕЕН

297д

YELLOW BLACK·RED $TRIPE YELLOW ·WHITE STRIPE 8LACK·GREEH STRIPE WHITE .АЕО STRIPE RED·BLUE STRIPE

э5

WHITf

37

BLACK·YE LLOW STRIPE

"

RED-WH1ТE SТЮРЕ

BROWH Bl.ACK.GREEN ST.RIPE

655

ОЕО

'04

(ОАЕЕН-АЕD

•

STARTINC MOTOR

Bl.ACK

262 297

."

IG_Т10N

STAIPE

PINK

57

-.

СООЕ

STRIPE RED·YELLOW STR IPE SPLICE

SWlTCH

GROUNO ЕХСЕРТ

MUSTANG

FALCON ONLY

39

PflESSURE IN08CATQR LAJlP ~<Т DНLY

COHSТAHT

VOLTAGE UNIT

СНААСЕ

INOICA TOR lAМP·FALCON ONLY

ТА.

SENDlIIG UIIIT

GROUIII)

31

-30A.j.........'!_

OIL

I

PRESSIIRE SWlTCH

37

FUSE PANEL

OIL PRESSURf ""ОЕ

MUSTANG ONLY

14289 ASSY. 14401 ASSY. дНО

10

МUSTAHC OНLY

. 1,3".4 ONIIS RESIST_E 14290 ASSY.

14401

ASS~Y'-.~1""--...J(

14401

14405

А55У .

Fig. WD4B Ignition, starting. chargin9 and gauges wiring diagram -1966 Icontinued)

• •

1~ --------------------------------------------------------------------~

•

ее

15237

MOTOR RELAY 32 262

152J - 3 7 ---" 32 - - ' -262-----------

STARTING

35

14290 ASSY.

4

:;

26д

14305 ASSY.

--26д--'

TERNATOR ASSY. , , - - - - 26 -.-/ 14289 ASSY.

14401 ASSY.

ё+- 39,,*

*г'1

31--(*

16

168 .у

477 г-----,

- - 16 - - - - - - - ,

==

26

• 57 I

4 152

•

14401 ASSY . 14290 ASSY .

О

зд2д

.).1

о

REGULATOR ALTERNATOR ASSY . L-_ _ _ _ _ _ _ _ _ _ _ _ ·14290 ASSY - - -

- --

482 --+0-1-,

~

1-32--~

37-

•• 168 1~6~Д~===

482 - - - -

943 ~~~~6;4~3~~==: 32д

14290 14401 ASSV . ASSV .

Fig. WD5A Ignition, starting and charging wiring diagram -1967

•

,I

~-------------------------------------------------------------------18З

WIRING

~

4

,

158 15 16д 16 21 26д 26 32д 32 35 37 39 38578 57 140Д 140 152 262 * '297 482 *640 *643 904 *977

I,

I , ,

, ТО

TRAHS. SWITCH

,-32--+<;-0:--:140 .... > ;, L-32 140 ......* ТО тден.

COLOR

СООЕ

WHITE-8LACK STRIPE REO-VELLOW STRIPE REO-GREEN STRIPE YELLON 8LACK-REO STRIPE REO-8LUE STRIPE WHITE 8LACK-YELLOW STRIPE REO-WНITE STRIPE 8LACK 8LACK-REO 5 TRIPE YELLON 8RONN 8LACK-GREEN STRIPE 8LUE-YELLON STRIPE RED-YELLOW STRIPE YELLON-8LACK STRIPE GREEN-REO STRIPE VIOLEТ

SPUCE GROUNO

14401 ASSY.

.J..

•

•

'г

297763

IGNIТION

1-297 -

* r

зtд

SWIТCH

297Д

.k

•

*1-25.../ 37

,

,

CONSTANT VOLTAGE UNIT

--14401 ASSY.

<

30С

•I

3030 CНARGE 'НО.

LAMP

I I I 643 *НОТЕ

14290 ASSY.

14401 ASSY.

WIRE FUNСПОN нот APPUCAllLE ТО THIS CIRCU1T

Fig. WD5B Ignition. starting and charging wiring diagram - , 967 (continued)

I

.' . <

1~ ----------------------------------------------=-----~

*5

*5

38-654-,

.• 5;--152--~\ ,--------

~38

WIRING

С

О

L

О

R

с

О

D

Е

о

13076 R. Н. HEADLAMP HI & LOW ВЕДМ

о

11Д--

ТО

2

3Д

3

14305

THRU

10 11 34 13 14 15 25 32

38 57D THRU

37 57 44

11Д

12д

12 13Д

14С

38А

297А

140А

(-373А--+-3д -

FOR R.P.O. TURN SIGNALS

WНIТЕ-ВШЕ

STRIPE GREEN-WHITE STRIPE ORANGE-BLUE STRIPE ORANGE-YELLOW STRIPE GREEN-ORANGE STRIPE GREEN-RED STRIPE BLACK-YELLOW STRIPE GREEN-BLACK STRIPE RED-BLACK STRIPE BLACK RED-YELLOW STRIPE BLACK-ORANGE STRIPE RED-BLUE STRIPE BLACK-YELLOW STRIPE BLACK

9

----1

R. Н. PARКlNG & TURN SIGNAL LAMP

WHITE

50 5 8

ASSY.

2 57С

2Д

35 49

-2~

STARTER MOTOR RELAY

ВШЕ

296 297

RED BLACK-GREEN STRIPE 383 RED-WHITE STRIPE 385 WHITE-RED STRIPE 460 YELLOW -37140 BLACK-RED STRIPE 511 GREEN 40 BLUE-WHIТE STRIPE 490 8LUE-RED STRIPE ,-- ~ 2SGROUND SPLICE 37 _ _ _ _ _ _-.J

•

21

-

2д

J.

з-------,

ТО IGNIТION

2-----'

SWITCH

32r-r-

-11-+ -12 -57--

-13-~

.,..-11.----~:-----34-

"-13

15 -

з--

L. Н. PARKING & TURN SIGNAL LAMP

~=iiА'-==

)

-37 -

14290 ASSY. ,

~11-

2-

13076 L. Н. HEADLAMP HI & LOW ВЕДМ

.......412 15 13 57Д

"'·-26 - /

HEADLAMP DIMMER SWIТCH ,----, ALTERNATOR REGULATOR

, Fig. WD6A Exterior lighting and turn signals wiring diagram - 1967

,-----------------------------------------------------------------,85 31-- -- ----, АМР .

20

,

FUSE

14 АМР FUSE

,

297А

70--_

490

У.

5

140

PoдNEL

FUSE

OF 1СНIТIOН 5WITCH

8

о

.

TERMINAL

2 7

296 I

Т О АССУ.

А. Н, REAR, STOP &

TURN StGNAL LAMP

140Д

4 BAck-ир

од

1

LAMP SW ITCH

(-44 511

32Д*

л-'

511

~O=

А. Н. ВДСк-ир

LAMP

~297Д

49

25-=

'« 3)

ан i)

460

:

'85

9

LICENSE PLATE ILLUMINATION LAMP

STEERING COLUMN WIRING

l

TURN SIGNAL

SWIТCH

STOPLAMP 5WITCH

I

-15~=~ -14 -1

-10160"=::;

1111401 А55У . 4Д-<С3){)

LIGHTIN,G SWITCH

L.

Н.

тиАН

REAR, 5TOI' & SIGNAL L.AMP

- 2 5 -J

FOR FOG LAMPS QNLY

8j;:) 44\:>

I

тиАН SIGNAl FLA:SHER

t I

40..,... 10 CIGAR LIG~TER

'8' 385AS5Y .

EMERGENCY W4.RNI\jG FLASHER

R .H. TURN SIGNAL INOICATOR

49

•

l,H. тиАН SIGNAl INDICA. ТОА

50

@ @ @ @ @ @

49

50

'4

Fig. WD68 Exterior lighting and turn signals wiring diagram -1967 IcontinuedJ

I I

10

*WIRE FUNCTION НОТ APPLICABLE то THIS CIRCUIT

•

-

•

1 ~----------------------------------------------------------------~

108942 ASSY.

DUAL BRAKE IND. LAMP

.р3)

, - - ' 9G

•

CLUS TER ILL.

14401 ASSY.

~MP

HI8EAM

RIGHT TURN IND.

~MP

TEMPERATURE GAUGE

CLUSTER ILL. ~MP

57

50 OIL ТЕМР. GAUGE LEFТ

TURN

IND. ~MP CLUSTER ILL. ~MP

CLUSTERILL.

~MP

---~'---=""---

-1- _~__~==~~=-

____

AMMETER ~GA~U~G~E___

-~19D

CLUSTER ILL. ~MP

CONS TANT VOLTAGE UNIТ

R.P,O. WIRING Д

THRU G Д

8

С

19 22 29 С 30 31 34 39 49 50 57 640 654 655 977

•-

...1...

-

О

L

О

R

С О О

Е

8LUE-RED STRIPE 8LUE-8~CK STRIPE YELLOW-WIiIТЕ STRIPE 8~CK-GREEN S TRIPE WHIТE-RED S TRIPE GREEN-B~CK STRIPE RЕD-WНПЕ STRIPE WHITE-BLUE STRIPE GREEN-WHIТE STRIPE

CLUSTER ILL. ~MP

FUEL GAUGE 29 98

CLUSТER

ILL.

~MP

B~CK

RED-YELLOW STRIPE VIOLET YELLOW VJOLET SPLICE GROUNO

Fig. WD7 Pre-wired instrument cluster wiring diagram - 1967

•

•

~-----------------------------------------------------------------------187

,

•

MOOEL

6з

ONLY

R. Н, " е " PILLAR LAMP

® .1

ВAH E RY ---J

'-ь"",с;:::t

)---57 lЗД709 A$SY

sт ARTI NG

011 J)

53

53

MOTOR RELAY

1

A55Y · / ,, 1

:J) Н, FRONT DOOR COURТES Y lдMP SWIТCH

R.

53 A$SY,

152

.J

14290

r=r-

ENGINE

A5SY.

COMPARTMENT LAMP

.;;/17t-- 37 Д --.., ~-

4 77 ~37:"::;-1 0 - 21

I

ТERMINAL

BATT.ERY OF IGNIТIQN $WIrCH

57

.[1:3(Д}7~'9~Д~5~ 5~Y:.~~~~-1~ J)

о ---{C:::J1D' а п

· ' - - - 2 5 - - , , _ 548 22

"'""\:tC:::J1DJ o~]a::l::I1)hL ______;:;::..J 1

54С../'

{

53 --::::.х-r.,,,W -57-

0I&,j

---54---,

f

GLDVE

,

7.5

I

АМР.

~

FUSE

-

53С­

53д-

00

138712

ВОХ LдMP

Д55У.

рап 1}-5З r=т--

57А

':' 1)8711 ASSY.

--37Д-~

LAMP~

CO NSOLE

I

(]) 1 ..& - -

FUSE PANEL 54д

DОМЕ

138711 ASS Y.

LдMP

13A70S ASSY,

-+---548 - - , ' - - - - - - 25

,

p-S7A ((

-~

I

L,

нО

Н. " с "

14334

PILlAR LAMP

AS5Y,

MOOEL 63 ONlY

'---_ _ _ _ _ _ _ _ _ 53 - - :

~

, 53

13д 709 А$$У.

, •

I

I

I

COLOR

WIRING

14405 ASSY,

С

ООЕ

477 OLUE-BLACK STRIPE 25 BLACK- ORANGE STRIPE 22 БLU f -ВLAСК STRIPf 37д 37 BLACK-УfLLOW STRIPf 53 5011

THRU THRU 57д

5ЗЕ 54С

57

• .L

GROUND

'

57-___

57 - -

)

13А769

53-~

ASSY,

53

BLACK-BLUE STRIPE GBffN-УfLLОW STRIPE

~~fcKE

553з8 ~:' ••

/

L, н, FRONT DOOR COURTfSY LAMP

('C:::>L:::: ...J-. ::::: ) 5ЗД -...\~Д7:9 AS

f= 54А ~(

0

11 D

14401

д55У .

~

{ 13A75fJ AS5Y.

. !ЗД 724

54

'--54-'"

I

: I

5'

LIGHТlNG SWIТCH

I

Г=

A5SY, н, FRONT DOOR COURТESY lЛМР

L.

S WIТCH

10

54-----' • +N OTE ; WIRE FUNCT t ON NOT APPllCABlE ТО THI5 CI RCU IT

I

Fig. WD8 Interior lighting wiring diagram - 1967

•

1 ~------------------------------------------------------~

14300 ASSY POWER SOURCE R. Н. ВООУ SIOE LAMP

·, 5

152--+,

~-38Д----+'

'---7--

' - - - - 654 - - \

д

'----38 WIRING

I

COLOR

С

О

О

Е

о

13076 R. Н. HEAOLAMP HI & LOW ВЕдМ

9В4д

о

>t+-11A -

ТО

2д

2

49

3А

3

50 5 8 9 10 11 34 13 14 15 25

14305

Д55У.

2 57F - R. Н. PARKING & TURN 5 1GNAL LAMP

11А

12А

•

t-----

12 13А

57 - - - '

14С

57Е

-./ . ; : - - 57F - . / ' - - - 57G-./

BROWN

984

THRU

WHITE-BLUE STRIPE GREEN-WHITE STRIPE ORANGE-BLUE STRIPE ORANGE-YELLOW STRIPE GREEN-ORANGE STRIPE GREEN-RED STRIPE BLACK-YELLOW STRIPE GREEN-BLACK 5TRIPE RED-BLACK STRI?E BLACK RED-YELLOW STRI?E BLACK-ORANGE STRIPE RED-BLUE STRIPE BLACK-YELLOW 5TRIPE BLACK

32

37 38д

38

57О

THRU

57 44 296 297 383

297д

ВШЕ

RED BLACK-GREEN 5TRIPE RED-WHITE 5TRIPE WhITE-RЕD STRIPE YELLOW BLACK-RED STRIPE GREEN BLUE-WHI ТЕ STRIPE BLUE-RED STRIPE GROUND SPLI CE

385

654 152 26 140А

~- 570 -~

:,...--

57С-,

- --.J 57 А ---.J

460

140 511

\ ' - - 5 7В

'---

40

г-

37 '-

~1--1-3A

FOR R.P.O. TURN SIGNALS

490

Е

О

• '"

Э

~~~1~984 - 11

3

---'11 Д -

L.H. PARKING & TURN SIGNAL LAMP С

11

==1

BROWN 57О-

14290

L. Н . ВООУ SIOE LAMP

D

11.-

Е

RED

--15--

•

HEADLAMP DIMMER 5WITCH

1112 13 12

12

L.H. HEADLAMP HI & LO ВЕАМ

814 - -

ДSГ.

12д

13

2 --------,

-12 - 13-

1

37 -

~3~7:-=~~~:j 477 1*

f"'._з

@

-+----+--2д

г-

STARTER MOTOR RELAY

-

~

5 ALTERNATOR REGULATOR 26~

IGNIТION SWIТCH

• Fig. WD9A Exterior lights and turn signals wiring diagram - 1968

,--------------------------------------------------------------------189 2 0 дмр. F US E

I

~ 137

~~~O

14 АМР. FUSE

~

;::;::;:~=,- 14 О . 140А

297д

"

49 0 У.

140

14С

5

32

FUSE PANEL

г-- 5 7С --....,.~

8

140

R. Н , АЕДА , 5 Т ОР &

iURN SIGNAl LAMP

о

•

38) 37 -.J

т

А, Н, BAck-ир

LAMP

30 3

9

2 - 385 482 - ...,-гт-460

Оп J) 148

,--37'

-1

хо:'.)

LICENSE PlдТE ILLUMINATION LAMP

- 4ЬО

-- 9 - 10 - 3

5 ТНА ING COLUMN WlRING

25 -

1...<{{?\

-2J

21

57. 1,57

- 385--0 - 44_

к

"1,,,4"" .~"-' rr 140

TURN SIGNAL SWITCH

L _ _ _ _::.".'-.H__.'-.BAC K-UP LAM Р

s TQPLAMP 5wrTCH

25

г

14

<1

!

14li~

9

L.

140? • 1

13А449

I

ASSY,

,

,

0

383

1

F Lд5HEA А . Н.

TURN SIGNAL

IHOIC'" ТDА

FLд5HER

49----

G

-

- 49--

G

~~34HI

ВЕДМ

,на.

/

ВШЕ

38' TURN SIGNAl

, 9

(jj3 1;»

SWIТCH

' 404" ТО CIGAR LIGJHER

I

&

TURN S IGNAllAMP

~

UCHTING

Н . АЕДА , 5 Т ОР

34-~_

Q)}

5 •

1

~8\ \

9 9~H4 I I 1 14401 ASSY.

-

l'

•

н

N.O ТЕ: UNLESS OTHERWISE 5PECIFIED

AlL CONNECTORS

140Д

дАЕ

BLACK

f"Д\ All lEHER5 CIRCLED А5 \J INOICAТE CONNECTOR S

ВШЕ

5HQWN

*WIRE FUNCTION нот APPLICABlE ТО THI5 CIRCUIТ

-50'-L.H. TURN SIG.

I !

'НО.

-50-

Fig. WD9B Exterior lights and turn signals wiring diagram - '968 (continuedJ

•

1~ --------------------------------------------------------------------~

ее

ее

*

е

.

ВAHERY

POWER SOURCE

STARTING MOTOR RELAY

262 0.54

14290 ASSY, 37 г---32--'

14305 ASSY. STARTING

IGNIТlON

COI

16--

14290 ASSY. в

С

~c~1

,

14289-AS!Y.

L-16A::L..:.T=ER:::N=A~,~RE~G~U;L-!.A~T~OR~_ _ _ _~*1~~~39~_2:31~1~=

---;

__

32

14401 ASSY. 39 31

!* 168 - - - -

14290 ASSY.

32 904

37

654 5

Fig. WD1 ОА Ignition. star1ing and charging witing diagram - 1968

•

,--------------------------------------------------------------------191

WIRING

COLOR REO

055 *31

"2 "3

I'МITE-ВLUE STRIPE GREEN-WНIТE STRIPE

108

10

RED-GREEN STRIPE PINj( YELLOW 8LACK-ORANGE STRIPE 8LACK RED-8LUE STRIPE 8LACK-YELLOW STRIPE RED-I'МITE STRlPE ВLАСК-ЯЕD STRIPE 8RQWW ВLUE-YELLOW STRIPE RED-YELLOW STRIPE GREEN-REO SТRIPE SRLICE GROONO

10д

* 15 2A 152 654 21 20А

32д

378

I

--1

......

I

·.82

37д

r r-Q "O-t - , I L ___ I 1

I 1

1 I

1

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1

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L_

'*'

,2

- -

ТRANSMISSION Г

*25 20

37 *39 "'l40A *140 984 202

NEUТRAL SWIТCH FOR AUТOMATIC

_ __

СООЕ

*040 ·904

•

.о•

J

~ 140

, 15540 ASSY. F

• т

14401 ASSv.

*;-

140

25 IGNIТION SWIТCH

• 37 32 ДМ

8USS

eдR УЕ

н

FUSE PANEL 14401 ASSY О

14401 ASSY.;.____ Е

14290 ASSY

14290 ASSY. 1"

,....,,14401 ASSY.

108942 ASSY.

G NOTE,

o

2

32 •

UNLESS OTHERWISE SPECIFIED ALL CONNECTORS АЯЕ 8LACK ALL LEHERS CIRCLEO AS SHOWN INDICдTE CONNECTORS

НОТЕ,

WIRE ~UNCTION НОТ APPLICA8LE ТО THIS CIRCUIТ

I i

Fig. WD1 ОВ 19nition. staning and charging wiring diagram - 1968 (continued)

•

19 •

*

---

- '0 4 -32

L ENGINf GAQUND

8АТТЕА'!'

,

'~)O~

,

·26

\

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4 138

,

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I

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,

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ALTE ANATO R

I,

Д55У .

STA.R'fER

DISTAIB\HOR

SP"RK PlUGS

,

ALTERNA.TOR RE CULATOR

32

152

)7

"

1. I GN IТl ON

4

COIL

,.,

ENGINE QI L PRESSURE IТCH

I~ о u1

8

~I

,,-

1.

"

31'

31

,

а,д

2:,2 'НО

1 ASSY

Е\2 ,

EHGINE TEMPERATURE SEHDER

ЗJ

-- -

-

,2

- -~ 21Д

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А55У

904

"---- -.. '152 ___

152А. _~

ТО

977д

RADI O

__ _ ___ 904--,С:;:';;;",,':::'=",,',--_-,

DUAl

ВАДКЕ

WARNING $W

Fig . WD11A Ignition. starting and charging wiring diagram - 1969

•

•

,--------------------------------------------------------------193 WIAING

НОТЕ,

ALL CONNECTORS ДАЕ 8LACK

UNLESS

•

• ~

А

OTHERW~SE

'52

SpeCiFifO

SPLICE GROUNO АН

LEHERS CtRCLEO AS $HQW/t IHOtC'" ТЕ CQNNECTD RS

29, QASH PANEL ,О,

COLOR

• ""д

СООЕ

WHITE-6L.ACK АЕD-САЕЕН

PINK

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VELLOW

37

BLACK-УЕi..LОW

BLдCK-AED

ОААНСЕ

з.

8LACK

" '" '"

АЕD-ВШЕ

BROWN

ЗI

САЕЕН-АЕD WНIТЕ-ЯЕО

"40

AEO-YELLOW

;о

BLACK-GREEH

37

BI..'CI(-УЕlLОW YElLOW-8LAСК

"" з9

RED-WHITE

;од

VIOLEТ (RE5ISTANCE WIREJ О,

-

,

АССУ.

- 90<: _ ••

,

STARTER мотаА

&

, COIL, STAAT &

РАОУЕDит

I

I tCHITION

L

"

Р ШС5

/

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'97

О @

ol ~

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.,

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OIL PRE5SURE

WARNING .

DА5Н РАНЕ

I

L

,

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•

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CtRCUIT

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ТО

FUEL

WRNG.

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SENDER vrA 14405 A$SY.

,

• COHSТAHT

VOLTACE ин'Т

Fig. WD11

В Igпitiоп. stаrtiпg апd сhаrgiпg wiriпg

diagram -1969 (continu8dl

•

,

,~----------------------------------------------------------------~

POWER SOURCE

-

, ,-

Г

14300 А55У.

-

984" <18 57(; 08

--

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,

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u

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RELAV

U.MP 8АПЕRV

~8д 37-

,,

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Г

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(l8)

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,

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,

:.:...-;::t::t:~S7A 57 (lbI ( 6)

-

R .H. HIC H & LOW ВЕАМ HEADLAMP

12 (Ibl

<-51Е (1В'

1 2А (6)

12. (101 (1&\

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cb в

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LAMP 5WIТ CH

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98'

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~

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-

STOPLAMP SWITCH

W'HOSH'ELO W'S НЕА PUMP

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ENCIHE

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LAMP

( 18)

\L--= Fig. WD12A Exterior lights.

turп

signals

апd

brake lights wiring diagrem - 1969

•

,---------------------------------------------------------------------,95 НОТЕ;

OASH

/

PANEL

o

ALL LEHEA5 CIACLED AS SHOWN INDtCATE СОННЕСТОА5

, •

"-' ffi

I

50

5"

I

,

ТО

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~297

L

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г--++==============~ +-t--t---,

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-

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г+++-

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21 (12)

РАНН

ТО

ICNITION SWITCH

GAOUNO

8 (181

===O!J

44 (181 тиАН

-

SIGNAL

IHSTRUMENT

-

14 0 (1 81 14 0 А ( 8 )

дс--

--

385 (10)

383

<с >

РАНН САоино

FL.ASHEA

(16)

57 (20)

1 1

-

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о

49 (201

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,•

-

5

10

•

(НЕО)

."

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H!ADL.AMP

DIMMEA SWITCH

Fig. WD12B Exterior lights. turn signals and brake lights wiring diagram - 1969 (continued)

•

1%-----------------------------------------------------------------•

530

WIRING COLOR COD[

GlOV[ COMPf SWITCH

BLACk-vELLQW STRIPE

Н.\

11 22 40

53" THRU 530 54А ТНАи 540 57,\ THRU 57С 19Е

19

•

•

BLUE-BLACK STRIP[ SШЕ-wнПЕ STRIPE BlACK-ВlUЕ STRIPE GREEN-УЕllОW STRIP[ BLACK 8LUЕ-АЕО

STRIPE

SPLI.:E GROUND

NOTE: UNLESS OTHERWISE SPECIFIED МАР

.,.

ALL

LAMP

IЗ7Ь4

o

ASSY

R ,Р.О.

-- -

-

BLACK

ALL LЕПЕR5 CIRCLED AS SHQWN IHOICATE CONNECTORS

5 4 ' - ' 54

9L__ 57--, МАР

СОНН. ААЕ

540

HEATER ~

А.Р.О.

SWIfCН

CLOCK

ILLUM

LP. SWI ТСН

о

TOR.P.O. RADIO

=

190

01--

198 - - -..... 54С

578-!::;=3--57С ~

19Е

®= 19-~

22--

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х

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,--19A - - ' 5 71>-~,

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LAMP IlLUM. FOR ALL "UTO. TRAHS. (R.P.O J

о

19=~

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+ - +-19C

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1

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'о о"

ВОДАО

(CLUS ТЕА ILLUM. SHOWN)

II n D'I -СТ

,

L ___·__ , Fig.

WD1ЗД

Interior lights wiring diagram -1969

SЗБ

п

Q Q

U Q

51

,

,

I

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---_.-

•

,--------------------------------------------------------------197 г-~~~~~~---- '3 ------,

13871 1 ASSV .l'I:.P~ O .)

53-=--~igi 1 3А769 .Q.- 57

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ASS V.

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COURTESY lAMP S ТО. ON ",,'LL " 8 " MOOEL.S & 650 &

I

57

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МООН

53

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63

S ТО . PROOU СТIOН

)

о аООА

~

R ,Н. •

JAMB SWITCH

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PlllAR lAMP

'ОА COURТE SY LAMP5

INSTRUMENT

О .Н

РАНН

COURTESV

LAMPR .H .

STD . PRODUCTION MODEl 76 & 63

53с ----,

53 ' -

19

-j

, HDlP , .

,4С

490

,-= .::t,

-:1

РААК

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,

37

HEAOI..AMP SWITCH

L.H.

ТО

POWER SOURCE {ТО QASH PANEL DISC. & ТНЕН ТО ВАТТ. StDE

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,

О'

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IN STRUMENT PANEL COU RTE $Y LAMPL .H. 5 ТО . PROD UCTION

?

аООА

57

MQDEL 76 & 63

JAMB 5WITCH

ООМЕ lAMA моон 6s ONlY

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5ТО,

I

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13А 719 ASSY.

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53

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53

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д

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54 - -- -_ __ _ __

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Fig. WD1 ЭВ Interior lights wiring diagram - 1969 Icontinuedl

I •

,~--------------------------------------------------------------------,

14300'_ _ A$SY.-

-

~'~4~,-=~,~,;-:f-,

POWER SOURCE

едТТЕАУ

38'

LEHGINE GROUNO

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904

----@- '--- - - , STARTING мотаА

37

,,

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--

,,

\

,

-

ALTERNATOR

,,

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Р:Е

L.o.Y

I

262

9--~

,

,

4-14"240-" 14290 ASSY. SТДIПЕR МС

----35

DISTRIBUTOR

Г-@

,

904

AI,.TERNATOR REGULATOR

",

152

35

$PARK PLUGS

10

IGNI'fION COI L

37

262

ENGtNE 01L PRESSURE

$WIТCH О

I~

о

"1

(i-s1ВEN~'

р

.

з9

з9

л-

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262 14401 A5SY.

ТЕМРЕААтиАЕ

SENOER

32'

10"730-

35 4

L __

152

t'?1 ТО RAOIO 152Д~ , CONDENSER

977"

904 ---=-==~

9

DUAL

ВААКЕ

-14

WARNING SW.

Fig. WD14A Ignition. starting and charging wiring diagram - 1970

•

•

,--------------------------------------------------------------1~

WIRINC COLOR 4

16

НОТЕ:

ALL СОННЕСТОА5 ААЕ 8LACK UNLESS OTHERWISE SPECIFIED

••

, i'---,

lЕТТЕR5

CIRCLEO

А$

SHOWN

IMOICATE CONMECTORS

-' -~

31 643 39

," /"""-DА5Н PANEL

904, )ОА 977

-

STARTER МОТОМ

АЕD-САЕЕН

STRIPE

STRIPE

PINK

YELlOW BLACK-RED STRIPE ОААНСЕ

8LACK

REO-BLUE STRIPE 8LACK-YELLOW STRIPE

REO-YELLOW STRIPE BLACK-GREEN STRIPE BLACK-УЕLlOW

STRIPE YELLOW-BLACK STRIPE RED-WНlТЕ STRIPE IJIOLEТ

(RESISTANCE WIAEI

IJIOLEТ

-14"'464_

--

, 000 '

WHlTE-ВLАСК

9"31 640 297,30

,

l.

'6

38 32 37

С Аоино

AlL

152,21

" ,.,

SPLICE

(')

16А

СООЕ

,.---$ТЦТ

'~-;:::: OFF 'ОН

,::=-;;16

ГI-

, I I

,

"

,"С'

'1

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'97 904

•

977Д

L

ASSY. SWITCН

•

,UGS

0181

0 181

I.

"

.)...)2

32"

L SS4b

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15520

А55У.

---'1

--+

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_31

FOR MANUAL TRANS.

r297A

FOR

5ТААТ ~ НЕит.

FOR

Аито

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TRANS.

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т ДСНОМЕТЕА

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PRINTEO CIRCU IT

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WRNG. САМР

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-

ТО

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WRNG. САМР

29 ..., SENOER VIA 1440S ASSY

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ТО

FUSE

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Fig. WD14B Ignition. starting and charging wiring diagram 1970 (continued)

•

~----------------------------------------------------------~

IHOO ASSY,

{

-

984"(18)

2Al181

ЗВАНЫ

.

STARТlNC IIIОТОА:

II.H. SIDE

RELAY

"'ARICER ,",МР

ВАТТЕRV ,НООD

TURN

I

•

5ТО,

- - - - - - - - - - ...... - 1

13234

I

ASSY,

iI

I

I I

I ___________ II L

•••

11" -

2(181 - - - l ~L 57АО81 -

-

984С 2П81

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WHT ,-BLUE (181

о·

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--;--=== --,

-

-

-

57"-

1

13А357 ASSY •. - (

2АI181

I

г

I

• •

• ••

HEADLAMP

__ " __ _ -@[()j __ , _ J I I Г - - 2в - -@~ - 2 - J 57С -;;-==~

57(1 81 12081

II .H. SPOA:T LAMP МОО. ь)с DNLY

I 1I I I 1 I 1 I

r<E ROWNI

· 1)ЩИ

38А J (16)

12АIl81

J

f-13АП81 - - ,

1

L

13070

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ASSY.

I I

(B A:DWN)

1" 4 78А( 181 57Ш8) -

---,

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+ I

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SPORT LP.

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- --- -

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t

I WASHEII PUMP I '-I-t+-:--- - - -- - - - - - - I

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MARICER

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10

--Н е---2ПВJ

.. TURN SICNAL LAMP

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OASH _ / PANEL

1

1

l1А1l8! 9840

140

f

578

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132)5 ASSY,

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1

57"П81

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-

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j

LAMP SWITCH ASSY. 1554 Ь Г IIEo-еLUЕ (181

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57

г----- - -----Г: I I

S7 (lВI

AS5Y. -144 89-

.

984 ("

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11. '-

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L.H.

J

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I

R .Н.

517

)(181- - , I S7fl81- _ _ _ _ _

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-14489-

ВЕАМ

~ 1:1301 ~ ASSY.

О

-1448'

г

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80

•

. O~• •

- ~~

• • 00

-

МОО.О3С

ONLV

... (18\

\ Fig. WD15A Ext.rior lights end turn sign81s wiring di8gr8m -1970

•

-

, ~----------------------------------------------------------------~1

• НОТЕ :

г

148--

мао. ьзс ONLV -.J

.

-r

'8~- TO

ALL

LEТTERS

IHDICATE

МQ T O A:

"В.АУ

CONNECТORS

PRNOL, LAMP - - - - 1 \

I

.~ . . , -о -

AS $Y,

J

--l

_ - - - 57"- , 1 1

-",1-,,- _ 146(18111(18) I I~

,,

г-~

I

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,

5'7

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1

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1 1 1 1

, _ J

1

o~:

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о

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I I 3В3<1Ь! -~ I 1 Ч-'8ЮЫ .~

I I

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EMERCENCV WARNING FLA5HfR

I 1

I I ,-,

1 1

STOPLAM, SWITCH

1 ,

" I

21 2s

~

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PART OF

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'1 I t

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r<78--.J

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34

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-101489-

11

•

•

PAHEL GROUHD

FLA5HfR

11

==='

о

~ IHSTRUMENT

TURN SIGHAL

1 1 140 (8) 140" {ISI -

о

8(181

,

Т

ТО

о

44(181

, 1 , 1

,Н

о

-{о

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I

1

,~

7200 AS$Y.

, 1

, _J 1

.

50

SPORT

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DOZB-13A254 -A SPORT L.-.MP SW. MQD,b3CONLY

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_ _ _ _ _J

•• • от-о

49

•

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2 (;81

тss

1

-"

CIRC LED AS SHQWN

1 1

START IHC

-

- -

o

_ _'o~;

ч-

f--;..-======~ )А

__

_~::::::::::~F;U;"~P;AН;;E;L::::::::=~L::~~I~I==========~~~,.,--:::3 +

'"

ТО14405

" . _--.J

Fig. WD1 58 Exterior lights and turn signals wiring diagram - 1970 (continued)

,

•

~2------------------------------------------------------------------------'

WlRING COLOR

'!

".

'"

"40

CLOVE !ОХ

22

SW9TOI

53" THRU CLOVE

ВОХ

'МАР

LAMP

1'"

L..._ 5J •

БLAСК

ELUE-RfD STRIPE 5PLI\:E

GROU ND

".

UNLES 5(1THERWlSE SPEClflED

... -t

ALL

МАР LAMP SWITCН

,

7

o

,•.

rR.p,O.J

.

8LACK-VELlOW STRI?E 8LUЕ-БLAСК 5TAIO'( 8ШЕ.wl1tТЕ STRIPE 8lACK-eLUЕ STRIPE GR(EN-VELlOW STRIPE

НОТЕ :

7.

"'55У,

ПО

54,6, TIIAU 540 57!. THRU 57С 19 19Е •

, "164

СООЕ

138712 "55У.

СО Н"

ААЕ

BLACK

ALL LEH(R5 CIRCLED AS SHOWN

INOICATE CONN ECTQRS

r-~:;-;;-;:;-;-;~-;;-;:;;;;;;Z------------j CLQCK & 5ТО. ОН МQDS. 63С &6о5Е, А.Р . О. ALL

54'"

ОТНЕА

L.H. г­

1"5TfI . P""EL

54"'---,

COUflTESV

LAМP

MQDELS

ТО А.Р.О.

0-39

RADIO

СОАЕ[М

19'---~

А"

++--'70-+ >+-'''---,

;,J-,,,

--22-

" QASH PANEL

54

CLOC!( ILLUM fё:'r- 19" 571.

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L.AMPILLUM,

FOR "LL "UTO. TRAНS.

54.

г----------------, .

I

ТО 15А80В

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о о

о

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,, I

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CI RCU IT 80"11:0
ILLUM.

,

Q Q О

57

О о

•

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INSTR. PHL.

1381ft !t5SV .

CItOUND

Fig . WD16A Interior lights wiring diagram -1970

•

, ~-----------------------------------------------------~3

•

г

u

...

-~ ф "~

_ ,,~ ~ --­ Ф 5)А

L

__~'я~7~n~.~ss~У~.___________ "---------------

TOI M$1, PNL LP.,

"~

:g:=::;-;::::

111 .Н.

А55У.

138711,0111 13А769

ТО 'Н5Т.

769 53

000.

сои'П[5У u.мp

PHL • ..LP •• ....J

"

w

О. 13А769

'-7--

- - >3---. т

...,--

! ?

>3.

111

,Н

• "С" РILI..NI LAII'

DOO1t JAMB SWITCH FOI: COUItTESY L.AMPS

IHSTIIIUMENT

R.M .

COUltTE5V

Р,,"Н

!.АМР

• •Н •

.,-- - - - ' , , ~.6

~·PAHEL !с----->3. --"""

••

,

rfSY LAUP

• -/---

,

--t=== ~~=:j:= г--1---- .. o---l-=..-,o(

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~ , ;

25--1-

, HOL1. , , ,

~, = ~

.цк

о

--- - -

" 37"1

--t--' + i

L .H.·C" P1LlAR САМ'.-

та РОМ.

SQURCE (ТО OASH PAHEL 015C . ' ТНЕН то ВАТТ.

13776

SIOE

OF STARTER МОТОIII RELAV'I

'" ----'"

I

"55У,

ТО 13150..0 А55У. КЕУ REMINOER BUZZEIt

МОDН

63

ONLY

".

IНSТRUМЕIП

l' PANEL COURTESY

LAMP L .H.

M~89-

I

000111 JAM8 SWtTCH FOIt (XIURTESY L.AMP5

ООМЕ

L .Н.

",ООН

138712

ТО R,H. tHSTR. . _____ "55У. РАНН COURTESY \""

,

LAMP

65

..Q.

1З"719

' 36763

"55.,.. .

"55У .

--,,-'----

Н8

САМ'

AI

lUCCAGE ,

r

СОМРЦТМЕМТ u.мp,

SWlTCH

(BLUE)

L$~S_SY_,_

.,~"

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АЕО ,

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•

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1).756 ASSY ,

RE

L -- - - - > 3

------------"

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-----~ ....---4@

~

10

"------~г_--------"-----------------

()

ASSY .

_ _ _ _.....J. '__ _ _ _ _ _ _ , . _________________________

Fig. WD1681nterior lights wiring diagr8m - 1970 Icontinu8dl

•

•

1~300' __- ,

ASSY,-

-

DOS8-14448-A ТЕЯМ, BLOCK

"

о

еДТТЕИУ

LENGJNE GROUND

-

-

[\

•

\

,,

з7C ct\r32А----@1 i'" ~/ --1 ' оъ- - о

'" -

"

-(}

37'

. (88

МОТОЯ

СИЕЕН

-

14431 ASSY.

16.

РЕи.у

36

- - -Ig)

/

STARTING

8LUE

Ь:)4

088 -

•

--

1гН

,..

-

З7В~655

-"'000'---

31с-

6" AL Т[ЯН"ТОII 51'ДIПЕR

-

" ...J

I

DIS TRI8UTOR

~

,

ALTERNATOR REGULATOR

5

-

-

I

--

5PARK PLUG5

~

8

3

16

3

I

?

6

32

•

2

-

7 IGNПIОN

" '"

COIL 1. .

ENGINE OIL

0-887

PRESSURE

SWITCH О

1~

-о

~

"1

о

0-83

./ - 39 -

-

31- CI 14289

ASSY .

ав,О

.,

0-8'\

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39 31 16 ,

l

7

6

-

-

-

=:

1" 14290 A5SY.

ENGINE -0-88

5

r

I

ТЕМРЕидтиЯЕ

-:-

32

16

$ЕНОЕИ

6

32'

, , С7АВ-14А:Ю 9 - А

"36

655 I I

t

90'

L-_36'_©

ТО RАОЮ

•I

L

:3

)7"

-Cf::=

,' 904 .C6AB-14A309-A

CONOENSER

I

-

39 91,7.1.

~~

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Fig. W017A Ignition. charging and

8R~

staгting

WARHING SW

,

'6

~

977

LC8AB-14A309-A

wiring diagtam -1971

i~ DА$Н PANEl

•

,-----------------------------------------------------------~5

СООЕ

WIAING COLOR

Эl

RED-lТ. GREEN STRIPE WНITE-REO STRIPE

"

YELLOW.oWHIТE ООТ

16

НОТЕ:

ALL CQNNECТORS дЯЕ BI..ACK UNLESS OTHERWISE 5PECIFIED

32 35

)0"',36 •

з7

SPL IC E GROUND

~

А

38

"

ALL lEHERS CIRCLEO AS 5 HQWN INDICATE CONNECTOAS дно ARE

•,

:!-,- DА5Н РАНН

STAltTER

МОТОА

РАНН

-•

RЕD-WИIТЕ

STRIPE STRIPE

9"

LT. GREEN-RED STRIPE

YELLOW-l Т. GREEN STRIPE RED~RANGE

STRIPE

PURPLE-WHIТE

STRfPE

YElLOW-WИIТЕ

STRIPE

START

'r - - - ."'

г-- -

-

"297

I~

,

'-' 16А

BLACK~RANGE

"'97" '" '" 9" '"

DIAB- 14489 -LA F"USE

YELlQW BLACK BLACK-L Т. CREEH ООТ BLACK-L Т • САЕЕН НА5Н RED-YELLOW HASH

29

ТО

RED-LT. BLUE STRIPE LT. GREEN-6LACK STRIPE ORANGE-l Т. BLUE 5TRIPE

DFF lOCK АССУ .

37д

IS ACTUATED ВУ rGNlТlDH КЕУ

' LUG5

,

0-121

~=-~=16 ТО FUSE 168 POl.

01-32-, "--31А

'54-"'"

"

51ART· HEUT. SW. FOR AU ТО TRANS.

Эl

7к

~

•

, ,

19J

14401 "55'\'.

ТО ·

FUSE PHL .

16

ТАСНОМЕТЕ!!: 5ТО. 63R ALL ОТНЕ!!: МОО5. II:.P.O.

10В923

А55У.

PRINTED crRCUIT

,

977"

• ----977--'

00000 080 0 0 9"

--+I--.J LI-

DUAL BRAKE ТО

FUEL I GAGE 29 ~ SENDER VrA 14405 ASSY.

ТО

FUSE PNL.

10 COHSТAНT

VOLTAGE UNIT

Fig. WD17B Ignition. charging and starting wiring diagram - 1971 (continuedl

•

,

~ ----------------------------------------------------------~

,-14300 "55У.

--

-1"18-, 57С

37' ,

START'~

MOTDR REL.AY

R,H.SIt)E МАНКЕН ,-,М.

8AHERV '_С ' - - ~301

г C8ZB-13A210-A

1----------1-: I

А55)'. ~

0::::= = - - 1 4

ELK.-YEL. \181 WHT .-BLUE !JB) .

G

BLACK

U

=-'

-,

- - 2 - - +---,

'---:-::: =': Н,Н. FRONT РАНК & тинн

"55)'

13234

I,

I I I I

-

srCNAL

l

5"

САм.

,,-

, ,

C8"'8-14489-Y

57' _-'~_

'

,

"

_ 511> ШJ)

-<><:' .d...

-

Н.Н. ~IGH &. LOW 8ЕАМ HEAOL.AMP

BLK -

37.

НЕО

( 18 )-

,

BlK - НЕй (18)

1141

ЬЛJ LAМP SWIТCH

н

"'55У

1554 Ь ~~U.E (/8)

138

2

12С

,

10'

37 (10)

DASH - - ' PANEL

14290

"'55.,.. C8A8-14489-Y

:=t======!:=

~ --1"---13'--

11(18) 13(18)

(18)

~~-------57H-------,

(

HEADLAMP

Щ

ТО

W'HOSHIELD

WASHER PUMP

,- - - - - - - - - - - :

C'lAE

14

L,H . HICH &. lOW ВЕАМ

140

F:

: I

-, I :

13-

C8ze-IJАlIО-А

13235

А55)'. \

0-84

aLK.-УЕL. (181 - \' . 'о\НТ .-еШЕ

,1- _ __ __________ 1.

2818

140(18 14808

(18)

3(18)

-BLACK 570

l.H. FRONT PARK &. TURH SIGNAL

57" _ (lЮ

)(18

2(181

САМ'

140

I

57Н

- - 37(10) - -

57.

L _ _ _';28

(181

DASH PANEL

L,H. SIDE

..

МААКЕА

"'

Fig. WD18A Exterior lights and turn sign81s wiring di8gram -1971

'-- PAltT OF С808-14489-6

•

,--------------------------------------------------------------------207 •

--7

"":--.

'--t

НОТЕ:

r - DA SH

IV

::;::;

г\,l'\ ~

CiJ ALL lEHER S CIR CLED 1.5

SHOWN

INDICATE CONNECTORS

PANEL

\ STIJtTING МОТОА

REL.AY

'аЮ6

C8AB- J ~489-AA - ' то п оо ASSY.

,

)

>

( в

" • .- -+-1-+--+ - -:

•

"-~

~~ -,,

OIA8-14489-LA ТО IGNITIQN SWITCH

г С 92 8- 144 89-"

. :.> ........_ ..... -т-

2

,--',, --'

29EoC - - - ,

С_ "

57С

TURN 51GHAL FL.ASHER

57О -,

г

57,

]

j~'' -

'---385( 16

АМР CIRCUl T ВАЕАКЕА

IS

i ••

I

I

,

-11 )u

I '""

'

,

d 1'-'

( ....... "1 ';I

Q

I--H-i, -

1

v

ЕМЕАGЕНСУ

WARNINC F~S,Ii~R

000 8- 14489-" - /' Т О PRINТE D СКТ .

----:.--t-т,,;;:---+- ==Г'

I

57r

-

~~UJ

( С >

8О ДА D

-

STO'L.AMP

•

SWITCH

."

< и> о

l S(8) 14

о о

C9A8-14489 - K

---~ " ~I~-tI ---++--"C ---''1----

2

--:!'::==-~ "=-;-12>======t---

ТО HEADLAMP SWIТ CH

,

(,>

,

I

'.7А

" ',' •

I

CSAB-llА648 -А ~

"с

+-

I

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I 5

-14'

< ','

f

10 FUSE pANEL

)

:.. \...... C4f}8-144~9_A,

HEADLAMP ' - _ _. _- , OIMMER SWIT CH

Fig. W01 88 Exterior lights and turn signals wiring diagram - 1971 (continued)

rтEM о - 4 - --' RED ТО l •• 05

,

•

208 GLOVE

14300 ASSY,

'" ~ 19,. ~ --4!l! \ _ - ~

--

LAMP

O"SH PANEL

?

ВОХ

([1i

11,

,,

GLOVE вох SWITCH

546

;Г::Г -

0) &

~

г

STARTINC

'3B71~~.

rem

ВАТТЕАУ

,"')1 ASSV.

(R.P.O.J

1'1 ~ i

•

.ос

-

,

7 1/2 АМР

376

BLK ' (18)

,, ,, I

МАР

57

lAMP & SWITCH ASSY.

5,7

г---------------,

1

,,

53

ffiП''1Е'J

30

15650-

A.ssy.

54

I L _ _______ _ __

'-

19·

15702

37'

AS SY, (R , P .O,)

~

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0-4'

~

,с

ENCINE.

он

СОМРТ. САМР т , Р. О)

•

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, 114.

,

CO NSOLE ClOCK

•

,

-

40

::УI , -@ ~ -а: tIf~~1iL ' , icj...

& МОО

•

Ь3А

CLOCK

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r

5 Т О. МОО. b5F'

r

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1) 1

~

57.

\

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57'

~

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,

,

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W!SWIPER.~

+'

SW.I LLUM.

но. LP.

~75

:'76

14Е

Q

т

ILLUM.

О5SY. ISAsoe PIINDL

•

I

•

SW. ®=.5,:~

ТО

~M.

Т1I AНS.OI,P, O,)

DASH

г

Г ,, ,< "Е

•

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0- 7

PANEL~I

, •

i.'1

ff····

fIICIфе • • •

.'10 .to , "7/

54.

.: o~

•••••• фее&ее

6--'

о

1 00

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go

ОООО О Ф

0 00000

r О о'

1-,. ';6

о о

.J

,

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15056 ASSY.

,

R.P ,O.

1* 37'

5:4

157'

НТА.

• •

LA мр ILLUM ОА ALL AUTO

й~576

[Q(

О

20 О

F'US E PANEL.

'J.

Fig. WD19A Interior lights wiring diagram - 1971

о

о

о

о

.: : О

qО

О

О

'I ,I ' , , 1,О ,' ,, ,, , 01О ') О

О

I О

О I

t (]

О I

,о

О

т

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, , ;~ О "~-

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,о ,о

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,--------------------------------------------------------------------209 т,Р.О.)

-----54А -

=-,54

=

г

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53

C8AB-14489-L

, \

OOD8-1~489-D

I

J

"

,

"6- ~ 1

'. :~.

~

9

~,

WIRING COLOR

L . _ __

SWITCH FOR COURTESY L.AMPS L.H. А,Р,О. CONV, СНЕСК.

,

14 .1.9 37 40 53

'4 55 57 159 ] 73

-------I~-~I--Q А.Н.

CQURTESY LAMP

':Ji:I (АТ INSTR. PANEU -

5>С:-'

СООЕ

DООА JA.МE!

C81.8-14489-T -

BROWN LT. 8LUE1tED 5TRIPE YELLOW LT.BLUE-wнrТЕS1ll:IРЕ

BLACK-LT. BLUE SntlPE

LТ. GREEN-УЕlLОW STRIPE

BLACK-PINK STRIPE BLACK RED·PIHK STRIPE PINK-wl-iIТЕ SТRI~E

ОООА J"MB SWITCH

FOR COUATESY LAMPS А,Н. 5ТО. РАОD.

-

•

GRDUND

SPLICE

ОК

BLANK

НОТЕ

UNLESS ОТНЕRWlSЕ SPECIFIED ALL CONNECTORS ARI! BL.AQК

SWITCH

t';\

5>

-

5

ЗА

l8ii---

\fJI

L,H. COU.RTESY LAMP (АТ INSTR. PANELJ

C3T8-141.309-06 ....1

14401 ASSY. ТО КЕУ

WARNING

BUZZER OOOB-14489-o \

!

i

-, 173 ,.,,J,

138712 ASSY.

" 5ЗВ~ г 54С -

. . . 1 +, ,

" ' '

'-C3TB-14A309-A

.-

,

,,

ОООН

JAMB SWITCH FOR COURTESY LAMPS L,H.

LUGGAGE СОМРТ, LAMP & SWITCH ASSY, - (R ,Р ,О ,) 14401

S4~~ 5>" 5>'

-PRINTEO СIRСUП аО АНО CLUSTER ILLUM, SHOWN

--

54

~o

.., "1 oг.i~ .. о

-137

НЕО

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"~7~' , , ,О'55У ,

5> ----1@':;;>:>-_"LU' 'Ш~, Ю,.

ASSY.

,, ООМЕ lдMP ~S:SY,

10

1- _ _ _ _ _ _

- -______ -.J Fig. WD19B Interior lights wiring diagram - 1971 (continuedl

•

,

•

I•• I --

--

_.

• •

•~

-

.' r:

--

,,

'" .:. '"-•3 (

-

+с

о

•

•

1___1

1

,

, ••,

••

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-

о

о

-• -

-•

,

,•, •• •

•, ," •

6

-

•

•

•

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, •, I

.. .-

•••

:"

•

••

• - - .'• Г'• 1,

••

-о

,-

• -.••••_. (~I'

о

• •••

-о

~T-

•

•

•

•

••-

,• ••• •• • • , • ••• • -• I •

•• ..

>

>

. ,i-----о 1 ••

•

~ ..... 'iЗО .,:1:11.--

-о

-'I!"

"'5"

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е

• ~ ." .-

...,-- •< ••J,- -•

... > ::;

,

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L

,

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Wirin" Di.",.m -1972

Compone"t Air conditioner clutch Alternator Дltemator regulator Clock

Location

Power windows lH front door АН front door АН геаг Quarter LH геаг Quaгter Starting Wlndshield washer Windshield wiper Aadios

К-79

F-3 J-4 D-47

Circuit brsakers

Power ass;st

В-В

Stop lamp С-97 Capacitor (сопdепиг) nol88 luppr88slon J-5 Choke-noise suppression D-2B

Battery

В-2

Buzzer IHeadlamp 'ON') and key ,

F-53

wаГПlпg

Cigar lighter Distributor Engine ооуегпог Flashers

D-73 F-G-H-7 F-10

Emergency warning

D-96

Тигп

В-91

5ignal

Gauges Ammeter Fuel Instrurnent voltage regul8tor

0'1

ргеззиге

Tachometer Tempersture Governor (intermittent wiper) Heated back-light (h88t8r .Iements) Heater. Д/С bIower resistor Ноrnз

Ig"/t;o" соН Illumination 'атрз Cigar light8r Clock (console) Gauge cluster Headlamp switch

Heater controls Mai" cluster Radio W! 5 wiper-w8sher switches Indicator lamps Alteгnator Dиаl

brake waming Heated back-light 'ON ' High Ьеат High-water temp Left turn Low оВ pressure Parking brake Right turn Seat belt Lights Eng. compt. (lig"t and switch) Back-up LH Back- up АН Grifle 'атрз (2 lamps) Glove 00)(

D-25 Е-2В С- 26

D-24 С-22

D-22 В-В4,В5

J-32,33 G-7B G,H-74 F-12 Е-65

F-62 F-69,70 F-64 G-67 E,F,G,H.J-71 Е-68

F-66 D-26 D-20 J-34 Н-100

D-21 F-91 D-21 F-25 F-92 J-16 Е-7 Н-102 Н-104

Ооте

J-97 F-44 D-57

Headlights

Н-96,99

PRND21

Н-96

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& D-B6,B7

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J-35

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J-84

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С-119 Н-28

Н-23 Н-21

J -41,42 К-6

К-8 В-9 В-36

F-34 Е -42

F-54 Е-115

J-116 J-119 J - 15 К-13

G-15 Е - 81

F-81 D-78 D- 103,D- 104 8 , С-41

D-56 Н - 19 С- 95 Н-45

D-100 D-34

D-77 C,D,E-18 С-52 Н -22

J-25 D-36,37 ,38 ,39 Н -37 Н-38 Н -39

D-98 Н-21 С - 94

G-51 D-83 С- 87

F-35 F- 14 Е-7

Н - 16 Е-44

D-59 Е-7

Ногп

D-74

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К - 11

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Campone"t Дjг conditioner

clutch solenoid

I

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Wiring diagram - 1973 (continued) (see pages 219 and 231 for

r.If:.'. ' ..тсн .1 'Кеу')

..

, ,---------------------------------------------------------------------231

Wiring color key Prim.ry colors Black Brown

ВК

Тап

Т

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R

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О У

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I

Dark green Light green Dark bIue Light bIue

DG

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I

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Heavy solid liпе represents battery feed - - - - - - - - - - - -__ Невуу dashed line represents ассеззогу feed - - - - - - - - - - _

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•

•

Chapter 11 Suspension and steering Content. Adjuster plug (lntegf81 power steering) - dismantling and reassembIy ...... " .. , .......... , ........ ..... " . 32 СОВ spring - гетоуаl and In5t8118tion . . . . . . . . . . ,......... 6 Fault diagnosis - suspension and steering ................ 44 Front hub and bearing (disc brakes) - removaland i"5t8118tio" .. з Front hub and bearing (drum brakes) - removal and inst8118tion . 2 Front shock аЬзогЬег - removaland in5t8118tion ............ 11 Front wheel alignment - checking and adjustment . . . . . . . . . .. 42 Front wheel spindle - removal and i"st8118tion . . . . . . . . . . . . . 1О General description .. , .... , ......... ,... ....... .. .. 1 Integral power steering gear - dismantling . .... ........... 30 Integr81 power steerlng gear houslng - dlsmantllng, renovation and reassembIy .. .. ................. .. ........... . 31 Int8gral power steering g8ar - геаззетЫу ................ 35 Integral power steering gear - гетоуа l and inst811ation ...... . 29 Lower suspension агт - removal and Installation ........... 7 5 Lower suspension агт strut - гетоуаl and Installatlon ........ Manual 5teering geer - edjustment (in-situ) ...........•. .. 17 M8nual steering gear - olllevel check .............. . •... 16 Non-lntegral power steering control velve - overhaul ......... 26 Non-integral power steering control valve - гетоуаl and Installation .. ..... ............ . ............... 25 Non-Integral power steering cyllnder - remov818nd Inst811ation 27 Non-integral power steering system control У81уе centering springadjustment .......... .... . . . . . . . . . . . . . . . . . . . . . . . . 24 Power steering - checks and adjustments . . . . . . . . . . . . . . . .. 18

Power steering cyllnder 5eal - гетоуа' and installatlon ....... Power steering ge8r (non-integral) - гетоуаl. overhaul 8nd In5tallation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power 5teering pump drlvebelt - renewal ................. Power steering pump - overhaul . . . . . . . . . . . . . . . . . . . . . . . Power steering pump - геmоуаl and In5t8118tion ............ Power steering pump - staгt-up procedure after overhaul ...... Aack p15ton (integral power steerlng) - dism8ntling and re8ssembIy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Аеаг 5hock absorber - гетоуе' and installation ............. Аеаг spring - геmоувl and installation .................. . Stabilizer Ьаг - гетОУ81 and Instelletion .................. Steering column - гетоуаl and installation ...... . . . . . . . . .. Steering column иррвг shaft besring - removal and instatlation Steering gear (manual) - di5mantling. overhaul and reassembIy Steering gear (тапиа!) - гетоуаl and In5tallation ........... Steering 11nkage connecting rod end5 - removal and installatlon . Steering linkage idler агт and brscket - геmоуа' and installation Steering wheel- removal and installation .. .. ............. Stub shaft and rotaгy valve essembIy (integral power steering) - di5mantling and reassembIy . . . . . . . . . . . . . . . . . .. Tilt steering column mechanism - гетОУ81 and In5t811ation ..... Upper 5uspension arm - гетоуаl and installation ... .... .... Upper suspension агm shaft and/or bushing - renewal ... ..... Wheels and tires . . . . . . . . . . . . . . . . . . . . . . . . . . ....... .

28 19 20 22 21 23 34 12 ,3 4 38 37 15 14 40 41 36 33 39

8 9 43

Specific8tions

Front suspension Туре

. ............... • . •..• • • • • ... • . •..• • • • • .•.• . ..

Balljoints - radia l play : Lower b811joint .. , , ... .•••..•.• .. . . .•• ••.• ••• •••... Upper balljolnt .. " , ... • ' • . . .. , • ....• ' •. . ... " " " . Аеа.

suspension

Туре

... . . " , . . . ....... " ,.. . . . " . . . . , . . . . . . . . . " . .

Independent. coil springs, upper and lower shock absorbers. 5tabilizer Ьаг .

агтз ,

.....................,.....,..............",. Model , ... , .. , ...... , .... " ..... " .... " ......... " Gear ratio .... , ..... •. •. ••••• .• • •• . ....• . •....•••.• ' Turn510ck-to-lock . '..... , ....• ' •.•... , , ...• ' •.•.•.•.. , ' Lubricant .... , ............ , , , .•........ • .•.•.•.•. , . , Cap8city ' Ь (g) . . .......... ,.' • .•... , ....• , • . • . • . . .... Worm beari ng preload , ... • ... • • •. ...• • • .• .• .••• . • ..••• .

Total center meshload , , ......... , •.•.• , , .... , .•.•.•.•. ,

Adju5tments

.......• ' • .. , .. ...• , • . . ........ • . • , • . . ..

doubIe-асtiпg

Renew If visibIy 1005e 0 .250 '" (6,35 тm) maximum

Semi-ellipti c leaf springs with

doubIe-а с tiпg

Steering (manual and power-assistad steering gearl Туре

and

shock absorbers •

Worm and recirculsting ball 5MB- D 5MB-K

SMA-R

SMA-T

19.9:1

16:1

22 : 1

24:1

4f

3t

5!

6t

-

ESW-MIC87-A

ESW-MIC87-A

ESW-MIC87 -A

ESW-MIC87-A

0 .55 + 0 . 05 1 Ь 1249 + 22g) 4 'о 5 Ibf '" 14 .6105.7 5

0.87 + 0 .07 Ib 1349 + 31 g) 4 'о 5 Ibf '" 14.6105.75

0 .87 + 0.07 Ib 1349 + 31 g)

~cm )

0 .55 + 0.05 1Ь 1249 + 22g) 4 'о 5 Ibf '" 14.6105.75 kgfcm )

~cm)

~cm )

9t010lbfin

9t010lbfin

9t010lbfin

9t010lbfin

110.31011.5

110.31011.5

110.31011.5

110 .• 1011.5

4 to 5 Ibf '"

14.610 5.7 5

kgf ст) kgf ст) kgf ст) kgf ст) Adjusting screw to bottom of sector shaft Т -510t clearance 010 0.002 in 10 10 0.050 mm)

Ch8pter 11 Suspension 8nd steering Powe, steering

ритр

Make ........ _ ........ .....................•. • .•.•. Туре

2ЗЗ

. . . . . . . . . . . . . .... .....................•.•.•...

Ford-Thompson Belt-driven slipper type

RotOf shaft endplay ....... ............. . .....•.•.•.•. . . Ма.х.. torque allowed to rotate rotor shaft .... .•.. . • . •.• . • . •. . . Worm bearing preload .... ..... ....... , . • ...• . •.•. • .•. . .

0.00310 0.017 in 10.076 10 0.43 1 т т) 151Ы in 117.25 kgf ст)

Worm-to-piston preload ......... " .... " , ..•.•.•.•.•.•.

0.5104 .5

9 Ibf in (1 0.3 kgf cm) mex IЫ

in 10.57 10 5.17 kgf ст)

1nteg'81 power steering gears Make .... ...... ..................•.•. .. •.•••.•. . . . . ~e

.

..... . . . .

.....

Saginaw Recirculation

Ьаll

torsion

Ьаг

Ratio : 16 : 1 сепtег to 13 : 1 at tock

VariabIe ........ ............ . . , , ..... • . • ... . ..... Сопstапt ..... .. . ................... . • • •....... . . Ftuid capacity (i ncluding reservoir) .......... . ..• . • . ........ Fluid specification ...... . .............. .... •.•.•.•. . . . . Total meshload over worm bearing pretoad .......•.•.•.•.•... Total meshload over mechanical сепtег .......... • .• . . . . ..... Steering wheel turпiпg effort .............. . ..• • •.• . ••. . .. Manual steering . .. ..... : ........•... .. •.• , •.•.•... Power stеегiпg ...........•.•.•..........•.•.•.•...

37 6.5

Front wheel alignment

Min

Мах

Optimum

Caster - 1965 .........................•.•.. . ........ 1 966 ...... . ........•.•....... • . . ........... 1 96 7 . . . . . . . . . . . . . .. .. .. .. . . . . . . .. ...• ... • . . 19 68 ... ....... .. •. . . . ....... . •.• .. . . •.•.•. • 1970-7 1 .... . .....•.•. . .. .... . ...•.• . ........ 1972-73 ....•.....•.•. . ..........•.•.........

-to

+to + 1о +to

+to 0°

+1-10

+to 0° 0°

СатЬег

- 1965

1966 1967 1968 1969

• • •

• • •

•

•

•

•

•

• • • •

• • • •

•

•

•

•

•

•

•

•

•

•

•

•

•• • • •

• • • • •

• • • •

•

•

•

• • • •

•

•

• • •

• •

•

•

•

.

•

•

• • • • •

•

•

•

· . . . ..... . . . . • •

•

•

•

•

•

• •

~

•

•

•

• • • • • • • • • • • •

•

• • • • • • • •

•

• • • • • • • • • •

•

•

• •

•

• •

•

•

•

•

•

•

• •

.. . . . . . . . . . . . . . . . . . . . . . •

• •

•

•

•

•

•

• • • • • • • • • • • • •

1970-71 . ...•....... ... •.•...... .... •.•. • .•. 1972-73 ....•.•..........•.•........•.•...•. Тое- ; п

- 1965 ............ • .. .....•.• .. •...........•. 1966 ........... . •.•.. ...• • • .. . . • ..... . . . . •.

1967andI969 . . . . • . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 9 68 . ..........•............•.•............ 1970-71 .. ....................•.•............ 1972-73 ..............• • • . . . ..•.•..• . •.•.• . ..

Torque wrench settings

17.5 : 1 1.6 pt (0.75 titre)

арргох.

D2AZ-19582-A 4 to 8 tbf iп (4.6 to 9.2 kgf cm) 18 'Ы iп (20.7 kgf сm) max. IЬ

-11

kg 16.7 2.9

о

-to -to -1 о _2° 0° -to +to +to +to 0° -to

арргох.

Р

+ 1о +2° + 1о

+to +to + 1о +1" +to + 1о +to

+1-10 +1t o +1-10 +1t o +чо +чо

0.2510 0.312 in 16.3 10 7.9

тт)

0 .125 to 0.375 in (3.1 to 9.5 mm)

0.12510 0.250 in 13.1 106.3 тт) 0.18710 0.312 in 14.7 10 7.9 тт) 0.062 to 0.312 in (1.5 to 7.9 mm)

0.06210 0 .375 in 11.5 10 9.5

тт)

'Ы"

kgfm

101015 20 10 30 7510100 60 10 90 70 10105 7510100 171030 60 10 80 51012

1.3t02,0

2.7104.1 10.31013.8 8.210 12.4 9.6 10 14.4 10.31013.8 2.3104.1 8.21011.0 0.69 10 1.65

221029 451065 151025

3.0 10 4.0 6.2 10 8.9 2.0 10 3.4

35 to 50

4.8 to 6.9

8010110 70 10 95

11.01015.1 9.61013.1

151022 321040 181042 451060

2.0 10 3.0 4.410 5.5 20.7 1048.3 6.2 10 8.2

3109

0.4t01.2

Front suspension Shock absorber иррег attachment ........ . ........•.•.•.• . Shock absorber иррег bracket-to-body ..... . . . • .... .• . • • • • •. Upper агm ;ппег shaft-to-body ...........•..............•. Ba lljoi nt-to-spindle ...................•.•.............. Strut-to-lower arm ... , ........", ......•.•. . " " ....... , Lower arm-to-underbody , , ... , , , .. . . . •.•. ...•. • .. . . . ..•. Stabllizer bracket-to-underbody , . , .....• . • . .. . • ' ........ , , Strut-to-underbody . ' , , , , ... , , ....... , •.•.. , ......... , , Stabl lizer bar-to-Iower агm ... " ....... , •.• .. " ........•.

-

Яеаг

suspension

Spring shackle bars-to-body and spring . . ..... •......... ..... Shock absorber-to-upper mounting bracket ....•.•............ Shock absorber-to- spring сliр plate ..........•.•. ... ........ Spring-to-axle U-bolt nut .................•.•............ Spring-to-fronl hanger bolt .......... . . . .. • . •.. . . • • • . • ... Spring-to-front hang~r nut . , ..............•.•... . ........

Steering Sector shaft cover bolts .... • •. •. . • . • • • .. . . . ••• . •. . ... . •. Adjusting screw locknut .... • .•......•.....••••• ... ...•. 8al l guide clamp screw .. . ..•................•. • .•.•.... Preload adjuster locknut . . .. • .•. . ..............•.•.•.•.. Filler Plug ...... ..........•.•. . ............•.•.•.•..

•

Power steering рumр Pump-to-front bracket ........•.•.•.•.... . . ......• . • . • .. Pump pivot ............... • .•.•.•.•..............•.. Pump-to-rear bracket nut .....• . •.•.•.•..• . ......•...•..

30 10 45 251040 20 10 30

4.1106.2 3.410 5.5 2.7104.1

Chapter 11 Suspension and steering

234

Reservoir-to-housing nut . . . . . . . . . . . • . • . . . . . . . . . . • . • .•.•.

IbIft

kgfm

43 to 47

5.9 to 6.4

30 to 35 30 to 35 3 to 6 50t0110 50to 100 25 to 34

4.1 to 4.8 4.1 to 4 .8 0.4 to 0.8 6.9t015.1 6.9 to 13.8 3.4 to 4.6

1В to 24 30 to 40 28 to 35 35 to 47 60 to 80 10t014 35t047

2.4 to 3.3 4. I to 5.5 3.В to 4.В 4.8 to 6.4 В.2 to 11.0 1.3tol.9 4 .8 to 6.4

24 to 37 10t018 30 to 40

3.3t05.1 1.3t02.4 4.1t05.5

In tegral power steeгing уеаг Sector shaft соуег bolts . . . . . . . . . . . . • . . . . • . • . . ... ~ • • • • • • . Mesh load adjusting screw locknut ... .•.• . .........•.• . • . •. ВаН return guide clamp screw . . . . . . . . . • . • . . . . . . . . . . . . . . • . Preload adjusting locknut ...... .... •.• .•.. . . . . . . . . . . .. •. Piston end сар ... ........ ... ......•. ...• ... . . . . . . .. •. Pressure and retuгn hoses-to-gear . . . . . . . . . . . . . . . . . . . . . . . . .

Steering linkage Power cylinder-to-bracket (power assisted steering) . . . . . . . . . . . . . Connecting rod end-to- spindle . . . . . . . . . . . . . . . . . . . . . . . . . . . . Idler arm Ьгасkено- fгаmе .... ....... .. .... .. . . . . . . . . . .. . Pitman arm-to-control valve (power steering) ... .•. ........... Idler arm-to-Pitman arm-to-idler агт rod .......•.•.......... Connecting rod adjusting sleeve clamp .........• .. ..• . • . • . .. Pitman arm -to-steering arm-to-idler arm rod .....•... . •.• . • . . .

Steering column Flex coupling-to-steering gear ... .. ..... . ... . • . •....• . •. .. Flex coupling-to-steering shaft 11аП9е ....... . . . • • •.. .. . . • . •. Steerin9 wheel attaching nut ........... , ... . • . •. . ... . •. •.

Яеаг

1

General description

Front suspension 1 The 1ront wheels rotate оп spindles which аге mounted to the upper and lower suspension arms through baJljoints. The upper arms pivot оп bushing and shaft assembIies which аге bolted to the frame. The lower arms pivot оп bolts in the crossmember. The coil springs and shock absorbers аге located between the upper arms and the top 01 the spring housings оп the body. Struts аге installed to prevent foreand-aft movement 01 the suspension arms.

suspension

2 The semi-elliptic leal springs аге suspended from the underbody side rail Ьу hanger and shackle assembIies 8t the front and геаг. Thвr axle housing is mounted оп the center 01 the sprl"gs and secured Ьу U-bolts. The integral mounting stud 8! the upper end 01 e8ch shock absorber 'э attached (о the erossmember Ьу 8 mounting pl8te. The lower end is attached to а stud whieh is i"t8gral with 8 bracket welded to the axie housing.

Steering 3 The manual steering is 01 the worm and recirculating ball !уре. The sector shaft is straddle-mounted wlth а bushing located '" the еОУег

SHOCK ABSORBER

UPPER

_ _ SHOCK ABSORBER

MOUNТlNG ~

.-'

ВААСКЕТ

, SPRING

ВАН

UPPER

ДАМ

JOINT

__

,

ECCENTRIC AND 80L Т

SLEEVE

/

STABlllZER

\

STA8 1LI ZER LIN K 80L Т

.д>

(-'\

,

\

\\ ,•

,

-

I

ER PIN

,I

I,,, II

INSUlATOR

I

~.

FRONT CASTELLAТEO

NUT

80LT

Fig. 11.1 Front suspension

\

, (8ве

1)

• •

, Chapter 11 Suspension and steering

235

I

---- --

,

REAR SHACKLE

/

••

FRONT HANGER - - -__

Fig. 11.2 Аваг suspension (Sec 11

IN PU1" SHAFT

SECTQR SHAFT ADJUHMEN T SCREW

I

i

I

I

ID ЕNТ I F IСАТЮN

SECTf)R SHAFT

SECТOR

TAG

SHAFT CQVER

Fig. 11.3 Steering gear - manual and non-integral power steering (Sec 1) аЬоуе

the gear and агоНег bearing in the housing below the gear. The worm bearing preload is controlled Ьу the large adjusting nut w hich is threaded int o the housing, and the sector shaft mesh is controlled Ьу эп adjusting sc rew located in the housing соуег. The steering linkage consist s of а Pitman агт, steering 8rm -t o-idler агт rod , idler агт and connecting rods. 4 Two types of power steering аге аvаi l а Ы е as ап option . ОП model s 10 1970 а non-integral power steer1ng system 1s used. It 1s а hydraulical ly controlled linkage type wh1 ch includes ап 1nte9ra l pum p and fluid r ese гvo 1r . а control valve . а power cyHnder and flu1d 11nes. The pump 1s belt-driven from the engine crank-shaft. Оп 1971 / 7 3 models а Sag1naw integral power steering gear is 5 used. It operates Ьу displac1ng fluid to provide pressure ass1stance only when tu rn 1ng. As the gear assembIy 1s always fu ll of fluid. all internal componen ts of the gear аге immersed in flu id making per1od1c lubrication unnecessary. The fluid also acts as а cushi on to absorb road shocks th at may Ь е transmitted to the driver. AII fluid passages аге internal except the pressure and return hoses between the gear and the pump I Fig. 11 .4 ).

6 The steering column 1s of the collapsibIe type. It will coJlapse Ьу approximately s1x inches upon а hard impact. Опсе the steering colu mn has Ьееп collapsed. а complete new steering column must Ье installed , together with new brackets, which also shear away during impact. ,

2

Front hub and bearing (drum brakes) - removal and install8-

tion 1 Apply the parking brake, chock the гваг wheels. jack-up the fгont of the саг and support it оп jack stands. Remove the roadwheel . 2 Carefully ргу off the grease сар. Aemove the cotter pin. nut lock, adjusting nut and washer (photos). 3 Aemove the outer beating сопе and гоНег assembIy. then pull the hub assembIy off the wheel spindle . I 4 Aemove and discard the gtease retainer. Remove the inner bearing с опе and roller assembIy fгom the hub. 5 Clean the outer and inner bearing cups in the hub with solvent and

11

~ ------------------------------------------------------~

ADJUSTER

VALVE

TORSIDN ВАА

INLET

STUB

о ,

,

ТEFLDN

N

RING

RING

'

BEARINGS

ААУ

VALVE TEFLON SEALS

ААСК

NUT SECTOR SHAFT

Fig. 11 .4 Cutaway view of int89r81 power steering 988Г ISec 1)

нив "'но BRAKE

DRUM

GREASE

INNER BEARIHG

A5SEМBLY

REТAINER

QUTER

ADJUSTING NUT

BEARrNG QUTER BEARING

2.2А Remove the cotter pin, nut lock. adjusting

nut ...

СОНЕ АНО

INNER СОНЕАНО

ROLLER

СОПЕR

PIN_

NUT lOCK

NUT~

A5SEМBLY

нив BOLТ

Fig . 11 .5 E)(plodвd view offront wheel and bearings - drum brakes (Sec 2)

2.28 ... and washer

I

I

I

r

f

Chapter 11 Suspension and steering inspect far scoring. pitting and excessive wear. If the cups

аге

worn

237

О!

damaged. гетovе them from the hub with а suitabIe drift. 6 Clean the cone and roller assembIies, and examine them far wear аnd damage. If апу part of the bearing assembIy i5 defective the Ьеаrinя must ьв renewed as а complete unit. Сlезп the hub and

spindle 10 гетоуе

а1l

old grease.

7 Install the outer and inner bearing cups in the hub, using а suitabIe diameter tubular drift 10 drive them fully home. 8 Pack the inside of the hub with the specified wheel bearing grease until t he grease i5 flush with the inside diameter of both bearing cups. lubricate the bearing сапе and roller assembIies Ьу working аз mu ch grea se 85 possibIe between the rollers and cages (photo! . 9 Ins eгt the inner bearing сопе and roller assembIy in the hub then install а new grease retainer using а tubular drift. Take саге not 10 disto гt the retainer, and ensure that it i5 properly 5eated. 10 Дdjust the brake shoe5, as described in Chapter 9, then install the hub and drum assembIy оп the wheel spindle. Кеер the hub centered оп the 5pindle to avoid damaging the grease retaineT. 11 In5ta ll the outer bearing сопе and roller assembIy, the flat washer and adjusting nut. 12 In5tall the roadwheel . 13 Whi!e rotating the hub, torque tighten the adjusting nut to 17 to 25 !Ы ft (2. 4 to 3.4 kgf т! to seat the bearings. Ba ck-off the adjusting nut опе half turn , Ihen retighten il to 1 О to 15 Ibfft (1.4 10 2 .0 kg1 т! . 14 Inslal! the nut lock so that the c8stellations аге aligned with the cotter pin hole оп the spindle. Install а new cotter pin and bend the ends round the castellated 11ange of the nut lock. In5tall the grease сар .

15

Дdjust

the brakes as described in Chapter 9. Install the hub wheel соу ег, and lower the 1ront 01 the саг .

сар ог

з

Front hub Bnd b8aring (dilc brBkes) - гетоувl Bnd in8t8118tion

1

Сапу

out the operations in Section 2, paragraph 1. 2 Remove the brake caliper from the rotor, as described in Chapter 9. and tie il up to prevent damage to the brake hose. 3 Carry out the operations in Section 2, paragraph 2 through 9. 4 Inslsll the hub and rotor assembIy оп the spindle, taking саге not 10 damage the grease retainer. 5 In5tall the outer bearing сопе and roller assembIy, the flat washer ancl adjusting nut. 6 Дdjust the wheel bearings аз described in Seclion 2, paragraph5 1Запd1 4 .

7 In slat! the brake саНрег (see Chapter 9) 8 Inslall the roadwheel and hub сар , ог wheel соуег, and lower the front of the с аг . 9 8efore driving the саг, pump the brake pedal several lime5 10 obtain normal psd 11ning-Io-rotor clearance.

tUS

АНО

ROTOR

2 .8 Hub packed with grease

4

St8bilizer Ьаг - гетоуаl and inlt8118tio"

Raise the 1ront of the саг and support 11 оп jack 5tand5. Remove the link bolts and in5ulators attaching the stabitizer Ьаг to the lower suspension arms. 3 Disconnect both attaching brackets and remove the stabilizer Ьаг. 4 Installation is the геуегзе of the removal procedure. Always U5e new insulators. When Installlng the link bolts make sure that the bolt head Is а! the top to prevent It foullng the brake hose.

1 2

5

Lower suspension

вгт

гетОУ81

8nd inlt811ation

1 Position а support between the upper arm and frame side гаН . as shown in Fig. 11.7 , then raise the front of the с аг and support It оп jack stands. Remove the roadwheel. 2 Remove the cotter pin , caste llated nut and adjusting nut from the fronl of the strut. 3 Using two pry bars, опе at each side and at the rear of the front washer, separate the inner sleeve from the outer sleeve and remove the front insulator.

INNER aEARING CUP

.uSEМ8LY

strut -

GREASE I

OUTER lEARING

ADJUSТING

NUT ouтeo

lEARING СОНЕАНО

GREASE САР

ROLLER

11

.... -

COII&

HUТ

'оек

ASSEМILY

HU.IOLT

• Flg. 11.6 Exploded view of front hub Bnd bearings - disc brakes (Sec З)

Chapter 11 Suspension and steering

ZЗ8

SECUII:ELY

Fig. 11.7

иррег агт

support in position (Secs 5 and 7)

ЗА" CQLD

.OlLED

.-...;

RADtUS ВОТТОМ ЕDСЕ--'

4

Remove the strut-to-tower arm attaching bolts and 11ft out the

strut. 5 In5tall а new геаг washer, aute r sleeve and insulator bushing оп the 1ront end 01 the strut. 6 Locate the strut in the crossmember and install the strut-to-arm attaching bolts. Install а new 1ront insulator, washer, inner sleeve and adjustment nut.

7

Install the roadwheel and lower the саг. Аетоуе the upper агт

support.

8

Adjust the

сатЬег

and caster (see Section 42) then install the

castellated nut and cotter pin.

в

Coil spring - removal and i"5t8118tio"

1 Raise the hood. Undo the attaching nuts and гетоуе the shock absorber and upper mounting bracket as ап assembIy. TURN

ТО

N U T - - -....

Тоо! Т

63

Р.SЗ10-А

• sрппg.

7 Position the spring upper insu lator оп the spring and secure it in place with tape. В Position the spring in the spring tower and compress the spting with the spring compressor. 9 Swing the upper агт inward and insert the bolts through the holes in the side of the spring tower. Install the nuts and tighten them to а torque of 75 to 100 Ibfft (10.4to 13 . В kgf m). 1О Release the spring pressure and guide the spting into the upper arm spring seat. The end of the spring must not Ье more than 0.5 in ( 12.7 mm) from the tab оп the spring seat. Remove the spring соm­ pressor. 11 Install the hub assembly as described in Section 2 ог 3. 12 Lower the front о' the саг and install the shock absorber and upper bracket assembly, making sure the shock absorber lower studs аге in the pivot plate holes.

7 1 - - - - - - 1 1 " '.. Adopt~r P/ot~

SHAFТ SCREW----=

T~'

Low~r Adopt~r

Raise the front of the саг and support it оп jack stands. 3 Remove the hub assembIy as described in Section 2 ог 3. 4 Install а spring compressor tool (see Fig. 11.В) and compress the spring to remove all tension from the control arms. 5 Remove the two upper arm-to-spring tower attaching nuts and swing the upper arm outward from the spring towet. 6 Release the spring compressor and remove it, then lift out the 2

Plote

HALF BALL RETAINER

Fig. 11.8 Installing the spring compressor tool (Sec 6)

Lower suspension

агт

- removal and installation

1 Position а support between the иррег arm апр side rail as shown in Fig. 11.7. Raise the front of the саг and suppor1 it оп jack stands. Remove the roadwheel. 2 Disconnect the stabilizer Ьаг and the strut from the lower arm (see Sections 4 and 5). 3 Remove the cotter pin from the nut оп the lower balljoint stud , loosen the nut опе ог two turns but do not remove it а! this stage. 4 Straighten the cotter pin оп the upper balljoint stud nut. Positi on а balljoint remover tool between the иррег and lower balljoint studs (see Fig. 11.9). Make sure the (ооl is seated оп the ends of the Stud5 ~nd not оп the nuts. 5 Turn the tool with а wrench until the studs аге under cOn5iderabIe pressure, and then strike the spindle, пеаг the lower stud, а sharp bIow with а hammer to break the stud 1005е from the spindle. 00 not free the stud with tool pressuгe only. 6 Remove the nut from the lower balljoint stud and lower the агm. 7 Remove the lower arm-to-underbody pivot bolt and Hh out the lower arm. 8 Examine the агт for damage and the balljoint for wear. Renew the arm , if necessary, аз а complete unit. 00 not install new balljoints оп а used suspension arm. 9 Installation is the reverse of the removal procedure. Tighten the

I

Chapter 11 Suspension and steering

[,

paragraph 3 through 5) then гетоуе the nut from the upper balljoint

Tool- T62F-3006-A

UPPER 8All

239

stud and litt the stud out of the spindle. 7 Аетоуе the upper агт inner shaft attaching nuts, from inside the

~PPO'-'-

engine compartment, and lift out the upper агт.

8 Examine the агт for damage and the balljoint for wear. 00 not wash the balljoint in grease solvent. Aenew the агт, if necessary, 85 а coтplete unit. Оо not install new balljoints оп а used агт. 9 In5tallation is the f8verse of the removal procedure. Tighten the

I

upper balljoint stud nut and the upper агт inner shaft nuts to the specified torque. If the upper агт is being renewed as а result of accident damage, check the cBster, сатЬе г and toe-in (see Section

421. .

иррег

9

Toel_ Т57Р·ЗОО6-А LOWER BALL JQINT

Fig. 11.9 Loosening the balljoint studs (Sec 7) lower balljoint stud nut and the lower arm-to-underbody pivot bolt nut to the specified torque. Check caster, camber and toe-in (see Section

421.

8

иррег

sU5pension

агт

-

гвтоуаl

8"d i"5t8118tio"

1 Raise the front of the саг and support it оп jack stands positioned und er th e frame. Remove the roadwheel. 2 Remove the shock аЬэогЬег lower attaching nuts. 3 Undo the attaching nuts and remove the shock absorber and upper mounting bracket аэ ап aS5embIy. Instal! а spring compressor tool and compress the spring, (see 4 Section 6). 5 Position а jack stand ог other suitabIe support under the lower агт.

6

Loosen the upper balljoint stud

ёп

the spindle, (see Section 7 ,

suspension

агт

shaft and/or bushing - renewel

1 Aemove the upper arm as described in Section 8. 2 Un5crew the bushings from the shaft and arm, then remove the shaft from the arm. 3 P05ition the shaft in the arm, grease the new bushings and 0rin9s, then install the bushings 1005е оп the shaft. 4 Center the shaft in the suspension arm. Aefer to Fig. 11.11 and screw in the bushings until the dimensions Д and В аге equal. 5 Make а spacer from а piece of 0.75 in (19 mm) diameter steel tube. The spacer should Ье 6li ёп (176 mm) long for рге 1971 models, and 8-1 in (206 mm) long for models from 1971 оп. 6 Force the spacer between the flanges of the upper агт, as shown ёп Fig. 11.12, then torque-tighten the bushings to 25 to 35 Ibf ft (3.5 to 4.8 kgf m). 7 Aemove the spacer and check that the shaft is free to turn without binding. 8 Install the upper arm (see Section 8).

1 О Front wheel 5pindle -

гетоуа'

and in5t8118tio"

1 Aemove the hub assembIy as described in Section 2 ог З. 2 Оп models with drum brakes remove the brake backing plate (see Chapter 9), and suppoгt it to avoid damage to the brake hose. ОП

BUSHING

I

.

'

------.-.-.-'ВUsнING

.....

) ,НОС, ДВ")"

1 ,,'

::----

---- ~'-

СдМ

REAR HUT

"дТ

----.1

SEAT-I-_..

I

BUSHING

SLEEve

i--~

INNER SLEEVE

FR~T

ADJUSTMENT

BRACKEТ

...,

WASНER

HUT

Fig. 11.1 О Exploded view offront suspension (Sec 8)

LOWER BALL JOINT

•

Chapter "

240

Suspension and steering

•

Fig. 11.11 Centering the upper arm shaft (Sae 9)

models with disc brakes remove the three caliper shield attaching bolts and lift off the shield . 3 Using а balljoint separator, disconnect the connecting rod end from the spindle arm . 4 Loosen the upper and lower suspension агт balljoints in the spindle аз described in Section 7. 5 Position а jack ог similar support under the lower suspension вгт. Аетоуе

the upper and lower balljoint stud nuts. then lower the jack

and remove the spindle. 6 Installation i5 the reverse of the removal procedure.

11 Front shock 1

аЬаогЬег

Raise the hood and

shock

гетоуе

аЬзогЬег

Fig. 11.12 Torque-tighten the upper

втт

bushings (Sec 9)

access соуег, Fig. 11.1 З. Оп convertibIe models the геаг seat and seat back must Ье removed. 3 Remove the shock аЬзогЬег upper attaching nut. 4 The shock аЬзогЬег сап now Ье compressed and rernoved lгот the саг. Remove the bushings lгот the studs. 5 Inspect and check the shock absorber as described in Section 11. 6 In stallation is the reverse 01 the removal procedure.

the shock

аЬзогЬег иррег

1Э

-

гетоуаl

and installation

1 Disconnect the shock absorber lrom the spring clip plate (see Fig. 11.15 and photo). 2 Working in the luggage compartment, гетоуе the shock аЬзогЬег

11.1 Front shock absorber upper mounting

Аваг

spring - removal and installation

mounting

2 Aaise the front of the vehicle and position jack stands under the lower агтз. 3 Remove the two shock absorber lower attaching nuts and the insulators (photo). 4 Lift the shock аЬзогЬег and upper bracket from the spring tower. and гетоуе the bracket lrom the shock аЬзогЬег. 5 Clean the exterior and inspect the shaft 10г signs of corTosion ОГ distortion, and the body for damage ог 10г slgns 01 hydraulic fluid leaks. 6 Check the action Ьу expanding and contracting to ascertain if equal resistance is lelt оп both strokes. If the resistance is уегу uneven the unit must Ье renewed. Always renew them in pairs, either both lront опез ог both геаг ones. 7 Installation is the reverse 01 the removal procedure . When positioning the shock absorber and upper mounting bracket in the spring tower ensure that the shock absorber lower studs аге in the pivot plate holes.

Аваг

SUPPORT STAND

- removal and in5t8118tion

bracket attaching nuts (photo).

12

SPACER

1 Aaise the геаг of the саг and support it with jack stands under the body and under the геаг axle. 2 Disconnect the lower end of the shock absorber lrom the spting clip plate and push the shock absorber out 01 the way. Аетоуе the supports lгот under the axle. 3 Автоуе the spring cl ip plate retaining nuts lгот the U-bolts and remove the plate. Jack-up the геаг axle just enough to take the weight off the spting. 4 Aemove the two attaching nuts, the геаг shackle Ьаг and the two shackle inner bushings. Aemove the гваг shackle assembIy and the two outer bushings. 5 Aemove the 1ront hanger bolt from the еуе at the lront end of the spring and then lift out the spring. 6 If апу 01 the shackles ог bushings аге worn they must Ье renewed. 11 the lront еуе bushing is being renewed , it сап Ье removed and а new опе installed Ьу using а long threaded bolt , а distance piece 01 similar diametet as the bushing and large llat washers. Tightening the nut will draw the old bushing out 01 the spring еуе ог draw а new опе into positlon. Fig. 11.14 shows the Ford tool being used to install а new bushing. 7 If а spring leal is broken ог the spring has weakened, then it should Ье renewed: in this event the othet геаг spring should Ье renewed at the same time. 8 Installation is the reverse 01 the removal procedure. Тighten the

11.3 Front shock absorber lower mounting

12.1

Аеаг

shock absorber lower mounting

Chapter 1 1 Suspension and steering

SНOCK

241

ABSQRBER ACCESS СОУЕ!!:

т001- T64N.S781.

,

AJ"

А4

( дdopfer)

I ,

. ВЗ

·81 ( 801t)

,

Tool-

• Fig. 11.14 Removing the

гваг

spring front bushing (Sec 13)

LUGGAGE COMPДRTMENT

FlOOR PANEL

Fig . 11 . 1 3 Removing the

гваг

ассезз соувг (Sвc

shock 12)

аЬзогЬег

,,

VIEW

SНACKLE

PS

SPRI NG

У

VlEW Z

SНACKlE

REAR

BU5HING

5НACKLE

-. SF'RI NG

SHOCK ABSORBER

MOUNTING BQL Т QIREC TION QF SHACKLE QPTIONAL

VlEW W

FRONT

ЕУЕ

SPRING

PLATE V1EW

У

Fig. 11 .1 5 Exploded view 01 гваг suspension (Secs 12 and 13)

front hanger bolt and the shack!e locknuts 10 the specified torque after the саг has Ьееп lowered 10 the ground.

14 Steering

g88t (тапиаl)

- removal end instelletion

1 Raise the front of the саг and support it оп jack stands. 2 Aemove the bolts connecting the flexibIe coupling to the steering shaft. 3 Ае тоуе the nut that secures the Pitman агт to the sector shaft and. using а putter. гетоуе the агт from the sector shaft. Do not hammer оп the end of the puller as this сап damage the steering gear. 4 Оп some models with manual transmission it тау Ье necessary {о

disconnect the clutch linkage. and оп some models the exhaust system must Ье lowered. {о provide enough clearance for removal of the агт. 5 Аетоуе the three bolts securing the steering gear {о the side rai! and lift out the steering gear. 6 Installation is the reverse of the гетоуаl procedure.

15 Steering reassembIy

gear

(manual)

-

dismantling.

overhaul

and

•

1 Clean the exterior of the steering gear. гетоуе the filler ptug and drain the oil. 2 Rotate the steering shaft to the center position.

11

Chapter 11 Suspension and steering

242

~\ АНО

SHIM

8USHING

SECTOR SHAFT ADJUSTING SCREW ' S E AL

Fig. 11.17 Sector shaft and housing - manual steering _

ШР

lOCK NUT STEERING

BEARING - агт

~

GШОЕ \

(See 14)

(See 15)

HQIJSING 8EARING

Fig. 11.16 Removing the pitman

яеаг

•

8EARINGS

~,-CCA"P

8EAR1NG CUP

SEAL

. BEARI

НС

NUT

Fig. 1, .18 Steering shaft and associated parts - manual steering gear (Sae 15)

3

Аетоуе

the sector shaft adjusting screw locknut and the housing соуег securing bOlts, then гетоуе the sector shaft with the соуег. Separate the CQver from the shaft Ьу turning the adjusting screw clockwise. Кеер the shim with the screw. 4 Loosen the worm bearing adjuster nut, then гетоуе the adjuster assembIy and the steering shaft upper bearing. 5 Carefully риН the steer;ng shaft and ballnut from the housing. Кеер the ballnut from running down to either end of the worm as it тау damage the ball return guides. 6 Аетоуе the ball return guide clamp and the ball геlигп guides from the Ьаllпиl. Кеер the ballnul 'clamp side up' until ready to гетоуе the balls. 7 Науе а suitabIe clean container ready, then turn the ballnut оуег and rotale the worm shaft from side to side until all the bafls have Ьееп collected. The ballnut will now slide off the worm. 8 Аетоуе the иррег bearing сир from the bearing adjuster and the lower сир from the housing. If necessary. tap the housing ог adjusler оп а bIock of wood to get the bearing cups out. 9 If the sector shaft bearing is worn ог damaged press 11 and the оН seal out of the housing. 10 Clean all lhe dismantled parts. Inspect the sector shaft and steering shaft for pitting, burrs. cracks ог wear. Examine the bearlngs for wear ог damage. Aenew all the oil seals. 11 During assembIy apply steering gear lubricant to the bearing5 and 5eals. 12 If the sector shaft bearing wa5 removed, press а new bearing into the housing and install а new oil seal . 13 In5tall а bearing cup in the lower end of the housing and in the adju5ter. In5tall а new seal in the bearing adjuster. 14 In5ert the ball guide5 into the hole5 in the ballnut. tap them lightly. if necessary. to seat them. Use the wooden handle of а 5crewdriver ог similar. 15 tnsert half of the 'balls into the hole in the to p of each ball guide. It та у Ье necessary to rotale the shaft slightly опе way, then the other to distribute the ba115. 16 In5tall the ball guide clamp and tighten the securing screW5 to the specified torque. Check that the worm 5haft rotates freely. 17 Соа! the th read5 of the 5teering shaft bea ring adjuster, the housing соуег bolts and the sector adjusting screw with ап oilresistant sealing compound. Take саге not to 9е1 апу sealer оп the steering shaft bearings. 18 Lubricate the worm bearings. sector shaft bearings and gear teeth with steering gear oil. 19 Clamp the housing in а vise with the sector shaft horizontal and

install the steering shaft lower bearing in its cup, then insert the steering shaft and ballnut assembIy in the housing. 20 Position lhe steering shaft иррег bearing оп the top of the worm and install the steering shaft bearing adju5ter and then the adjuster nut. Leave the nut loose. 21 Using а Ibf in torque wrench. preload the worm bearing to the specified value (see Specifications at the beginning of lhis Chapter). 22 Inslall the sector shaft adjusting screw and shim, and check the end clearance between the screw head and the end of the sector shaft. The end clearance must not exceed 0·002 in (0·050 mm); add shims, if necessary. to reduce the endplay. 23 Start the adjusling screw into the housing соуег. InSlal1 а new gaskel оп the housing соуег. 24 Aotate the steering shaft until lhe ballnut teeth аге in position 10 mesh with the sector gear. tilling the housing so that the ballnut will tip toward the housing соуег opening. 25 With the соуе г screwed onto the adjusting screw. inslall the sector shaft and соуег to the housing. 26 Тиrn the соуег out of the way and fill lhe housing wilh lhe specified steering gear oil. Push the housing соуег and sector shaft аээетЫу into place and install the two соуег securing bolts. While

NUT

LOCK NUT \.-'."

• Fig. 11.19 Checking lhe shaft bearing pteload (Sec 15)

I

! Chapter 11 Suspension and steering

243

I

I

,

Fig. 11.22 Power steering

ритр

dipstick (Sec 18)

Fig. 11.21 Checking steering gear preload (Sec 17)

Fig. 11.20 Adjusting the sector shaft mesh load (Sec 17) tightening the

соуег

and the Full mark (see Fig. 11.221. If necessary top-up with automatic transmission fluid. Take саге not {о overfill the reservoir.

bolts make sure there is clearance between the

ballnut and sector яеаг teeth. 27 In5tafl the sector shaft adjusting screw locknut loosely

оп

the adjusting screw, adjust the sector shaft mesh load to the specified value (see Specifications at the beginning of this Chapter) then tighten the locknut.

,6

Мвпиаl

steering gear - oillevel check

1

Аетоуе

the fi ller pl ug and

2

Slowly

tuгп

иррег соуег

bolt.

the steering wheel to the right

and check that the oil rises to the

соуег

'о

the end of its travel

bolt hole, then slowly turn the

5teering wheel to the left to the end of it5 travel and check that the oil rise5 to the filler plug hole. 3 If the оН does по! ri5e in both the cover bolt hole and the filler plug hole. tap-up with the specified steering gear оН. 4 In5tatl the cover bolt and filler plug.

AirbIeeding 4 If there 1з air (п the system. 1ndicated Ьу bubbIes (п the f luid, then the system mU5t Ье bIed. 5 Ensure that the reservoir (5 f illed to the correct level and that the fluid 1s а! normal operating temperature (1 65 ° 10 175°F). Тигп the steering wheel from lock-to-Iock until the bubbIes аге removed. Оо поl hold the wheels against their stops. Recheck the fluid level . Рumр drivebelt 6 If the pump belt i5 broken , glazed ог worn it must 7 The pump drivebelt tension cannot Ье checked

renewed. accuгately using the thumb pressure and belt deflection method. Д belt tension gauge must Ье used. Check and adjust the belt tension as follows : (8) When installin9 а new beft the tension shoufd Ье within 120

(ь)

17 Manual steering gear - adjustment (in-situ) 1 Disco nnect the Pitman arm from the 5teering Pitman arm-to-idler arm rod (see Section 14) . 2 loo5en the sector shaft adjusting screw locknut and turn the adjusting screw counterclockwise. 3 Usin g а torque wrench оп the steering wheel nut (see Fig. 11.21) and with the steering whee l off-center, check that the pull required to rotate the input shaft about lt turn5, either side of center, is within the limits specified (see Specifications at the beginning of thi5 Chapter). 4 Adjustment i5 Ьу loosening the steering shaft bearing adjuster locknut, and tightening ог backing-off the bearing adjuster to obtain the со ггес! preload. Тighten the bearing adjuster locknut and recheck the preload. 5 Turn the 5teering wheel slowly to either stop, (turn gently against the 5tops to avoid damaging the ball return guides) then center the ballnut. 6 Тшп the sector adjust1ng screw clockwi5e until the specified torque required to rotate the worm past its center (high spot) 1s reached . Hold the sector adjusting screw from turn1ng and tighten the locknut, then recheck. the backlash. 7 Connect the Pitman arm to the steering arm-to-idler arm rod. 18 Power steering - checks and adjustments

Fluid 'еуеl check 1 Аип the engine until the fluid 1s at normal operating temperature, then turn the steering wheel slowly from lock-to-Iock several times (do по! hold against the stops). 2 Switch off the engine. 3 Check the fluid level in the power 5teering reservo1r. The level must show оп the cross-hatching between the bottom of the dipstick

Ье

to 150 (Ь (54 (о 68 *9) and a(ter it has Ьееп гuп (ог 15 minutes it shoufd Ье within 90 (о 120 IЬ (40 to 54 *9) Adjust the tension Ьу 100senin9 the adjusting and mounting bolts оп the (гоп! (асе о( the рumр cover plate (hub sidel (see Fig. 11.231. Place а tension уаuие in the drivebeft, insert а ргу Ьаг as shown in Fi9. 11.24 and adjust the tension. CAUTI О N : 00 not fever against the f/uid reservoir as it сап easi!y Ье damaged. Тighten the adjusting агm bolt (irst and then the mоuпапи bolts. Rechec* the tension.

Power steering hoses В

Examine the input and output hoses for signs of leakage, cracks deterioration. Aenew defective hoses.

ог

19 Power steering gear (non-integra!) - removal, overhaul and installat10n Refer to Sections 14 and 15.

20 Power steering pump drivebelt - renewal 1 If equipped with ап air conditioner, loosen the idler риllеу , attaching bolts and remove the compressor drivebelt. 2 loosen the three bolt5 and опе nut attach1ng the pump to the pump bracket, and remove the belt. 3 Install the new belt оп the pulleY5 and adju5t the tension (5ее Section 18). 4 Install the compressor drivebelt (if so equipped) and adjust the tension as described in Chapter 2. 21 Pawer steering pump - removal and installation 1 Disconnect the fluid into а container.

гeturn

hose

а!

I

the reservoir and drain the fluid

11

Chapter 11 Suspension and steering

21.3 Aemoving the power steering pump Fig. 11.23 Power steering pump adjusting and mounting bolts (Sec 18)

Fig. 11.24

power steering pump drive

belt tension (Sec 18) 2

Disconnect the pressure hose from the

ритр.

3 Аетоуе the three bolts and опе nut attaching the pump to the mounting bracket , and Hft out the ритр and drivebelt (photo). 4 Installation is the re verse of the removal procedure . Adjust the drivebelt tensi on (see Section 18). Fill the pump reservoir with power steering fluid and cycle the system to гетоуе air from the system as

described in Sectio" 18.

22 Power steering pump - overhaul

1 Overhaul of the unit must Ье carried out in а clean агеа as cleanliness is of the utmost imроrtэпсе. Before dismantling the pump, clean the exterior with а 50lvent and drain as much of the fluid а5 p05sibIe. Wa5h all the parts (except 5ealsJ in а cleaning 50lvent. 2 It i5 recommended that the pump is attached to ап adaptor ptate, for mounting it in а vise, to prevent damage to the unit when It Is being dlsmantled and reassembIed. А suitabIe adaptor сап Ье made from steet ptate. The Ford adaptor i5 5hown in the associated iIIustratlons. 3 Remove the outtet fltting nut and the identi1ication tag.

4 Position the pump with the pulley upwards and, using а bIock of wood and а ptastic hammer, remove the риmр reservoir and зеаl Ьу tapping around the flange 01 the reservoir and оп the underside 01 the flller neck. 5 Invert the pump assembIy, undo the pump housing attaching bolts and remove the pump housing. 6 Remove the O-rlng seal, the oil зсгееп (if instalted) and the рге­ ssure springs 1rom the риmр housing. 7 Remove and discard the pump соуег gasket. 8 Remove the retainer end ptatB and иррвг pressure ptate (in some pumps, the end plate and иррег pressure plate аге integral). 9 Remove the loose-fitting dowet pin. Take саге not to bend the fixed dowel pin which remains in the housing plate assembIy. 1О Remove the rotor assembIy taking саге to prevent the springs and slippers from falling out and getting lost. 11 Using а suitabIe puller remove the риmр pulley. Install а t - 16 in cap5crew in the end of the риmр shaft to prevent damaging the end of the shaft (see Fig. 11.27). Note: То prevent damage (о the inteгna!

thrust areas the pulley must pressure оп the рumр shaft. 12 Clean

апу

rust, dirt and

Ье

removed without app!ying in-and-out

Ьиггз

from the end 01 the rotor shaft and

О'

DRIVE PULLEY

SL IPPER AND SPRI NG .....~ FILLER TUBE

_

M EТERI NG

""

FLOW. CONTROL VALVE

ORIFICE PLUG

Fig. 11.25 Sectional view 01 power steering

риmр

(Sec. 22)

,

Chapter 11 Suspension and steering

245 LOWER PRESSURE

UPPER PRESSURE PLATE

• RETAINER

ROTOR SHAFT

ЕНD

PUMP VAlVE

P'N

ASS EMBl у

r

СДМ

AND ROTO,ll: ASSEMBLY

I

PUМP H()JS ING

Q·RING ' -

ASSEMBL

'ОЕНТ

PULLEY

PRESSURE SPRING

,

, PLA ТЕ AND BUSHING ASSEMB Lу

I

F1ТПNG

GASKE T

SCR EW дно WASHER ASSE MBL у

RESERVQIR НЕХ

O·RI NG

HGUSING GASKET

Fig . 11.26 Exploded view of power steering pump (Sec 22)

NUT

I

t I RELIEF VALVE PLUNGER

Fig. 11.28 Cleaning the pawer steering pump relief valve (Sec 221 сат

Fig. 11.27 Removing the power steering purnp pulley (Sec 22) •

гетоуе

it from the housing ptate.

13 Aemove the lower pressure plate. 14 Wash all the parts in air. Clean the relief valve

with

а

а

naptha 50lvent, and dry with compressed Ьу depressing the tip of the relief уа1уе pin,

pin punch, several times to remove the oi l, then submerge the

valve in а container of clean solvent and гврезt the procedure. The valve must тоуе freely ; jf the pin is bent ог damaged the valve mЦБt Ье renewed. 15 Renew all gaskets and seals ехсер! the rotor shaft seal which does по! have (о Ье renewed un less it is defective. Examine all the сот­ ponent parts for wear and damage. Do not dismantle the rotor and

assembIy: if the slippers аге wоrп renew the assembIy. Examine the rotor shaft front and геаг thrust faces for scorlng and wear, and the seal for damage. When removing the rotor shaft seal wrap а piece of 0·005 shim stock round the shaft and push it into the inside diameter of the seal until it Is against the bushing, (о prevent scoring of the shaft. Use а sharp tool to pierce the metal part 01 the seal and prise it out, see Fig. 11 .29. Install а new seal , using а suitabIe piece 01 stee~ tubing to tap the seal ,п flush with the end of the seal Ьоге . 16 Mount the pump with the pulley end facing down, and insert the lower pressure plate оп the anchor pin with the wide chamfered slots а! the cen ter hole facing upward (see Fig. 11 .ЗО). ,7 Dip the rotor shaft , п power steering fluid , then insert the shaft through the lower pressure plate and housing. 18 Install the rotor and сат assembIy onto the ритр housing plate with the fixed dowel passing through the first hole to the left 01 the сат notch when the arrow оп the са т outside diameter is pointing toward the 10wer pressure plate (see Fig. 11 . З 1 ). If the сат and rotor assembIy will not seat, turn the rotor shaft slightly until the spline teeth mesh. allowing the сат and rotor to drop down into position.

11 ...;...;..--

Chapter 11 Suspension and steering

246 •

,9

In5eгt

the 1005e-flttlng do wel through the

с ат

insert and lower

plate . into the hole in the housing plate assembIy. The height of both dowels should Ье equal. lubri cate the rotor, springs, slippers and inseгt with pawer steering fluid.

20 In5tall the

иррег

сат

pressure plate with the face having the tapered

notch down against the сат inseгt . The fixed dowel should pass through the round dowel hole and the 10058 dowel through the elo ngated hole. The 510t between the ears о п the pressure plate

outside diameter should match the notch diameter ( зее Fig. 1 1.32) .

оп

the

са т

insert outside

21 In stall the retainer end plate 50 that the 51о! о п the end plate outside diameter matches the notches 01 the upper pressure plate and

c_m I Fig. 11 .331. 22 Install the ритр valve assembIy O- ring seal onto the pump valve,

.005

SНI M

taking care not to twist the seal. 23 Place the pump valve assembIy оп top of the retainer end plate with the large exhaust slot оп the pump valve in line with the outside diameter notches of the previously assembIed parts. Ensure that the stack o f parts аге 1ully seated ; ;f correctly assembIed the relief valve stem w il l Ье in I;ne with the fl uid return hole ;п the pump housing plate . 24 Smear а I;ttle petroleum jelly оп the pump housing plate and ;nstall the gasket. 25 Insert the pressure plate springs in the pockets in the pump valve assembIy. Use а little petroleum jelly to hold them in position. 26 Using а clamp. bIапk-оff the intake hole in the housing , as shown in Fig. 11.35. 27 Lubricate the inside 01 the housing and the housing cover seal with power steering fluid. Using two studs (t- 1 6 х '·55 ;п) as positioning guides, instal l опе in the housing plate bolt hole closest to the drain hole and the other in the bolt hole d;ametri cally opposite.

STOCK

, Fig. 11.29 Removing the rotor shaft seal (Sec 22)

FIXED

ROUND NQT CH QN THI S SIDE

STE P WIDE CHAMFERED

Fig. 11.30

Fig. 11.31

IпstаШпg

the lower pressure plate (Sec 22)

IпstаШпg

аS5етЫу

the сат and rotor (Sec 22)

Fig. 11.32 In5talling the upper pressure plate (Sec 22)

Too l

FIXED

169Р· З В586.А

ЕХ НД ЩТ

SLOT

Fig. 11.33 Align the 510t оп the endplat8 with the notches of the upper pre5sure plate (Sec 22)

Fig . 11.34 Install;ng the valve and springs

IS.c 221

Fig. 11.35 Using а clamp to bIапk-оff the intake hole (Sec 22)

,

Chapter 11 Suspension and steering

247

23 Power steering pump - st8rt-up procedure 8fter overh8ul

,

Ироп iпШаl

, Fig. 11.36 Checking the ритр rotating torque IS.c 22)

5tart-up after а power 5teering риmр ог steering gear overhaul there is frequently excessive noise and aeration. This is due (о air trapped "п the overhauled unit which mixes with the surging fluid and causes aeration. The ргоЫеm сап Ье minimized if the following procedure is used: 1 Disconnect the соН wire to prevent the engine staгting. 2 Fill the reseгvoir with power steering fluid. 3 While continuing to add fluid , have ап assistant crank the engine and at the same time turn the steering wheel approximately 30 degrees each side of center. 4 Recheck the fluid level and fill as required. 5 Aeconnect the coil wire, then 5tart the engine and allow it to run for several minutes. 8 Rotate the steeting wheel from 5top- to- stop to remove the air from the sY5tem. 7 Shut ОН the engine and check the fluid level.

24 Non-integral power 5teering system control valve centering spring - adjustment 1 Raise the front of the саг and support it оп stand5. 2 Aemove the two spring сар attaching screws and the 5pring сар !photo). 3 Tighten the adjusting nut, then loosen il t tutn . ОО not tighten the adjusling nut too tight (72 to 100 Ibf in ). 4 Install the spring сар 10 the valve housing and 5ecure it with the two screws and lockwashers. 5 lower the саг . Staгt the engine and check the turning effort with а spring scale attached to the rim of the steering wheel. The etfort required to turn the steering wheel in both directions should not exceed 8·51Ь (2·9 kg).

I Too/·T6SP· 3А733 - А

25 Non-integral power 5188ring control valve - removal and installation

Fig. 11.37 Installin9 the

,

ритр

pulley ISec 22)

28 Align the small oil hole in the housing rim with the 011 hole in the housing plate. 29 Install the housing, applying ап even downward pressure . Take саге not 10 move the pressure ptate springs out of position. Aemove the guide studs. 30 In5ta11 the housing retaining bolts f inger- tight and remove the

clamp. 3 1 Tighten the retaining bolts eventy to

1 Disconnect the four flu1d line fitting5 at the controt valve and drain the fluid into а suitаЫе container. Тшп the frOnl wheets 10 the left and right several times to force all the fluid from the system (photo) . loosen the clamping nut and bolt at the right end of the sleeve. 2 Аетоуе the roll pin from the steering arm-to-idler агт rod through the hole in the sleeve. 3 Аетоуе the control valve ball stud nut and IJsing а suitabIe baltjoint separator disconnect the Ьа" 5tud from the Pitman arm . 4 Turn the front wheels fully to the left and remove the control valve Ьу un5crewing it from the center link steering arm-to-idler агт rod. 5 То in5talt the valve, 5crew il onto the center link until about four

а

torque of 28 10 32 'Ы tt (3·8 to 4·4 kgf m). Install а t х 16 hex head screw, finger-tight , into the end 01 the rotor shaft, then using а torque wrench check the input torque of the shaft (эее Fig. 11 .36). The torque should not exceed 15 'Ы in (17·2 kgf ст). If it does, loosen the retaining bolts, rotate the rotor shaft, then re-torque the bolts evenly and again check the shaft torque. (lf the input 5haft torque 5till exceeds the limit specified it cannot Ье u5ed and must Ье dismantled and re-examined). 32 Install the reservoir O-ring оп the housing plate. Apply petroleum jelly to the seal and to the in5ide diameter of the reservoir flange. 33 Install the reservoir with the notch in the reseгvoir flange aligned with the notch in the outside diameter of the pump housing plate and bushing аssеmЫу. Тар at the геаг оп the outer согпеГ5 of the reservoir. Use а pla5tic hammer to avoid damaging the reseгvoir. Make 5ure the reservoir 1s seated оп the housing plate. 34 In5tall the service tag and the outlet valve fltting , then the outlet valve fitting nut and tighten it to а torque of 43 (о 47 Ibf ft (5·9 to 8·4 kgfm). . 35 Using а 5uitаЫе tool install the pulley оп the shaft. Fig. 11 .37 shows the special Ford t.ool being u5ed. It Is most Important that the pulley i5 installed without applying in- and-out pressure оп the shaft, to prevent damage to internal thrust areas.

11

24.2 Non-integral power steering control valve with spring

сар

removed

Chapter 11 Suspension and steering

248 •

PUMP

ERVO IR

25.1 Disconnect the fluid lines from the control valve CONTROL V AL УЕ

СОNNЕСТ1NG

ROD STUD

!:!J VALvE

PQWER CYLINDER

Fig. 1, .38 Non-integral power steering system ISec 25) Fig. 11.39 Insta11in9 the control valve (поп­ inte9f81 power steering) (Sec. 25)

threads аге still visibIe ОП the link. 6 Position the ball stud in the Pitman агт. 7 Measure the distance between the center of the grease plug in the sleeve and the center of the stud а! the inner end of the left spindle connecting rod (зее Fig. 11.39). The distance should Ье 4·8751п (124 тт). If necessary, turn the valve оп the center link to in crease ОГ decrease the distance. 8 Align the hole in the steering arm-to-idler агт rod with the slot пваг the end of the valve sleeve. 1"5tall the roll pin in the rod hole to lock the valve оп the rod. 9 Tighten the valve sleeve clamp bolt and the ball stud nut. 1"5tall а new cotter pin. 10 Fill the reservoir with steering яеаг fluid. Run the engine for а few minutes then turn the steering wheel from lock-to-Iock several times and check the system for leaks. 11 Check the fluid level and top-up if necessary. 12 Check the effoгt to turn the steering wheel in both directions (see Section 24).

7 Remove the spacer, bushing and seal from the sleeve end of the housing. 8 Drive the stop pin out of the regulator stop with а punch (see Fig.11 .401. 9 Turn the travel regulator stop counterclockwise in the slee"e and withdraw it from the slee"e. 1О Remo"e the valve spool bolt, spacer and rubber washer. 11 Remove the rubber boot and clamp fTom the "al"e sleeve. 12 Slide the bumper, spring and ball stud seat out and гето"е the ball socket from the sleeve. 1 3 Remo"e the return poгt hose seat and then the return poгt reHef val"e.

.-

VALVE

26 Non-integral power steering control velve - overhaul 1 Clean all fluid and diгt from the exterior of the contro! valve. 2 Remove the two attaching screws and the centering spring сар from the valve housing, (see Fig. 11.41 ). 3 Mount the valve in а soft-jawed vise. hold it Ьу the sleeve flange to prevent damage to the housing spool ог sleeve. 4 Undo the nut" оп the end of the valve spoo! bolt and remove the washers, spacer, centering spring , adaptor and bushing. 5 Undo the two attaching bolts and separate the housing from 'the sleeve, then remove the plug from the sleeve. 6 Push the valve spool out of the centering spring end of the valve housing and remove the seal from the spool.

;...-STOP PlN ВДН

STUD

SOCKEТ

TRAVEL REGULATOR STOP

Fig. 11,40 Driving out the stop pin (Sec 26)

Chapter 11 Suspension and steering

249

SPRING RЕАаЮN

ADAPТER

•

NUT

510Р

PIN

SPRING PLUG AND

SPACER

WASHER

CUSHION

SPACER

VALYE SPOOl SEALS

•

VALVE SEAl BUSHINGS

I

LUBRICATION

:.~

1RAVEl REGUlATOR

,

BUMPER SPRING BAll

SEATS

ВАН

SOCKET

VAlVE

SlEEVE

Fig. 11.41 Exploded view 01 control valve Inon-integral power steering) (Sec 26) TIGHТEN

NUT 5NUG

PUSH FORWARD ТО СНЕСК

(90·1001101· LBS) ТНЕН LOOSEN % TURN О" THREADS OF BOL Т

I

VALVE SPOOl MOVEMENT

ADJUSTING ---..... NUT

,

CENTERING SPRING

Fig. 11.42 Removing the reaction valve 15.с

I

261

АОАРТЕА

Fig. 11.43 Adjusting the control valve centering spring (Sec 26)

14 Аетоуе the plug , spring , O-r1ng and reaction valve (see Fig . 11.421. 15 Clean all the parts and inspect for wear, scoring ог other damage. Install new seals and O- rings. Before reassembIing the contгol valve , coat аН metal parts with steering gear fluid . Smear the seals with а silicone grease. 16 AeassembIy is the reverse of the dismantling procedure. Adjust the control valve centering spring as described in Section 24. 17 Mount the valve in а vise , as shown in Fig. 11.44. and check the spool for freedom of movement Ьу pushing foгward оп the сар end and then turning it Tound and pushing оп the sleeve end.

27 Non-i"tegral power steering cylinder tio"

геmоуаl

8nd i"st8118-

1 Disconnect the two fluid hoses fгom the power cylinder and allow them to drain into а container (photo). 2 Aemove the nuts, washer and insulator from the end of the power cylinder rod . 3 Withdraw the cotter pin and гетоуе the power cylinder stud-toce"ter link securing nut, then disconnect the cylinder from the center link, using а balljoint separator.

Fig. 11 .44 Checking the control valve spool for friction of movement (Sec 26)

4 Aemove the insulator sleeve and washer from the end of the power cylinder rod. 5 Installation is the reverse of the removal procedure. Fill the reservoir and bIeed the air from the system as described in Section 18.

28 Power steeri"g cyli"der

зеа)

- removal and i"stallation

1 Mount the power cylinder in а vise, taking саге not to damage it. and remove the snap-ring from the end of the cylinder. 2 Pull the piston rod out all the way to гетоуе the scraper. bushing.. and seals. If the seals do not соте out with the piston rod use а sharp tool to pick them out taking саге not to damage the shaft ог seal seat. 3 Use аН the parts in the repair kit. Coat the seals and the piston rod with silicone grease and then install all the parts оп the piston rod in the order shown in Fig. 11 .45. 4 Push the rod all the way into the cylinder then tap the assembIed parts fully in. as shown in Fig. 11.46, and install the snap-ring.

11

29 l"tegr81 power steering gear - removal and i"8t8118t10" 1

Disconnect the pressure and return lines from the steering gear.

•

Chapter 11 Suspension and steering

250 •

'ЕАС

RUBBER WIPER

, 27.1 Disconnect the fluid hoses from the power cylinder

Fig. 1, .45 Removing the power cylinder seaJs (Sec 281

RETURN PQRT

PORT SECТOR SНДFТ

TORSION BAR

ЮWER

ADJUSnIENT SCREW

CYUNDER

STUB

SНAFT

ADJUSTER PLUG

Fig. 11.46 In5t811ing the power cylinder seal5 (58С 28)

RETAINING RING

HQUSING

SEC TOR SHAFT

END PLUG Fig, 1, .47 Removing the retaining ring (Sec 29)

Fig. 11 .48 Integral power 5teering gear - Saginaw (Sec ЗО)

Plug the lines and ports to prevent the ingress of dirt. 2 Remove the tWQ bolts securing the flex соирliпя to the steering яеаг and to the column. 3 Raise the front of the саг and support it оп stands. Undo the Pitman агт securing nut and using а suitabIe puller гетоуе the Pitman агrn . 00 not hammer оп the end of the puHer as the steering 9еаг may Ье damaged. 4 Оп cars with manual transmission remove the clutch 'еувг retracting spring. 5 Support the 5teering яеаг and remove the three anaching bolt5. Work the 5teering яеаг 1гее 01 the 11ех cou pling and lift it out. 6 When in5talling the 5teering gear, 5et the 5teering wheel 50 that the 5poke5 аге horizontal and the roadwheel5 аге in the 5traight-ahead p05ition. Center the 5teering gear input 5haft and then in5tall the 5teering gear u5ing the геуеГ5е 01 the removal procedure. Tighten the Pitman arm 5ecuring nut and the 5teering gear attaching bolt5 to the 5pecified torque. 7 Саггу out the 5tart-up procedure described in Section 23.

ЗО

Integral power steering gear - dismantling

Note: Specia/

(00/ по.

Т65Р-ЗD517--А

о, аn

equ;valen(

wШ Ье

needed du,;ng th;s ope,ation. 1 Аеlег to Section 22 paragraph 1. 2 Mount the steering gear in а vise. 3 Remove the retaining ring (see Fig. 11.47). 4 Rotate the input shaft counterc1ockwi5e to foree the plug out of the housing. Do not rotate the shaft more than neeessary ог the balls will lall out. Remove the O-ring. 5 Aotate the input shaft clockwise to draw the piston inward then гетоуе the end plug lгот the piston. 6 Aemove the seetor shaft adjusting serew and the lour cover attaching screws then rotate the adjusting serew with ап Allen wreneh until the соуег is lгее 01 the housing. Remove the еоуег and O-ring. 7 Aemove the seetor shaft. 11 neee5sary, tap the shaft with а plastic hammer.

Chapter 11 Suspension and steering

•

•

8

251

Aemove the adjuster plug locknut and the adjuster plug (Fig.

11.501.

31 l"t89r81 power steering оваг houaing - dismantling. геПОУ8-

9 Insert the tool shown in Fig. 1 1.51 Into the end of the rack piston until it contacts the wormshaft. Rotate the stub shaft counterclockwise until the worm is free 01 the rack piston. Withdraw the piston and keep the tool in position to prevent the balls dropping out. 10 Pull the stub shaft and valve assembIy from the housing and li" out the worm, lower thrust bearing and the races.

tio" and reassembIy 1 Refer to Fig. 11 .52 and гетоуе the snap-ring, lower зрасег washer, lower зеаl (doubIe lip), зрасег washer апd upper зеаl. 2 Examine the housing bearing far wear; гетоуе it, if worn ог damaged using а suitabIe drift. Д stop ring is 10cated in the piston Ьоге.

TEFLON RINGS O-RING SEAL

---+

....

~~

VAlVE SPOOL

ADJUSTER--+

• SECТOR

(З)

SHAFT

,._

PORT SEAT ЕСК VALVE т

--

VAlVE

ClAMP-- - - + ВALL REТURN

_

GUIDE ТНRUSТ

BALLS - - - -..

RING

··6EARING RACK

SEAL SEAL AOJUSTER PLUG SEAl

BEARING

ЕНО

PLUG RIHG

ЕНО

PLUG

RING

Fig _11.49 Exploded view 01 power steering ооаг - Saginaw (Sec за)

UPPER SЕдl (SINGLE

SECTOR 5НАFТ BEARING тооl

LIP )

LOWER SEAl

SPACER WASHER

,"АР

RING

•

Fig. 11.50 Removing the adjuster plug (Sec ЗО)

О,

11

INlET PORT SEAT Л RПURN

PORT

SEAT Тооl

_

т

6SP_3Dsf7_A

Fig. 11.51 Removing the rack piston (Sec

Fig . 11.52 Exploded viow 01 steering gear housing sssombIy (Sec за)

З1)

Chapter 11 Suspension and steering

252 •

Do по1 attempt to гетоуе it; if it is damaged the housing assembIy must Ье renewed. То гетоуе а damaged paгt seat, cut а thread in the seat and, using а bolt, nut and flst washer, withdraw the seat (see Fig. 11.53). Аетоуе the check valve and spring from the inlet part. 3 Insert the spring, check valve and new seat in the inlet part and using а drift with а СОПС8уе end to fit оп the valve seat, drive the seat

into place. In5tall the ouHet part seat. 4 Press а new sector shaft bearing into the housing until the иррег end is 0·030 in (О· 76 тт) below the housing Ьоге. 5 Lubricate the new seals with power steering fluid. Install the single lip seal and spacer washer, and using а suitabIe drift, drive them in far enough to ptovide clearance for the other эеаl. The эеаl muэt not bottom оп the end of the counterbore. Fit the doubI e liр seal and эрасег washer, and drive them in only far enough 10 allow for the installation of the retaining snap-ring.

32 Adjuster plug (int8gr81 power steeringJ re8ssembIy

dismentling snd

Remove the thrust bearing retainer, as эhоwп in Fig. 11.54, taking саге not 10 зсоге the needle bearing Ьоге . then lift the зрасег, thrust bearing, гасез and O-ring from the plug. 2 Remove the dust seal retaining ring , and using а drift iпэеrtеd from the зрас ег end, remove the roller bearing, oil seal and dust зеаl ( зее 1

Fig. 11.55). 3 Install the new bearing with the manufacluгer's marking facing outwards and drive it into the plug until it i5 flush with the bottom suriace of the stub shaft 5еаl Ьоге. 4 Install the new оН seal, dust эеаl and snap-ring. Fit the duэt seal with it5 smooth rubber suriace facing outwards. 5 Install а new O-ring seal, then аэsеmЫе 1he thrust bearing outer гасе, the thrust bearing, inner гасе and spacer оп the adjuster plug , then install the bearing retainer.

;::--., 5/ 16·18.2" Т

33 Stub Sh8ft a"d rotary valve аззвтЫу (i"t8gral pOW8r st88ri"g) - dismantling a"d Г8аВВ8тЫу Invert the valve and tap оп а bIock of wood until the torsion Ьаг сар 5eparates from the valve body. Discard the cap-to-body O-ring. 2 PU5h the stub shaft through the valve body until the drive pin hole is visibIe. 3 TBt the stub shaft, зо that the drive pin witl disengage from the 5pool, and геmоуе it from the valve body and зрооl assembIy (Fig. 1

11.56). Slide the 5рооl out of the top of the valve body. 5 Clean а" the parts, examine 10г wear ог damage. and renew defective parts. In5tall new 0 -ring5 and Teflon 5eals оп the valve body. lubri cate the part5 with power steering fluid. 6 In5tall the dampener O-ring оп the 5pool and 51ide the 5pool into the body with а turning motion. Take саге по! to damage the O-ring. locate the drive pin hole opposite the deep notch in the valve body. 7 In51sl1 lhe stub 5haft in the spool with the drive pin hole aligned with the hole in the spool. 8 In5ert lhe drive pin inl0 the зрооl hole and риН the assembIy into lhe va lve body keeping the сар 510t and pin aligned. When the сар 5eats correctly in the valve body, the top surface of the сар 5hould Ье at least 0·094 in (2·38 mm) below the notch . 9 In5tall а new cap-to-body O-ring. 4

Fig. 11.53 Removing а port seat (Sec 31 J

BEARING RETAINER

SPACER

34 Rsck pi5ton (i"t8gral pOW8r 8t88ring) reass8mbly Not8 : Specia/ tool

по.

Т65Р-3D517-А

ог аn

dismantling and

equivalent will

Ье

needed during this operation.

Fig. 11.54 Removing the thrust bearing r8tain8r (Sec 32)

BEARING I

1 Cut the Teflon ring and O-ring from lhe piston. 2 Place the assembIy оп а clean lint-free cloth; remove the 5creW5 attaching the ball return guide cla mp (о the rack piston , and remove the clamp (Fi9. 11.57). 3 lift off the Ьа" return guides from the rack piston . 4 Remove the tool. left in the piston when dismantling the steering 9еаг, and remove the remaining balls. PlUG

THRUSТ

OOST SEAl

Q.RING

r

SPACER

I

., INNER RACE

I

QUTER RACE

Fig . 11 .55 Exploded view of adjuster plug (Sec 321

ROllER BEARING

RETAINING RING

Chapter 11 Suspension and steering

•

5 Clean the parts, examining for damage tive parts.

ог

wear; renew

апу

defec-

Fig. 11 .59 for sizes of service replacement Ьаllз availabIe . 13 Note the ball 5ize 5tamped оп the rack piston. In5tatl the next size targer to increase preload. If the rack piston is devoid of а size-stamp, the original batl code size was No. 7. 14 Each ball size larger increase5 preload approximately 1 'Ы in (, ·1 5 kgf cm). Final preload оп replacement balls should Ье 2 to 3 'Ы in (2·3

6 Lubricate а new O-ri"g and Teflo" ri"g, then i"5t811 the O-r1"g оп the piston taking саге по1 to twist 1t. Slide the Теllо" r1"g 1"to place. Do not stretch it unnecessarily. 7 Slide the worm (Fig. 11.58) fuHy i"to the rack piston. Load 16 balls into the guide hole "earest the Т8110" ring , slowly rot8ti"g the worm counterclockwise. thus feeding the balls through circuit. Alter"8te the dark colored and polished balls through the circuit as they аге loaded. в Apply petroleum jelly to опе of the ba ll return guides and i"5tall the remaining balls in the guide. The constant f8tio gear reQuires 22 balls, and the v8fiabIe ratio gear 24 balls. Position the other half of the guide, and insert the balls into the holes in the rack piston. Ensure that dark and pollshed balls аге alternated in the rack piston. In5tall the ball return guide ctamp, and retain with the 5CreWS and lockwa5her5. 9 When the rack piston passes оувг the high point in the center of the worm ягооув there 5hould Ьв а preload of 1 to 41Ы in (1·,5 to 4 ·6 kgf ст). Clamp the rack piston in а soft-jawed vise, wormshaft pointing up. Avoid overtightening which might cause distortion. 1О Place the valvв assembIy оп thв worm , and engage the worm drive pins. Rotate the worm untll It extends 1t in (32 mm) from the rack piston to thв thrust bвaring face to obtain the center position. 11 Place а torque wrench (t in deep wall, 12-point socket) оп the stub shaft, rotating the wrench through а 600 агс in both directions several times. Take а torque reading. The optimum reading with the worm rot8ting should Ье between 1 and 4 'Ы in (1 · 15 and 4·6 kgf cm). 12 In8tall а new set of balls if this reading is too high ог too low. See

•

10 3 -45 kgf ст).

15 Remove the valve aS8embIy from the worm and retease the rack piston from the vise. 16 Iпзвrt tool Т65Р-3D517 -А into the plug end of the rack and piston so that it contacts the wormshaft (Fig. 11.60). Apply pressure оп the tool and rotate the wormshaft out of the piston and rack. Leave the tool in p05ition untit the piston is instatled in the housing.

35 Int8gr81 pOW8r 5t88ring gear - re855embIy Mount the steering gear ho w 'ing in а vise. 2 During assembIy lubricate the parts with power steering fluid. Lubricate Teflon rings and 0 -ring5 with petroleum jetly. 3 See Fig. 11.49. In5tall the thrust bearing and гасез оп the worm. Align the valve body drive pin оп the worm with the narrow 510t in the valve body. 4 Instalt the valve and wormshaft a55embIy Ьу pushing оп the outer diameter of the valve body. The assembIy 15 correctly seated when the fluid return hole in the gear hou5ing is fully visibIe . 5 Install а new O-ring in the аdjuзtег plug groove and in5eгt the adjuster plug оувг the end of the stub 5haft and tighten it just enough to зваt the рагtз. Instatl the locknut loosely оп the adju5ter plug. 1

TEFLON SEAL$

о"'

HOLE

VALVE SPOOL

Q·AING

ВООУ

DAIVE PIN

DAMPENEA Q.RING

TOASION

едА

O·RINGS

Fig. 11.56 Stub shaft and rotary valve assembIy (Sвc 33)

I

RJNG

+ - - RACК

•

253

РI

STOO

DARK COlO RED BAlLS

END

Fig. 11.58 Installing the worm and balls (Sec 34)

Code Diameter Size Меап

Size Range о! (lnch)

ВаН

6

0.28117

0.28112-0.28122

7

0.28125

0.28120-0.28130

8

0.28133

0.28128-0.28138

9

0.28141

0.28136-0.28146

10

0.28149

0.28 144-0.28154

11

0.28157

0.28152-0.28162

-

Fig. 11 .59 Worm Ьа" sizes (Sec 34)

11

BAll RETURN GU1DE

CLAМP

Fig. 11.57 Exploded viвw of rack pi5ton assembIy (Sec 34)

Т65Р.3О517 · Д

Fig. 11 .60 Installing the Ьа" retaining tool in the rack pi5ton (Sec 35)

Chapter 11 Suspension and steering

254 •

AII.., Wrend!

SECTOR SHAFT дDJUSТМЕNТ

То"",,,

.оом

Wre,,,:h

NARROW PIN 5LOT

Fig. 11.61 Installing the valve and wormshaft assembIy ISec 351

Fig. 11.63 Adjusting the sector shaft mesh load (S8C Too l.

351

Т6SР·ЗDSJ7.Д

· 3805 ,.1

Fig. 11.62 Installing the rack piston ISec 351 Fig. 11.64 Steering wheel alignment matks (S8C 3бl

6 Tighten the adjuster plug white turning the input shaft. Аз 500П аз additional torque is noted back-off the adjuster plug t turn. Measure the input shaft turning torque with а torque wrench. 7 Tighten the adjuster plug to obtain а 1 to 3 'Ы in (,·15 to 3·45 kgf cm) preload in ехсвss of the figure noted in paragraph 6, then tighten the adjuster plug locknut. Recheck the preload; it тust not exceed 8

Ibf In (9·20 kgl cml. In5tall the rack piston in the housing. Ве sure the ball retaining tool is contacting the wormshaft and push the piston inward. Turn the stub shaft clockwise until the middle rack groove in the piston is aligned with the center of the sector shaft roller bearing, then remove the tool from the housing (Flg. 11.62). 9 Install а new O-ring in the sector shaft cover. Screw the cover onto the adjusting screw until it bottoms then back it оН 1t turns. 10 Install the sector shaft зо that the center gear tooth meshes with the centet groove in the rack piston; push the cover down оп the housing and install the securing screws. Install the locknut loosely оп the adjustet screw. 11 Install the end plug in the rack piston and tighten it to 50 to 100 Ibf ft (7 10 13 kgl ml . 12 Install а new епс! plug O-ring in the housing. Iпзегt the end plug in the housing and tap it lightly with а plastic hammer to зеа! it against the O-ring. then install the retainer ring. 1З Center the worm and fit а torque wrench оп the input shaft (зее 8

36 Steering wheel - removal and installation 1 Disconnect the ground саЫе from the negative terminal оп the battery. 2 Remove the crash pad attaching screws and lift оН the pad. Remove the horn ring (if so equipped) Ьу turning it clockwise to release the locking tabs. Disconnect the horn wires. 3 Remove the steering wheel securing nut. Make alignment marks оп the column shaft and wheel hub (unless already marked - Fig.

11.641. 4 Install

а

steering wheel puller and remove the wheel. 00 not изе а kпосk-оН риНег ог strike the end of the steering shaft with а hammer аз this will саиsе damage to the column bearing ог the collapsibIe column. 5 Installing is the reverse of the removal procedure. Make зиге the matching marks аге atigned. Tighten the steering wheel securing пи! to а torque of ЗА to 40 1Ы ft (4.14 to 5.52 kgf т).

31 Steering column upper 5haft beating - removal a"d i"5t81Iatio"

FIg. 11 . 631 .

Fixed columns

14 With the gear оп center and the sector shaft adjuster backed-off, measure the turning torque. Adjust the sector shaft thrust screw зо that the preload is 4 to 8 'Ы in (4·60 to 9·20 kgf cm) in ехсезз of the figure previously obtained. Readings should Ье made through ап аге not exceeding 20 degrees, with the gear оп center. 15 Tighten the sector shaft adjuster screw locknut to а torque of ЗА

1 Disconnect the horn and tur" indicator wires at the connectOT. 2 Remove the steering wheel (see Section З6). 3 Remove the turn indicator lever. 4 Undo the turn indicator switch attaching screws and lift the switch over the end of the steering shaft and place it to опе side. 5 Remove the snap-ring from the top of the steering shaft. 6 Loosen the two flange-to-steering column tube retaining nuts to

1035 Ibf 11 (4·14 10 4·83 kgl ml.

•

Chaptar 11 Suspension and steering

•

disengage them from the tube . then (alse the

I1аП9е

255

upward while

tapping the steering shaft lightly w ith а plastic hammer 10 free the bearing and flange from the shaft. 7 Аетоуе the bearing and insulator from the 11апяе . 8 Instaltation is the геуегsе 01 the removal procedure. When installing the new bearing, uзе а piece 01 tublng and the steering wheel nut 88 shown in Fig. 11.65 10 ргеss the bearing into position .

Tilt columns 9

Aemove the tilt column mechanism as described in Section 39.

1О Position the I1аП9е casting w ith the smaller bearing facing downward. Drive lightly оп the Quter гаее at each 5101 with а small diameter pin punch . Invert the 118П9е and remove the larger upper bearing in the звте way. 11 Install the bearings, using а socket wrench 01 the S8me diameter as the bearing outer races, and tap the bearlngs Into place. ,2 Install the tilt column mechanism as described in Section 39 .

•

эв

5t88ri"g column - гетОУ81 8nd in5t8118tio"

Disconnect the battery negati ... e саЫе. Disconnect the transmission lock rod О1 installed ) and the two nuts retaining the flex coupling to the steering shaft (fixed columns) . Оп tilt columns, remove the опе bolt attaching the flex coupling to the shaft.

1 2

Fig. 11 .65 Installing the

иррег

bearing - fixed steering column

(58С

37)

STEERING WHEEL

SUPPORT

!

BRAKE PEDA L SUPPORT

SIGNAL LEVER

r

СОШМN

UPPER

BRA CKEТ

I 0--'-:---------- COLUМN TU6E 1 LCМ'ER

6R ACK ET

,

'- ' ....-:;

11

TIL Т VACUUM MOTOR

ТОЕ PlдТE

-------- FlЕХ COJPLING

Fig . 11.66 Steering column assembIy 1969 model (Sec

З8)

Chapter 11 Suspension and steering

256

•

VIEW

TRIM

У

TRIM

_ - - - - CLIP, VIEW Z

BRACKET

~ _ _ _ _ _.:::::~~: BRACHT

Д

WIR E _----: CONN EC TOR 8R ACKEТ

Fig. 11.67 Steering column assembIy 1973 modellSec (Оп early models disconnect the vacuum motor control саЫе! ,

3 RemOV8 the four screws in the toe-ptate. 4 Disconnect the electrical connectors. 5 Аетоуе the four nuts securing the cotumn to the brake support bracket, then drop the column from the instrument panel and гетауе it from the саг. 6 '"stallation i5 the reverse of the гетоуаl procedure. Make sure the flex coupling i5 not distorted when tightening the attaching nuts.

39 Tilt steering column mechanism - temoval and i"st8118tio" 1 2 3 4

Disconnect the batteгy ground саЫе. Disconnect the steering shaft at the flex coupling. Aemove the steering wheel (see Section 36). Aemove the turn indicator lever and switch as described in Section

37 .

5

Insert а wire pin Ёп the hole located оп the outside of the flange casting adjacent to the turn indicator warning flasher button . 6 Turn the Ignition key 10 the ON position, depress the wire рЁп and 11ft out the lock cylinder. Aemove the lock cylinder spring clips from the lock cylinder housing. 7 Using а flat bIaded screwdriver, insert the bIade into the recess in the drivegear at the bottom of the housing. TUTn the drivegear three notches in а counterclockwise direction. Aemove the snap· ring , washer and drlvegear ( эее Fig. 11 .70) . Note the posltion of the drivegear to the upper actuator teeth. 8 Undo the cover attaching screws and lift the cover over the shaft. Unhook the upper actuator from the lower actuator. 9 Aemove the column {гЁт shrouds, the steering column instrument рапеl trim cover, and the bolts attaching the column brackets {о the brake support bracket. Allow the column to drop down, exposing the Ignition switch . 10 Aemove the three Allen screws attaching the lower flange casting {о the outer tube. 11 Loosen the Ignition switch nut and remove the rod from the switch end. 12 Aemove the two spring clips holding the wire Ьаlе which acts as а release lever for the 10cking lever and remove the wire bale (see Fig.

11.71). 13 Using а small drift, drive out the Aemove the locking lever and spring.

рЁп

securing the locking lever.

эв)

14 Aemove the steering shaft snap· ring. 15 Separate the upper and 10wer flange castings Ьу removing the two pivot рЁпэ as shown 1п Fig. 11 .72. 16 Aemove the 10wer actuator and ignltion switch rod . 17 То remove the socket casting . rotate the Ёппег tube and socket casting to expose the retaining bolt, then remove the Ьоlt and lift оН the casting. 18 Ins1a1lation is the reverse of the removal procedure. Use а C· clamp {о press the pivot pins in10 place. 00 not use the old рЁПЭ if loose in the holes (Fig . l ' .73 J.

40 Steering linakge connecting rod e"ds - remov81 8"d I"St8118· tion 1 The connect ing rod ends. which аге screwed into the adjusting sleeves. cannot Ье greased ог serviced. When the ball·studs Ьесоте worn and loose the ends must Ье renewed (photoJ. 2 Aemove the cotter рЁП and nut from the ball·stud . 3 Disconnect the end from the spindle агт ог сеп1ег link using а balljoint separator. 4 Loosen the connecting rod sleeve clamp bolts and count the number of turns required to remove the rod end . 5 Screw the new rod end Into the sleeve the same number of turns as was required 10 remove the old rod end and tighten the clamp boJts. 6 Connect the rod end to the spindle агт ог center link, then tigh1en the retaining nut to the specified torque and install the соНег рЁп. 7 It will Ье necessary to have the fTont wheel alignment checked, refer to Section 42.

41 Steering linkaQe idler tio"

агт

and bracket - removal and l"staI18-

1 When lhe idler arm bushings аге worn the complete idler arm assembIy must Ье renewed. 2 Aemove the cotter pin and nut attachlng the steering center 11nk to the idler агт . 3 Aemove 1he two bolts attaching the Idler агт and bracket assembIy to the frame and lift away the assembIy {photoJ. 4 Instatlation is the reverse of the removal procedure .

-

•

,

•

,

•

TERMINAL АНО

•

WIRE

,

иРРЕА

8EARtNG

SHAOUD

SLEEVE

TURN SIGNAL

LOCK CVLINDER

SHAFT

ASSEMBLY

WASHER IGNIТЮN SWIТCH

SHIFT

SNAP RIN.G

,'8 ,

_______----..CJ"', 2

- LOCK

тиВЕ

INSERT-ЗЕ71б

ORIVE

Р

~

,

LOCK

ASSEM8LY

,1'

L ___ --

АстиАТОА

\:rz.

•

SHAOUD AETAINER

СОУЕR

LtGHT

SWITCH - ' 5520 STEERING COLUMN тиве ASSEMBL у

<1 АстиА ТI

NG

АОО

# / $ HIFT тиВЕ ASSEMBLY

LDWEA SQCKET CASTING

CLIP

...,

BEARING

Fig. 11.68 Exploded view 01 fixed column - tvpical

•

....

(58С

РААТ

OF $HAF T ASSEMBL У

38)

~

•

'"

~ LOCK C YLINDEA

LO WER SOCKE T CASTING SNAP RIN G

ТЕ Я М INА L

AND WIAE ASSE MBL У

DRIVE GEAR

- ,~o

SPRING CLIP

L DCK IN SE AT TUAN SIGNAL SW1ТСН

WASHER

LDCK дстиАТ О А ASSEM6L У

UPPEA COVEA

A CTUATIN G АОО иРРЕА

SH I FT TUBE ASSEMBLY

BEARING 8ACKUP LIGHT

SW ITCH - 15520 CQVER

6ALE AETДINEA

LDWЕЯ

AC TUATO A

L DC КlN G

LEVEA

WIRE BALE

STEERING SHAfT

J..

ASSEMBLY

LDWER BEARING STEERING COLUMN TUBE ASSEMB L У

SEAl

~ CL IP LDWЕЯ

fLANGE

~

•

8EARING

TU8E

РдАТ

SHIFT T U BE ASSEM8LV

OF SH AFT ASSEMBL У

...,

ЯЕТДINЕR

,

Fig. 11.69 Exploded view 01 tilt column - typical (Sec 39)

~

,

,--------------------------------------------------------------------259 LASТ MUSТ

тоотн

01'1 GEAR ENGAGE LA ST .

НОТСН 01'1 ACTUA TOR FOR

CORRECT IN5TALLATION

•

UPPER 4,CTUA

MOUNTING SCREW

I

(2 REQ'O)

I

UPPER

STEERING WHEEL LOC'
CQYER

SNAP RING

- - - - LOCK CYllNDER

TURN SIGNAL

swпсн -S?RING CLIPS

DRIVE GEAR 1CX'4 ROO MOUNТlNG

SCREW - ' "

CQVER

MOUNTING SCREW

ALLEN SCREW

(4 REQ'D)

ASSEMBLY ТО

INSERT WIRE PIN (КЕУ

WARNING

(3 REQ'O)

RELEA5E LQCK

11'101'1

'Н

HOLE

PQSIТIOН

AND SНIFТ LEVER 11'1 PARK )

BUZZER

QUlCK

TERMINAL

Fig. 11.70 Tilt column mechanism (Sec 39) CLIP$

ТО

RElEASE WIRE BAlE

WIRE

RElEASE SPRING дно САР

_ _ _ SPRING

11 REMOVE PIN WITH DR IFТ

LOCKING LEVER

FLANGE AII

у

Fig. 11 .71 Removing the wire

and tilt locking lever (Sec 39)

,

ВЛВВIS БU!Jsп!ре pOJ БU!1::1ВUUО:J •

212

t 'Otr j

2

-

Nld

lОЛld

(6Е ::I8S) sщd Jол!d еЧ:J :J!J. Щ dШВI::I-::> е 6щsn EL' L L 'O!:I

( А 1NO

(6Е :>85) sщd :Jofl!d 8Ч~ БЩflОШ81;t

1113I:1JS)

..,. 6(lOC' dS'9!

,ОО!

'ZL·1. L 'Вы

•

,

~

,---------------------------------------------------------------------261

•

r

ADJUSTING 5L EEVE VtEW A RМ

Х

AND

ASSEMBL У

,,

,

~

/

vlEW Z

А'М

CONNE CTING ROQ

END A5SEMBl У (lNNER)

VIEW Z

Fig. 11.74 Steering linkage - manual or integral power steering (Sec 41 )

,• •

•

/ ASSEMBL У

•

(,

STEER ING CENTER LINK

•

\

.00 END ASSEMBLY 11

VIEW

Х

(OUTER )

VIEW CONNE CTING RO:O/ END ASS EMB L (INNER )

•

I

•

~:_4

1.•

/

VEHICLE PITМAN

.

ARM

- -.а

-

11 VIEW Z

Fig 1, .75 Steering linkage - non-integral power steering (Sec 41) I

FRONT OF _

VIEW U

Chapter 11 Suspension and steering

262

4 Indications of incorrect wheel alignment аге uneven tire wear and erratic steering, particularly when turning. То check, wheel alignment requires special mea5uring equipment so this is а job for а service stat10n with the necessaгy equipment. Ensure that а complete inspection of the fгопt susрепsiоп and steer1ng 1s made before the аligпmепt i5 check,ed.

•

43 Wheels and tires

41.3 Steering linkage idler

агт гетоуаl

42 Front wheel alignment - checking and

аdjustmвпt

1 Unless the front suspension ог steering linkage has Ьееп damaged , the castor angl8 , сат Ьег angle. turning angle and the 10e-in wilt ПО1 alt8r, provided the suspension balljoints ог suspension агт pivot bushings and 5t8erin9 linkages аге по1 worn.

2

Оп

modets before 1967 castot and

сатЬег

angles

аге

adjusted

Ьу

shims between the fгэте bracket and the upper suspension агт pivot shaft. Оп models from 1967 castor is adjusted Ьу al18rin9 the length of the struts, and сатЬег i5 adjusted Ьу the eccentric сат located at the lower агт attachment 10 the fгэте . Turning angle i5 по1 adjustabIe; it i5 а result of ca5tor, camber зпd toe-in adju5tment and i5 check,ed after the5e adju5tments аге made. 3 Toe-in is adjusted Ьу loosening the clamp5 оп the connecting rod sleeves and turning the sleeves as required.

1 То provide equal, and obtain maximum wear 1rom all the tires they shou ld Ье rotated оп the саг at inteгvals of 6000 miles (1 О 000 k,m) to the 10110wiпg pattern: Spare to offside rear Offside rear Со nearside front Nearside front (о nearside rear Nearside rear Со offside front Offside front to spare Wheels should Ье rebalanced when this is done. However, some owners baulk, at the prospect of having 10 Ьиу 1ive new tires al l а! опсе and tend to let two гип оп and replace а ра1г only. The new pair should always Ье оп the 1ront wheels, as these аге the most important 1rom the safety aspect 01 steering and braking. 2 Never mix tires of а radial and crosspJy construction оп the same саг, as the basic design differences сап cause unusual and, in certa in conditions, уегу dangerous hand ling and braking ch aracteristics. 11 ап emergency should 10гсе the use 01 two different types, make sure the radials аге оп the геаг wheels and drive particu larly care1ully. 11 three 01 the 1ive wheels have radial tires then make sure that по more than two гadia l s аге in use оп the саг (and those at the геаг) . Aationalize the tires at the earliest possibIe opportunity. 3 Wheels аге normally not subject {о seгvicing probIems, but when tires аге renewed ог changed the wheels should Ье balanced to reduce vibration and wear. 11 а wheel is suspected 01 damage - caused Ьу hitting а сигЬ ог pothole which could distort it out 01 true, change it and have it checked 10г balance and true-running at the earlie5t opportunity. 4 When install1n9 wheels do not overtighten the nuts. The maximum possibIe manual torque applied Ьу the manufacturers wheel wrench is adequate. It also prevents difficulty when the same wheel wrench has to Ье used in ап emergency to remove the wheels.

•

Chapter 11 Suspension and steering

263

•

I

•

44 Fault diagnosis - Suspension and steering Before diagnosing faults !гот the following chart, check that 1 Binding brakes 2 'псоггес! 'mix' of radial and cross-ply tires 3 Incorrect 1ire pressures 4 Misalignment of the body fгэmе ог геаг axle

апу iггеgu/агШеs аге поС

Symptom

Steering wheel апу

caused Ьу:

R88S0n/s

сап Ье

moved considerabIy before

sign of movement of the wheets i5

Vehicle difficult 10 steer in

а

Wear in the steering linkage, gear and column coupling

аррагепt

consistent straight lin8 (wandering)

As аЬоуе Wheel aHgnment incorrect (indicated Ьу excessive ог uneven 1ire wear) Front wheel hub bearings 1005e ОГ worn Wогп balljoints оп connecting rods ог suspension arms

Steering stiff and heavy

Incorrect wheel alignment findicated Ьу excessive ог uneven tire wear) Excessive wear ог seizure in опе ог more of the ЬаЩоiпts in the steering linkage ог suspension arms Excessive wear in the steering gear unit

Wheel wobbIe and vibration

Road wheels out of balance Road wheels buckled Wheel alignment incorrect Wear in the steering linkage , suspension arm balljoints suspension arm pivot bushings Broken front spring

Excessive pitching and rolling

оп

corners and during braking

ог

Defective shock absorbers and/ or broken spring

Faults which сап usually Ье attributed to the power steering system exclusively Саг

wanders

Low fluid level Air in system

Steering stiff

Steering stiff оп

Low fluid level Air in system Pump control valves seized Reservoir fНter bIocked Damaged seals in steering gear опе

lock only

Lack of pressure

оп опе

side of piston due to wear

Front wheels wobbIe

Air in system

Steering heavy if steering wheel is being turned

Slack pump driv:ebelt Pump control valve bIocked Air in system

11

-

•

•

•

Chapter 12 Bodywork and fittings Contents Air conditioning system - general . . . . . . • . . . . . . . . . . . . . . Ооог alignment .. ... ....... . ................•.. Ооог latch actuating rod - adjustment . . . . . . . . • . . . . . • • . Ооот latch - emergency opening procedure ..........•. ОООТ latch - геП'10vаl and installation .. .... . . ... ..... . Ооог latch striker - adjustment . . . . . . . . . . . . . , ... .... . 'Ооог ареп' warning switch - adjustment . ... .... ... .• . . Doors - гетоуаl and instal18tion . . . . . . . . . . • . . . . . . . • . .

37

Ооог

10

trim panel- гетоуаl and installation ...... . . . ..•. . Ооот window - гетоуа' and installation ..... .... .... • .. Ооог Ооот

windows learly models) - adjustment . . . . • . • . . . . . . . . .

windows (later modelsJ - adjustment . ...•........... Floor console - removal and installation .... .....• .•. . . ... Front bumper - removal and installation .... .....• . ....... General description ................. . ............. . Heater bIower motor - removal and installation ..... . . ..... . Heater саге - removal and installation .... . ....... , .... . Heater - general .. ...... ....... ...... .... • • . . ..... Heater - removal and installation ........... ... • . •...... Hood - alignment ..... .. ........... .... .•. · . . . . . . Hood latch - adjustment ................... •. • • • • • • • Hydraulic system (ConvertibIe top) - bIeeding .... . . · . . . . . .

1

12 16 25 14 13 15 11 18 20 21 28 31 1

40 41 38 39 6 7 35

General description

, The two-door body is of а unitized, all-welded construction which makes it а уегу strong and torsionally rigid shell which сап withstand а considerabIe amount of stress. 2 Three types of body аге used оп the different models: Hardtop, Fastback (Sportroof) and ConvertibIe.

2

МаiпtепаПС8

- body 8xterior

, The general condition of а car's bodywork is the опе thing that sig nificantly affects its value . Maintenance is easy but needs to Ье regular. Neglect. particularly after minor damage. сап lead quickly to further deterioration and costly repair bills. It is important also to keep watch оп those parts of the саг not immediately visibIe. for instance the underside. inside all the wheel aprons and the lower part of the engine compartment. 2 The basic maintenance routine for the bodywork 1s washing - рге­ ferably with а lot of water, from а hose. This will remove all the loose solids which тау have stuck to the саг. It (з important to flush these off (п such а way аз tp prevent grit from scratching the finish. 3 The wheel аргопз and underbody need wa5hing (п the same way 10 remove апу accumulated mud which will retain moisture and tend to encourage rust. Paradoxically enough, the best time to clean the underbody and wheel aprons is in wet weather when the mud (5 thoroughly wet and soft. In Уегу wet weather the underbody 15 usually cl eaned of large accumulations automatically and this is а good time for inspection. 4 Periodically, it is а good idea to have the whole о' the undet5ide of the саг steam cleaned. engine compartment included. 50 that а thorough inspection сап Ье carried out to see what minor repairs and renovations аге neces5ary. Steam clea ning is ауаilаЫе at тапу garages and i5 песв55агу 'ог removal of accumulation of оНу grime

Instrument panel pad - гетоуаl and installatlon ........ ... Lift cylinder (ConvertibIe top) - removal and ln5tallation ... . . . Maintenance - body exterior ........... .. ......... . .. Maintenance - body interior , ...... " .... , ... ,.... . .. . Major body damage - гераlг ....... " .... ,.. . ......... Minor body damage - repair .................... ,.... . Motor and ритр (ConvertlbIe top) - overhaul ., ...... " . , . . Motor and pump (ConvertibIe top) - гетоуа' and installation ... Out5ide door handle - гет оуа' and ln5tallation .. ,..... ..... Quarter window gla5s (Hardtop and ConvertibIe) - гетоуа' and installation ........... , ....... ,.... . .......... ... Ouarter window (Hardtop and СопуепlЫе) - adju5tment ...... Quarter window regulator (Hardtop and ConvertibIe) - removal and installation ......................... ,.,....... Radiator grille - гетоуа' and lnstallation . , ..... , . , . . . . .. Аваг Ьиmрег - removal and installatlon ........ , .'. ' . ,... Trunk lid - alignment ................... ... ..• , . . .. Trunk lid hinge torsion Ьаг - adjustment .............•... Window regulator mechani5m - Iubrication ... ,...... .... Window regulator - гетоуа' and installation .... , , . . . . . . . . W indshield and back window - general ., ..... ,......... .

29

36 2 3 5 4 34 зз

26 22 24 23

30 32 9

8 17 19 27

which 50metimes (з allowed to cake thick (п certain areas пеаг the engine, transmission and back axle. If steam cleaning facilities аге not availabIe, there аге опе ог two excellent grease solvents availabIe which сап Ье brU5h applied. The dirt сап then Ье simply hosed off, 5 After washing paintwork, wipe off with а chamois leather to 9ive ап un5potted clear fini5h. А coat of clear protective wax polish will give added protection against chemical pollutants in the air. If the paintwork sheen has dulled ог oxidised . и5е а cleaner/polishe r сот­ bination to restore the brilliance of the shine. Always check that the door and ventilator opening drain holes and pipes аге completely clear so that water сап drain out. 6 Bright work 5hould Ье treated (п the same way as paintwoгk. Windshields сап Ье kept clear of the smeary film. which often appears, if detergent is added to the water (п the windshield washer reservoir. Use а mild опе. such as washing-up liquid. Never и5е апу type of wax ог chromium polish оп glas5.

3

Меiпtепепсе

- body

iпtегiог

1 Mats and carpets 5hould Ье brushed ог vacuum cleaned regularly to keep them free from grlt. If they аге badly stained remove them from the саг for scrubbing ог sponging and make quite sure they аге dry before installation. Seats and interior trim panels сап Ье kept clean Ьу 8 wipe оуег with а damp cloth, If they do become stained (which с ап Ье more apparent оп light coloured upholstery) use а little liquid detergent and а soft паН brush to scour the grime out of the grain of the material, ОО not forget to keep the headlining clean in the same way as the upholstery. When using liquid cleaners inside the саг do not over-wet the surfaces being cleaned. Exce5sive damp could get into the seams and padded interior cau51ng 5tains, offensive odors ог еуеп rot. " the inside of the саг gets wet accidentally it is worthwhHe taking the troubIe to dry it out properly. particularly where carpets аге involved. Do поt 'еауе oil ог electric heaters inside the саг for thi5 риГР05е.

Chapter 12 Bodywork and fittings уои

•

,

I

I

I

265

4

Minor body damage - repair

See photo sequences оп pages 270 апd 27'

Repair о' minor scratches in the bodywork If the scratch is уегу superficial , and does not penetrate to the metal of the bodywork, repair is уегу simple. Lightly rub the агев of the scratch with а paintwork renovator ог а уегу fine cutting paste, to гетоуе loose paint from the scratch and to с1еаг the surrounding bodywork of wax polish . Rinse the агев with clean water. Apply touch-up paint to the scratch using а thin paint brush; соп ­ tinue to apply thin layers of paint until the surface of the paint in the scratch is level with the surrounding paintwork. Allow the new paint at teast two weeks to harden , then , bIend it into the surrounding paintwork Ьу rubbing the paintwork in the scratch агеа with а paintwork renovator ог а very fine cutting paste. Finally apply wax polish. Ап alternative to painting over the scratch is to use pa;nt patches. Use the same preparation for the affected агеа ; then simply pick а patch of а suitabIe size to cover the scratch completely. Hold the patch against the scratch and burnish its backing рарвг; the patch will adhere to the paintwork, freeing itself fгom the backing рарег at the same time. Polish the affected агеа to bIend the patch into the surгounding paintwork. Where а scratch has penetrated right through to the metal of the bodywork, causing the metal to rust, а diffetent repait technique is required, Remove апу loose rust from the bottom 01 the scratch with а penknife, then apply rust inhibiting paint to prevent the formation of rust in the future. Using а гиЬЬег ог nyton appHcator fill the scratch with bodystopper paste. If required , this paint сап Ье mixed with cellulose thinners 10 provide а very thin paste which is ideal 10г lilling narrow scratches, Before 1he stopper paste in the scratch hardens, wrap а piece of smooth соНоп rag around the tip of the finger, Dip the finger in cellulose thinners and then quickly sweep it across the surface of the stopper paste, this wШ ensure that it is stightly hollowed. The scratch сап now Ье painted over as described еагliег in th is 5ection,

Repair о' dents in the bodywork When deep denting of the bodywork has taken place, the first task is 10 риН the dent out, until the aHected bodywork almost attains its original shape, There is I1ttle роiпt iп trying to restore the огigiпаl shape comptetely, as the metal in the damaged агеа will have s1retched ОП impact and cannot Ье reshaped fully 10 its original contour, 11 is better to bring the level of the dent ир to а point which is about t inch (3тт) below the level of the surrounding bodywork, 'П cases where the dent Is veгy shallow anyway, it is not worth trying to pull i1 out at аll, If the underside of the dent is accessibIe, It сап Ье hammered out gentty from behind, using а mallet with а wooden ог plastic head. W hilst doing this, hold а suitabIe bIock 01 wood lirmly against the outside of the dent. This bIock will аЬзогЬ the impact lгот the hammer bIows and thus prevent а large аге а of bodywork from being 'beHedоиС

5hould the dent Ье in а section of the bodywork which has doubIe skin ог some other factor making it inaccessibIe from behind , а different technique is catled fot. Drill several зта" holes through the m etal inside the dent агеа - particularty in the deeper sections. Then screw long self-tapping screws into the holes just sufficiently for them 10 gain good purchase in the me1al. Now the dent сап Ье pulled out Ьу pulling оп the protruding heads of the screws with а pair of pliers. The next stage of the repair is the removal 01 the paint from the damaged агеа , and from ап inch ог so of the surrounding 'sound' bodywork. This is accomplished most easily Ьу using а wire brush ог abrasive pad оп а 'power driН, although i1 сап Ье done just as effectively Ьу hand, using shee1s of abrasive рарег. То complete the preparations for litting, score the surface of the Ьаге metal with а screwdriver ог the tang of а lile, ог alternatively, drill small holes in the affected агеа. This will pгovide а really good 'key' for the filler paste. То complete the гера]г see the 5ection оп filting and respraying.

-

Repair о' rust holes

ог

gashes in the bodywork

Remove all paint from the affected агеа and from ап inch ог so of the surrounding 'sound' bodywork, using ап abrasive pad ог а wire brush оп а power drill. 11 these аге not availabte а few sheets of аЬга­ sive рарег will do the job just as effectively. With the раiпt removed

will Ье аЫе to gauge the severity of the corrosion and therefore decide whether to renew the whole panel , (;f this is possibte), ог to repair the affected агеа. Replacement body panels аге not as ехреп ­ sive as most people think and it is often quicker and тоге satisfactory to lit а new рапеl than to attempt to repair large агеаз of corrosion. Remove all 1he littings from the affected агеа except those which will act as а guide to the or1g1nal shape of the damaged bodywork (eg headlamp shells etc). Then, using tin snips ог а hacksaw bIade , remove а" lоозе metal and апу other metal badly affected Ьу corrosion. Наттег the edges of the holes inwards in order to create а slight depression for the fШег paste. Wire-brush the affected агеа to remove the powdery rust from the surface of the remaining metal. Paint the affected агеа with rust inhibiting paint; 11 the back of the rus1ed агеа is accessibte , treat 1his also. Before filling сап take place it will Ье necessaгy to btock the hole in some way. This сап Ье achieved Ьу the use of опе 01 the following materials: Zinc gauze, Aluminum 1аре ог Polyuгethane foam. Zlnc gauze is ргоЬаЫу the best ma1erial to use 10г а large hole. CU1 а piece 10 the approximate size and shape 01 the hole to Ье filled, then position it in the hole so that its edges аге below the level of the зиг­ rounding bodywork. It сап Ье retained in position Ьу several btobs of filler paste around its peripheгy. Aluminum {аре should Ье used for small ог very narrow holes. Pull а piece оН the roll and trim i1 to the appгoximate size and shape required, then pull off the backing рарег (;f used) and stick the tape over the hole; it сап Ье overlapped if the thickness of опе piece is insufficient. Burnish down the edges 01 the tape with 1he handle of а screwdriver ог similar, 10 ensure that the tape is securely attached to the metal underneath. Polyurethane foam is best used where the hole is situated in а section of the bodywork 01 complex shape, backed Ьу а small Ьох section (eg where the sitl рапеl meets the геаг wheel аргоп оп mOS1 сагз). The изиаl mixing procedure for this foam is as follows: Put equal amounts of fluid from each of the two cans provided in the kits, in10 опе container. 5tir until the mixture begins 10 thicken , then quickly рош this mixture into the hole, and hold а piece 01 cardboard over the larger apertures. Almost immediately the polyurethane witl begin to expand and Ье forced out 01 апу small holes left unbtocked. When the foam hardens It сап Ье cut back to just below the level of the surrounding bodywork with а hacksaw btade. The affected агеа must now Ье filled and sprayed - see 5ection оп l111ing and respraying. в odywork

repairs - filling and respraying

Before using this 5ection, see the 5eC1ions оп dent, deep scratch, rust hole and gash repairs. Мапу types of bodyfitler аге availabte, but generatty speaking those proprietaгy kits which contain а tin of filler paste and а tube of resin hardener аге best for this type of repair. А wide, flexibIe plastic ог nylon applicator will Ье found invaluabIe for imparting а smooth and welt contoured finish to the surface 01 the filler. Mix ир а li111e fШег оп а clean piece of card ог board - use the hardener sparingly (foltow the maker's instructions оп the pack), otherwise the filler will set very rapidly. Using the appticator, apply the filler paste 10 1he prepared агеа; draw the applicator асгозз the зигfасе 01 the filter 10 achieve the coгrect contour and to level the ljlter suгface. As 50ОП as а contour that approximates the correct опе is achieved, stop working the paste - 11 уои саггу оп too 10ng the paste will Ьесоте sticky and begin 10 'pickир ' оп the applicator. Continue to add thin lауегз of filler paste at twenty-minute intervals until the level of the fШег is just 'proud ' of the surгounding bodywork. ~ Опсе the filler has hardened, excess сап Ье removed using а coarse-cut file. From then оп , progressively finer grades of abrasive рарег should Ье used, starting with а 40 grade ' wet - and - dгy' рарег. Always wrap the abraslve рарег around а flat rubber, cork ог wooden btock - otherwise the surface of the filter will not Ье completely flat. During the smoothing of the filler surface the 'wet-and-dгy' рарег should Ье periodically rinsed in water - this will ensure tha1 а veгy smooth finish is imparted to the filler at the final stage. At this stage the 'dent' should Ье surrounded Ьу а ring of Ьаге metal, which in turn should Ье encircled Ьу the finely 'feathered' edge of the good paintwork. Rinse the repair агеа with clean water, until alt of the dust produced Ьу the rubbing-down operation is gone.

12

Chapter 12 Bodywork and fittings

266 Spray the whole repair

•

will show up

агев

апу imреrfесtiопs

with

in the

а

light coat of grey primer - this

suгface

01 the filler. Aepair these

imperfections with fresh filler paste ог bodystopper and опев тоге smooth the surface with abrasive рарег. If bodystopper is used, it сап Ье

mixed with cellulose thinners to form

а

really thin paste which is

ideaJ for filling small holes. Repeat this spray and repair procedure until you аге satisfied that the surface of the filler, and the feathered edge of the paintwork аге perfect. Clean the repair агев with clean water and allow to dry fully. The repair агев is now ready for spraying. Paint spraying must Ье carried Qut in а warm, dry, windless and dust free atmosphere. This condition сап Ье created artificially if уои have access to а large indoor working агеа , but if you аге forced to work in the ореп , уои will have to pick уош day carefully. If уои аге working indoors, dousing the floor in the work агеа with water will 'Iay' the dust which would otherwise Ье in the эtmоsрhеге. If the герэiг агеэ is confined to опе body panel,

mэsk off the surrounding panets; this witl hetp to minimise the effects of а stight mis-match in paint cotours. Bodywork fittings (eg chrome

strips, door handles etc) will aJso need to Ье masked off. Use genuine masking tape and several thicknesses of newspaper for the masking operation. Before commencing to spray, agitate the aerosol сап thoroughly, then spray а test агаа (ап old tin, ог similar) until the technique is mastered. Соуег the repair агеа with а thick coat of primer; the thickness should Ье built up usif1g several thln layers of paint rather than опе thick опе. Using 400 grade 'wet-and-dry' рарег, rub down the surface of the primer until it is realty smooth. While doing this, the work агеа should Ье thoroughly doused with water, and the wet-anddry рарег periodically rinsed in water. Allow to dry before spraying оп тоге paint. Spray оп the top coat, again buitding ир the thickness Ьу using several thin layers of paint. Start spraying in the centre of the repair

Fig. 12.1 Hood alignment - adjustment points (Sec 6) Fig. 12.3 Typical hood bumper - adjustment (Sec 7)

,

~\ Fig. 12.2 Hood latch - adjustment (Sвc 7)

Fig. 12.4 Trunk lid torsion

Ьаг

- adjustment (Sec 8)

,

Chapter 12 Bodywork and fittings

• •

агев

and then using а circutar motion, work outwards until the whote repair агев and about 2 inches of the surrounding original paintwork is covered. Аетоуе all masking material 1О 10 , 5 minutes апег spraying оп the fiпаl coat of paint . AHow the new paint at least 2 weeks 10 harden fully, then, using а paintwork renovator ог а уегу fine cutting paste bIend the edges of the new раiпt into the existing paintwork . Finally apply wax polish.

5

, •

,

,

J.NU T

Major body damage - repair

Where serious damage has occuгred ог large areas need renewal due 10 neglect, it means that new sections will need welding in and this is best left 10 the professionals. 11 the damage is due 10 impact it will also Ье песезsагу 10 completely check the alignment of the body shell structure. Оие to the principle of construction the strength and shape of the whole сап Ье affected Ьу damage to а paгt . 'П such саэеэ the services of а Ford repair station with specialist checking jigs аге essential.

6 I

267

HINCiE ASSEM6L У

Hood - alignment

1 Loosen the hinge-to-hood securing bolts and move the hood from side to side аэ песеээагу. 2 Loosen the hinge-to-fender аргоп securing bolts and adjust the vertical . and fore-and-aft position of the hood (Fig. 12. 1). з The hood Ьитрегэ located оп 'ор of the radiator эиррогt сап Ье adjusted ир and down to provide а level surface alignment of the hood with the front fenders. 4 Tighten the securing bolts.

7

Fig. 12.5 Trunk lid hinge - 1965/70 (Sec 9)

Hood latch - adjustment $CRE'II'

The hood 18(ch сап Ье moved !гот s;de-(o-side (о align "с with the hood latch hook 8nd up-and-down (о obtain 8 flush Пс with the !ront fenders. The hood mU5t Ье properJy 8ligned before adjusting the hood /a(ch. 1 Loosen the hood lalch securing bolts until they аге just 'ооэе enough 10 move Ihe lalch. 2 Position the latch in aHgnment with Ihe hood latch hook. 3 Loosen the locknuts оп the two hood bumpers and lower the bumpers. 4 Adjust the hood latch ир ог down. as necessary. to obtain а flush fit between the 10P of the hood and the fenders when ап upward рге ­ ssure is applied 10 the front of the hood. then tighten the hood latch securlng bolts. 5 Raise the two hood bumpers 10 elimlnate апу looseness when the hood Is closed. Tighten the hood Ьитрег locknuts.

8

Trunk lid hinge torsion

Ьаг

ШССАС Е

CO MPARTMEHT DOOR

--

,, , , /

•

----

~~ ,-'----

- adjustment

•

-

-

Fig. 12.6 Trunk lid hinge - Hardtop and ConvertibIe (1971/73) (Sec 9) 1 Check the рор-ир distance of the trunk lid when il is ореп. 1I should Ье approximalely 3 inches. If the Irunk lid pops ореп тоге than 3 inches the torsion Ьаг 2 tension should Ье decreased and if it does not рор- ир when the catch is released the tension should Ье increased. Caution: Take саге when adjusting the tor5ion Ьаг 85 it ;5 under ten5ion and could 5pring ои! о! control '" not handled carefully. 3 То adjust the torsion Ьаг tension . place а piece of suitabIe 5teel Ьаг over the end of the t'orsion Ьаг . а5 shown in Fig. 12.4. then rotate the Ьаг rearward at point С and reposition point В in another notch 10 increase ог decrease the torsion Ьаг tension. as nece5sary. 4 After adju5tment . the difference of the position of the torsion Ьаг end5 between the right and left side must not Ье more Ihan опе notch.

9

Trunk lid - alignment

1 The trunk lid is adju5ted from side-to-5ide Ьу 100sen1ng the hingeto-lid attachment 5creW5 and moving the lid as песе55агу. 2 То adjust the veгtical aJignment оп рге-1971 models 1005еп the

hinge-to-hinge support attachment 5crews and move the lid up ог down а5 necessary. 3 Оп models from 1971 the vertical adjustment is made Ьу 1005еп­ ing the hinge-to-door attachment screws and the lid а5 reQuired. ог оп some models Ьу removing ог adding shims between the hinge and lid. 4 After correct alignment ha5 Ьееп achieved . tighten all the attachment screws. • 1 О Ooor trim panel - removal and installation

1965-1968 models 1 Оп early models remove the window regulator handle. using а handle-removing tool (availabIe at m05t auto supply shops! to di5engage the retaining spring сliр . ОП later models remove the handle retaining screw and withdraw the handle (photo). 2 Aemove the door-pull 5ecuring screws and the armrest (photos). 3 Undo the retaining 5crew and remove the door latch handle (photol.

12

Chapter 12 Bodywork and fittings

268

4 Аетоуе all the trim рапе' retaining screws and thеп pry the рапеl retaining clips out of the inner рапе' and гетоуе the panel. Аетоуе the watershield (photo). 5 Installation i5 the reverse 01 the гетоуаl procedure. Apply water-

•

resistant sealer at each

рапе'

retaining

сliр

and around the window

regulator shaft.

1969 - 73 models 6

Fig. 12.7 Trunk lid hinge-

Fastback 11971/731

158С

91

Аетоуе

the door lock push button control knob. 7 Аетоуе the window regulator retaining screw CDver and retaining screw and pull the handle off the shaft (photos). Аетоуе the three retaining screws from the armrest assembIy and 8 withdraw the armrest. , 9 Pry the two door-pull handle соуег assembIies from the handle , undo the two handle retaining screws and remove the pull handle. 1О Aem ove the two retaining nuts and remove the door remote control handle from the door.

10.1 Aemoving the window regulator handle retaining screw

1 0.2А Ooor-pull secu ring screws

, О. 28 Aemoving the door-pull and armrest

, 0.3 The door latch handle 1s secured with а screw

10.4 Ооог with trim panel removed and watershield pulied back

10.7 А Aemoving the window regulator handle retaining screw соуег ...

10.78 ... and the retaining screw

10.12 Fitting the trim panel

оп

the door

•

Chapter 12 Bodywork and fittings 11 Using а wide-bIаdеd knife, ог similar tool, ргу the trim рапе' retaining ctips out of the inner рапе' of the door and гетоуе the panel.

the watershield. 12 In5talli"9 the trim panel is the

Аетоуе

Apply water-resistant sealer

оуег

геуегэе

of the

гетоуа'

procedure.

each retaining clip hole and around

the window regulator shaft hole (photo).

,

I

11 Doors -

гетоуаl

and instelling

1 Ореп the door and place а support under the door to take its weight. The help 01 ап assistant should al50 Ье enlisted to hold the door. 2 Аетоуе the door trim рапе' as described in Section 10. 3 Scribe aHgnment marks оп the hinges and doOt to assist when installing. 4 Аетоуе the hinge-to-door attachment bolts and lift away the door. 5 InstaНing the door 1s the reverse of the removal procedure. Check the door aHgnment and, 1f песеззагу, adjust аз de5cribed in Section 12.

12

Ооог

alignment

1 The door hinges have enlarged holes to provide adjustment of the door position. Always ensure that hinge5 аге correctly positioned before making а latch 5triker adjustment. 2 Refer to Fig. 12.8 to determine which hinge bolts must Ье loosened to move the door in the required direction. 3 Remove the door trim рапеl and hinge access covers. Loosen the hinge bolt5 just enough to allow movement of the door with а padded ргу Ьаг. Take саге not to damage the paint finish when u5ing the ргу Ьаг.

4 Моуе the door as necessary, then tighten the hinge bolt5 and check the door fit. 5 Repeat the operation until the correct alignment is obtained, and check the striker plate a1ignment for correct clos1ng. 6 Install the door trim рапе! and h1nge ассе5З covers.

13

Ооог

269

latch striker - adjustment

1 The striker pin сап Ье adjusted tateratty and veгticaHy as well as fore-and-aft. 00 not adjust the /atch striker to overcome door S8g. 2 Adjust the latch striker position with 5hims (о obtain the clearance shown in Fig. 12.9. Check the clearance Ьу applying а thin film of grease to the striker, and then , as the door Is closed and opened а mеаsuгаЫе pattern witl result.

14

Ооог

latch -

геmоуа'

and Install8tion

1 Remove the door trim рапеl and watershield а5 described in Section 1О. 2 Disconnect the four rods from the latch аssеmЫу. 3 Undo the three latch attachment screW5 and remove the latch. 4 Remove the rod retaining clips and the 'doo r-open' warning switch from the latch. 5 Refitting i5 the rever5e of the removal procedure. Adjust the warning switch and the latch actuating rod as described in Sections 15 and 16 respectively.

15 'Door

ореп' waгning

switch - adjustment

1 Remove the door latch а5 de5cribed in Section 14. 2 Loosen the 5witch attachment screw and 5et the door latch in the cl05ed position. 3 Position the switch contact пеаг the latch cam, (з ее Fig. 12.10), but по! touching it, then t1ghten the switch attachment screw. 4 5е! the door latch foг the safety and ореп positions. The switch contact must make electrical contact with the cam when the latch i5 in the safety and ореп positions. 5 In5tall the door latch (See Section 14).

, LA ТСН SТRI КЕ R

I

,

•

I

3/32" MINIMUM

~,M"X IMUM lATCH

\

...

"'-

ASSEM6L у'

Fig. 12.9 Door latch striker - adjustment (Sec 13) ОРЕН

DOOR

WA.RNING

2 LATCH

Fig. 12.8 Ооог alignment - adjustment points (Sec 12!

SWITCH

Fig. 12.1 О 'Door

ореп' waгning

switch (Sec 15)

These photos illustrate а method of repairing simple dents. They are intended to supplement Body repair daтage in this Chapter and should по! Ье used as the sole instructions for body repair оп these vehicles .

•

11 уои can't access the backside 01 the body рапеl to hammer ои! the dent, pull it Qut with а slide-hammer-type dent puller. 1" the deepest por1ion 01 the dent ог alo"9 the crease line, drill ог punch hole(s) at least опе inch арап . ..

1

тinor

... then screw the slide-hammer into the hole and operate it. Тар with а hammer near the edge 01 the dent to help 'рор' the metal back to its original shape. When you're finished, the dent area should Ье close to its original contour and about 1/8-inch below the sur1ace 01 the surrounding metal

2

Using coarse-grit sandpaper, remove the paint down to the Ьаге metal. Hand sanding works fine, but the disc sander shown here makes the job faster. Use finer (about 320-grit) sandpaper to feather-edge the paint а! least опе inch around the dent агеа

4 When the paint is removed, touch will probabIy Ье more help1ul than sight 10r telling if the metal is 5traight. Hammer down the high spots or rai5e the low spots as nece55ary. Clean the repair area with waxlsilicone remover

5 Following 'аЬеl instructions, mix ир а batch 01 plastic filler and hardener. The ratio 01 filler to hardener is critical, and, if уои mix it incorrectly, it will either not сиге properly ог сиге too quickly (уои won't have time to file and sand it into shape)

6 Working quickly 50 the filler doesn't harden, u5e а pla5tic applicator to press the body filler firmly into the metal, assuring it bonds completely. Work the filler until it matches the original contour and is slightly аЬоуе the surrounding metal

з

•

•

,

7 Let the filler harden until уои сап just dent it with your fingernail. Use а body 1ile or Surform tool (shown here) to roughshape the filler

8 Use coarse-grit sandpaper and а sanding board or bIock to work the filler down until it's smooth and еуеп. Work down to finer grits 01 sandpaper - always using а board or bIock - ending up with 360 or 400 grit

I

I

,

10

9 Уои shouldn't Ье аЫе to 1ее' апу ridge at the tгапsitiоп from the fjller to the bare metal or from the bare теtзl to the old paint. As 500П as the repair is flat and uniform, remove the dust and mask off the adjacent panels or trim pieces

Appty severallayers 01 primer to the area. Don't spray the primer оп too heavy, so it sags or runs, and make sure each coat is dry be10re you spray оп the next опе. А pr01essional-type spray gun is being used here, but aerosol spray primer is availabIe inexpensively 1rom auto parts stores

11 The primer will help reveal imper1ections or scratches. Fill these with glazing compound. Follow the lаЬеl instructions and sand it with З6О ОТ 4oo-9rit sandpaper until it's smooth. Repeat the glazing, sanding and rеsрrауiпg until the primer reveals а perfectly smooth surface

12 Finish sand the primer with very fine sandpaper (400 or 600grit) to remove the primer overspray. Clean the area with wаtэr and allow it to dry. Use а tack rag to remove апу dust, then apply the 1inish coat. Don't attempt to rub out or wax the repair area until the paint has dried completely (at least мо weeks)

,

I

I

Chapter 12 Bodvwork and fittings

272

• 16 Door letch 8ctuating rod - adjustment

(XJТSIDE

QJTSIDE PUSH ВUТТCN PIN

HANDLE

BELLCRANK

1 Remove the door trim panel and watershield as described in Section 1 О. 2 Disconnect the latch actuating rod from the latch actuating rod lever. 3 Adjust the length of the rod to obtain the dimension 0.0 15 0.078 in (0.38 - 1.98 тт) at А in Fig. 12.11. 4 Install the latch actuating rod in the latch actuating rod lever and flt the retaining clip. 5 Check the operatlon of the door handle pushbutton and the latch assembIy. 6 Instatl the door watershield and trim panel, (See Section 1О).

17 Window regulator mechanism -lubric8tion

_l.ATCH

ACTUдTIНG

"00

1 The door window mechanlsm should Ье lubri cated whenever the glass channel ог window regulator is removed ог if excessive effort is . required (о operate the windows. 2 Apply ап even coating of polyethylene grease (о the window regulatot гоНегз. shafts and roller guides, where indicated Ьу shaded areas (Fig. 12 .12).

ADJUSТ RCD ТО 08TAIN DIМENSION "Д ..

18 Door window - removaland installation

Early models

l.ATCH ACTUATING R(Ю

LEVER LATCH LOCKING LEVER

Fig. 12.11 Door latch 8ctuating rod - adjustment (Sec 16)

,.<

-

1 Аетоуе the door trim рапеl and the watershield as described ,п Section 10. 2 Remove the геаг run retainer, undo the lower window stop retaining screws and temove the lower stop. 3 Lower the window опе third of the way, and temove the screw retaining the regulator guide channel to the window frame , and move the channel foгward. 4 Lower the window down '" the door; tilt it ninety degrees forward and 11ft it up and out of the door while tllting it slightly inwards. 5 Installin9 is the reverse of the removal. Adju5t the lower 5top.

Later models 6 7 8 9 the 1о

Remove the door trim panel and watershield. Remove the front and геаг guide5 from the gla5s channel. Аетоуе the геаг stop from the doot. Disconnect the wlndow regulator arm from the glas5 channel at pivot. (See Fig. 12.13). Remove the drive arm btacket from the gla5s channel. 11 Remove the belt weather5trip from the door and 11ft out the glass and channe l assembIy. 12 In5talling '5 the геуеГ5е of the removal procedure. Adjust the p05ition of the front and геаг 5topS. ,,, ,,

, ,9 Window regulator - remov81 8"d in8t8118tio"

Early models 1 Аетоуе the door trim рапеl and water5hield (refer to Section 1О). 2 Wedge the gla5s '" the fully closed p05ition. 3 Remove the nut 5ecuring the front glass run at the base. 4 Аетоуе the regulator attachment bolts, then di5engage the regulator arms from the equaHzer and window channel brackets, and гетоуе the regulator from the doot. 5 In5talling is the reverse of 111е removal ptocedure . .,

.. >0""'.''',o, ...... ·.с. о. 'У'. COOfI"~

01'

ICO···"..···,.O ... '-

..,.00. IIC"LAТO' 'OLLI." ... , .. '.0 '01 ..... 1 .'МОТ. О, 'О,с" о., ''-С.'''''''''О

... '1 . 1. '.1 ............

Fig. 12.12 Window regulator mechanism lubrication points (Sec 17)

Later models 6 Remove the door trim panel and watershield. (lf fitted with power ~,Г windows di5connect the wiring). 7 Disconnec1 the window regulator агтз from the glass channel and door inner рапеl а! the pivots (see Fig. 12.1 З). 8 Disconnect the glass channel bracket from the gla5s channel, and the remote contTol rod from the door latch. 9 Remove the геаг weathershield сар.

•

WINOQW REGUL AT DR

--

VIEW . G

, : - - GLASS RUN

I

GUIDE

CH ANN EL

-.

Е

VIEW.

~--

GLASS

BEL Т DUTSIDE WEATHE RST RIP

BR ACKET

LOWER STOP BUMPE R

GlASS RUN RE AR

CHAHNEL

SТOP

VIEW _D

FIGURE 2 FRONT STOP

'

...... WIN DOW

REGUl ATOR

, PIVDT

f

STOP 8RACKET - - "

VIEW -с

VIEW· В

Fig. 12 ,13 Ооо, window glass mechanism (Sec 19) VENTWI

ASSEMBLY GLASS!CHAN

L ASSEMBLY

А

,f

-

-•

о

UPPER RЕАR STOP ASSEMBLY

f

""'0

AND RETAINER ASSEMBLY

с

I

UPPER STOP ASSEMBLY

EQUALIZ ВААСКЕТ

f

ААМ

ASSEMBLY

VENT WI N DOW I ВАА RUN AND ВRАСКЕТ ASSEMBLY

Fig. 12.14 Ooor window - adjustment (early models) (Sec 20)

12

•

Chapter 12 Bodywork and fittings

274 1О

Аетоуе

the upper

геаг

stop and the belt weatherstrip and mould-

3 With the window closed, position the glass lirmly against the belt outer weatherstrip; then position the inner stabiHzers firmly against the glass and tighten the two screws А. 4 Tilt the glass in ог out as necessary to install it in the гооl гаН weatherstrip, then tighten the nuts and screws, С and D. 5 Моуе the two upper stop brackets firmly downward and tighten screws Е. 6 Lower the window until the {ор 01 the glass is 0.25 in (6.3 тт) аЬоуе the belt weatherstrip, then тоуе the lower stop up and tighten the screw F. 7 Check that the window operates correctly, then fit the watershield and trim panel.

• IПg.

11 Aemove the window regulator attachment screW$ and withdraw the regulator from the door.

12 Installing is the reverse 01 the removal procedure. Align the glass and adjust the stops and guides (See Section 20) then in5tall the watershield and trim panel.

20 Door windows (early models) - adjustment 1 Аетоув the door trim panel and watershield (see Section 1 О). 2 Close the window fully and adjust the уеп! window assembIy backwards and forwards ог up-and-down at А in Fig 12.1'4,50 that the front edge of the door уеп! window is рагаllеl with the windshield side moulding. Tighten the screw at А just enough to retain the vent window in position. 3 То aBgn the top edge 01 the vent w;ndow 1гате with the гaof га;1 weatherstrip, tilt -the уе п! window assembIy ;nwards ог outwards Ьу rotat;ng the adjusting screw at В , as necessary. Tighten the locknut at

22 Quarter

wiпdоw gl888

(Hardtop and

СопvеrtiЫе)

-

гетоуаl

апd iпstаllаtiоп

the геаг seat cushion and back. 2 Ргу off the regulator handle соуег to gain access to the regulator handle retaining screw, and then гетоуе the screw and handle. 3 Оп ConvertibIe models гетоуе the ttim рапе! attachment 5crews. Оп Hardtop models гетоуе the рапеl attachment screws and using а wide-bIаdеd knile ог similar tool, ргу the retaining clips out 01 the inner panel. 4 Disengage the trim рапе! from the upper retainers and гетоуе the panel. Аетоуе the watershield. 5 Loosen the window guide bracket lower attachment nuts. 6 Lower the glass fully and disengage the regulator агт from the glass channel . Аетоуе the upper Iront and геаг stops (see Fig. 12.17). 7 Loosen the window guide bracket иррег attachment nuts and гетоуе the glass and channel assembIy. 8 Instal1ing is the reverse 01 the гетоуаl procedure. Adjust the иррег stops and the window guide bracket, ( ге1ег {о Section 241. Ьеlоге litting the watershield, trim panel, seat back and cushion.

1

В.

Adjust the screw at С until the shoulder is against the vent window division Ьаг lower support. 5 Tighten the locknut at С and then lиНу tighten the screws at А. 6 То obtain the correct window-to-weatherstrip position, loosen the screws at D and Е and tilt the window inwards ог outwards as necessary, then tighten the screws at D and Е. 7 Adjustment 01 the door window to the vent window frame is Ьу loosen ing the screw а! F and moving the front stop up ог down , as necessary. Tighten the screw at F. 8 Adjust the top edge 01 the window parallel to the гооl rail weatherstrip Ьу loosening the screw at Н and the nuts at G, then тоуе the equalizer агт bracket and the геаг stop ир ог down as necessary, to align the window correctly. Tighten the nuts at G and the screw at

4

Аетоуе

Н.

23 QU8rter 21 Door windows {Iater modelsl- adjustment 1 2

гетоуаl апd

Аетоуе

the door trim рапеl and watershield; see Section 10. See Fig 12.15 and loosen the screws and nuts, А. В , С, О , Е and F.

wiпdоw

regulator installation

(Hardtop

апd

СопvеrtiЫеl

1 Аетоуе the геаг seat cushion and back, the trim watershield as described in Section 22.

UPPER

REAR SТOP

в в UPPER

FRONT SТOP

GlASS BRACKET АНО GUIDES

F

LOWER

SТOP

Fig. 12.15 Door window - adjustment (later modelsl (Sec 21)

рапеl

-

and

Chapter 12

,воdуwоrk

and fittings

275

, U PPER

FRONT НЕ.

-

QUARTER TRIM

(

Fig. 12.16 Quarter trim

рапв/-

Hardtop (Sec 24)

TRIM I (2 REQ'O)

-

' - , _ _ ARM REH

//

WINQOW

LO(K PllLAR

REGULATOR

с--"

•

,t

•

VIEW . A,

®')-:::=::~ CQVER -

~9\

FRDNT STOP 30600

WINQOW DUТER

WINDOW AS5EMBL У

REA R

DUТ5ЮЕ

MDULDING UPP ER

GLASS дно ASSEMBL у

STQP

WINQDW

ТО'

8ElT MDULDING

I

,

WINDQW GUIDE

WINDOW

GUIDE BR A(KET

,

WINDDW EXТENSIQN

Fig. 12.17 Quarter window mechanism - Hardtop and ConvertibIe (Secs 22 and 241

, I

2 Lower the glass and disengage the regulator агт from the glass channel. 3 Raise the glass and support it in the closed position , then remove the four window regutator attachment screW$ and withdraw the regulator through the lower aperture. 4 Installing is the reverse of the removal procedure.

stop up into position and tighten the secuгing screw N. 5 With the window still fuHy closed, move the top of the window in ог out to obtain а good seal between the quaгter window and the roof гаН weatherstrip, then tighten screw К . 6 Check the operation of the quarter window and then install the watershield and trim panel .

•

,

•

•

24 Quarter window IHardtop and ConvertibIe) - adjustment 1

Аеmоуе

the trim

рапе'

and watershield as described in Section

22. 2 Referto Fig. 12.17, and loosen screws Е, Н , К, N and Р . 3 Close the window fully, then position the glass to obtain а parallel fit and а flush height between the door and quarter window . Now tighten screws Е and Н. 4 Моуе the front stop down against the stop bracket оп the glass channel and tighten the securing screws Р, then move the upper геаг

25 Door latch - emergency opening procedure 1 If the door la1ch mechanism faBs. and the door cannot Ье opened from either the outside ог the inside of the саг, get а piece of 0.125 in (3 mm) diameter rod and bend it to the dimensions in Fig. 12.18 . 2 Lower the window fully and insert the rod in the glass opening at the геаг edge of the door and engage the latch pawlleveг , as shown in Fig. 12.19; then press down оп the latch pawllever to ореп the door. 3 Check the latch and actuating rod assembIy ; see Section 14, to ascertain the cause of the failure.

12

,

Chapter 12 Bodywork and fittings

276

•

----,," ---•

,

i ,

3·112"

II.!" 1" .. DIA. WELJ)ING

RСЮ

ТО

- -

,ItONf

О, аооу

OR EQUIVALENT

Fig. 12.18 Ооог latch pawllever rele8sB tool (Sec 25)

- - RПАJNfR·КfY CYLINDER

__

о С"

... Ac,_t'n.

Тоо'

: - - DOOR INstDE LOCK PUSН ВUПQol

Fig. 12.20 Removing the outside door handle (Sec 26)

ux: IC СУ LINDfR CQ NSO l (

~ //.. i ( '

/ .' ,----- . ~·.~:1, ·

-.. . . . '. 1

LA ТСН P"WI..

--

LEVER

-.

,;.,~~

'- ," '.

~"~"

Fig. 12.21 Floor console assembIy fSec 28)

27 Windshield and back window - яепегаl

Fig. 12.19 Releasing the door latch pawllever (Sec 25) ,

28 Outsid. door handle -

гетоуаl

If you аге unfortunate enough to have а windshield ог back window shatter, 11ttin9 а replacement is опе of the jobs that the ауегаяе owner is advised to 'еаув to а body repair specia!ist ог Fщd repair station, а5 they have the песе55агу tool5 and equipment required.

and installation 28 Floor cOnlole - removaland installation

1 2

Remove the door trim рапе' and watershield; see Section 10. Аетovв the four screws attaching the door weatherstrip а! the

belt line.

3 Disconnect the door 18tch actuator rod from the outside handle, undo the two nuts and washers securing the handle to the door and

then remove the handle and pad (see Fig. 12.20) 4

1"5t81Iatio" is the tBVBrse of the removal procedure.

1 Ореп the 91оуе Ьох door and remove the retaining screws and the top 1inish рапеl assembIy 1rom the console. 2 Аетоуе the screws attaching the console to the shift аsзетЫу and to the 11оог. 3 Note the wire connections. then disconnect them and remove the console.

•

Chapter 12 Bodywork and fittings 4

Inslallation 15 the reverse of the

геmо"зl

procedure .

remove the pad and retainer assembIy .

4

In5tallatio" i5 the reverse of the removal procedure. Ensure that all

the spring nuts

29 Instrument

•

рапеl

pad -

геmоvаlапd

аге

positioned as shown in Fig. 12.22 .

i"8t8118tio"

1 Remove the right and left lower-end mouldings for access to the attachment screws at the lower ends of the pad ( зее Fig. 12.22) . 2 Remove the three screws at the tap inner edge of the pad-to- pad support. the tWQ screws at the right and left lower pad end-toinstrument panel , and the two lower center pad-to-instrument рапе'

30 Radiator

gгШе

- removal and installation

Early models 1 Remove the snap-in rivets from the gгШе attachment points, then undo the lower center attachment screw at the center support and remove the gгШе.

screws. 3

277

Disconnect the clock and courtesy light wiring (if fitted) and

SC REWS

SPR

::isup~~~' .~(

,

Fig. 12.22 Instrument pad and retainerremoval (Sec 29)

ING~N:U~T;---'\ REQ ' D)

~

•

•

NUT ,

I

r I

I NST RUME NT PANE l

SCR[W

REQ' D)

', '/1 _ _ L!NER END MQULOING

I ,

I

Fig.

r

12.2З

Radiator grille assembIy - early models (Sec за)

CEN TER SUPPQRT

Э~

12

NUT

I ORNAMENI

VIEW

А

VIEW 6

VIEW

С

Chapter 12 Bodywork and fittings

278 •

Later models 2 Undo the four attaching screws ОП e8ch side and remove both headlamp doors. 3 Ореп the hood and remove the parking light assembIies. 4 Аетоуе the attachment grille attachment screws and tift away the 9 rill e.

5

In5t811i"9 15 the reverse of the гетоуа' procedure.

31 Front bumper - removaland i"st8118tio"

Early models 1 Jack up and support the саг to provide working height. 2 Remove the parking lights from the bumper. 3 Аетоуе the right and left end Ьгзсkеt bolts from the fender. 4 Аетоуе the bumper bar-to-inner arm and outer агт attachment bolts, then liп away the bumper and end brackets аз ап assembIy. 5 Installing 15 the reverse of the гетоуа' procedure.

33 Motor 8nd pump (ConvertibIe top) - r8moval and in8tal18tion 1 Operate the top to the lully raised position, 2 Remove the геаг seat cushion and seat back. 3 Disconnect the motor leads and the ground wire. 4 Remove the fШег plug and vent the reseгvoir , to equalize the pressure , This prevents flu id spraying оп to the trim and paint finish when the hoses аге disconnected, 5 Place cloths under the hose connections, disconnect the hoses and then plug the ореп litt;ngs and lines, 6 Remove the attachment nuts and lift the motor and pump assembIy from the 1100г рап . Take саге not to lose the rubber grom mets. 7 l"stallatlon is the reverse of the removal procedure, Bleed the system, as described in Section 35.

-

•

Later models 6 Aemove the six bolts securing the bumper assembIy to the Isolators and 11ft away the bumper, 7 U"do the 10ur "uts and six screws a"d separate the rei"forcement a"d 11ce"se plate bracket fгom the bumper. 8 l"stalll"g is the reverse 01 the removal procedure, Tighten the bolts to the torque value given in Fig. 12.26,

32 R8ar bumper - removal 8nd i"8t8118tion 1 Oisconnect the license plate light wiring connector in the luggage companment and push the grommet out of the геаг panel, 2 Aemove the four bracket-to-body attachment bolts and lilt away the bumper assembIy. 3 I"stallation is the reverse 01 removal procedure. Oon't forget to connect the license plate light wiring.

34 Motor and pump (ConvertibIe top) - overhaul А ,ера;г

kit is avaifabIe; use ling the рumр and reservoir.

а"

the parts in the kit when reassemb-

Remove the filler plug and drain the fluid into а suitabIe container. Scribe matching lines оп the reseгvoir and pump body so that they сап Ье reassembIed in their original position. 3 Unscrew the center bolt and remove the reseгvoir соуег and the O-ring seal. 4 Remove the bolts securing the valve body to the pump body, then carefully remove the valve Ьodу , taking саге not to lose the check balls, Remove the inner and outer гotors and the drive Ьаll, 5 ReassembIy is the reverse 01 the dismantling procedure, Position the assembIy horizontally and lill the reseгvoir with automatic transmission lluid (C IAZ-19582 -A) to the level of the bottom of the filler hole, then fit the fitler plug , using а new seal, )1 2

~.

..х:--

.-.~

SCAEW

HEADLAMP

AADIATOA GAILLE-

SCAEW

SPAING NUT

SCAEW AND WASHER

Fig. 12.24 Radiator gril18 assembIy -18t8r models (Sec 30)

,

,---------------------------------------------------------------------279 INSUlA Т О!;! •

SТONe

i ,

DEFLECTOR

CXJTER ДRМ

, • VIEW

•

С

ВUMPE!;!

rfэ/ •

-дRМ

ENO BRACKET

FRONT __- - '

VIEW

.UМP,"

_РЕ.

GUARD

__•

В

INSUlATOR

У1Е. А

I

Fig. 12.25 Front bumper assembIy - early models ISec 311

RE IN f ORCEMEN1" нит

_TOROUE

12.18 fT. LB.

1

SU PPQRl

BUMrER CQVER

I

_S(R EW

I I

NUT

lQRQU!:. 10·60 fl. llJ .

дно RET·\INE~

6 REQ'D

Rl:lNF ORtE MEN l

I

~~

I

5C RE ....·

I I

NIЯ.АNО

I

VIEW А

VtEW

В

VIEW

Fig. 12.26 Front bumper assembIy - later models

•

VIEW D

С

($ес Э1'

RETAINER

ta

•

Chapter 12 Bodywork and fittings

280 • ••

..

LIGHJ ASSEMBL У

•

, •••••••

'"

"

,

" ,,

,

•

• ,

••••••

" "

•••••• •••••••

" " " " ••••

YIEW·B

8UMPER GUARD

" " " "

.

HUT

PLUG ВUТТON

• _

BUМPER

GUARD BRACKEТ

VIEW ....

Fig. 12.27 Rear bumpвr assembIy - Iatsr models (Sec 32)

of the cylinder.

3

Undo the mounting bolts and

гетоуе

the bracket and bush ings

from the cylinder. 4 Place cloths under the hose connections to protect the раiпt finish then pull down the cylinder, disconnect the hydrautic tines and гетоуе the lift cyl inder. Plug the ends of the hydrautic Jines. 5 Installation is the reverse of the гетоуа' procedure. Bteed the system аз described in Section 35.

37 Air conditioning 5Y5tem - gener81

Should

ап

Ье

fitted and it5 performance i5 unsatisfactoгy , от it has to Ье removed to give access to other parts, it i5 recommended that this Ье left to the local Ford repair 5tation. This i5 because the unit is of а complex nature and specialist knowledge and

Fig. 12 .28 Dism8ntling the motor and pump ConvertibIe top (Sec 34)

air conditioning unit

equipment i5 required to service the unit.

35 Hydr8ulic 5y5tem (ConvertibIe top) - bIeeding

38 He8ter - gener81

1 Remove the геаг seat cushion and seat back. Lower the door quarter w indows . 2 Аетоуе the reservoir filler plug and check the level and , if necessary, top-up with the specified automatic transmission fluid to the bottom of the liller plug hole . 3 Screw the filler plug in опе ог two threads, and with the engine running, cycle the convertibIe top (up, then down etc ) until the system i5 purged 01 air pocket5. If air is present it с ап Ье 5ееп in the transparent line5 . Check the llu id 'еуеl in the reservoir during the bIeed ing and top- up а5 necessary. 4 After the air has Ьееп purged from the sY5tem top-up the re5ervoir, il ne cessaгy. then lit and tighten the filler plug. Note : The top

1

Оп

model5 litted with air conditionlng , the refrigerant line5 have to Ье di5connected when removing the he8ter, therelore thi5 5hould Ье left to the 'оса' Ford repair 5t8tion , as explained in Section 37. 2 Оп model5 without air conditioning the heater aS5embIy is а bIend air 5Y5tem receiving out5ide air through ап opening in the right-hand vent duct , which i5 connected directly to ап opening in the upper cowl. Outside air i5 drawn into the system lгот the cowl through the right vent duct into the bIower housing, 10rced through and/or aTound the heater саге , mixed and then di5charged through outlets in the discharge air duct to the 1100г агеа ог t hrough the defroster outlet5.

must Ье ир when the fJuid level is checked.

The procedures described in the following Sections аге ,"п respect о' heater assembIies fitted оп models without air conditioning.

36 Lift cylinder (ConvertlbIe top) - remov81 8"d 1"5t8118tio"

39 He8ter -

1 2

Аетоуе Аетоуе

the геаг зеа! and quarter trim panel. the hairpin clip, washer and clevis pi"

lгот

the

иррег

end

1 2

гетОУ81

and i"5t8118tI0"

Disconnect the ground са Ые from the battery negative terminal. Drain the cooling system: зее Chapter 2.

,

Chapter , 2 Bodywork and fittings

281

'1'

А1,

МОТOR

RESISTOR

,

<

LEFT

RдМ-дIR

УЕНТ

rCABLE

то

RIGНТ RAМ

-AIR

OEFROSTERS

•

НЕ.А.ТЕА

l'

•

_ _.~

REG1STER

HEAT~EFROST

то LEFТ

REGISTER

(CABLE

ТО RIGНT

COНTROLLED)

ОООА

(C,A,BLE C(I\ITROLLfD) ТО

то

FLOOR ТО

,

FLOOR

Fig. 12.29 Heater and vent svstem - schematic (Sec 38)

1965-66 models з

Aemove the glove housing.

4

I

Ьох

and disconnect the defroster hoses at the

Disconnect the heater hoses at the water pump and carburetor.

5 Disconnect the wiring to the motor and the ground wire. 6 Undo the heater assembIy attachment nuts, disconnect the fresh air inlet and withdraw the heater assembIy.

1967-68 models

•,

FLOOR

7 8 9

Disconnect the heater hoses in the engine compartment. Disconnect the hose from the choke housing . Remove the glove Ьо)( liner and the nuts attaching the heater to

the 10 11 12 the

dash. Disconnect the ground wire and the motor wires. Disconnect the three control cabIes and the defroster hoses. Undo the screw attaching the heatвr to the air intake and гетоУе heater assembIy.

1969-70 models 13 Аетоуе the instrument рапеl pad (see Section 29). 14 Аетоуе thв glove compartment liner and door. 15 Аетоуе the air distribution duct and disconnect the control cabIes from the heater assembIy. 16 Disconnect the wire from the bIower motor resistor. Remove the

DEFROSTER NOZZLE"'--

SIDE

УI

ASSEMBLY

EW

(fYPIC"L)

.1. DUCT

••

, , о

ASSEMBLY

I

,I

Fig. 12.30 Removing heater

/

...;;р"

,

•

,

~

, ~ ~

-1969/ 70 modols (S.c 39)

?, -

'-

,

Chapter 12 Bodywork and fittings

282 •

- .--- -

. . . ,.-

I

- INSTRUMENT

•

PANEl иРРЕА

'f'

I

DEFROSТER

•

VIEW

NQZZ LE

В

RtGHT УЕ НТ AIR ООСТ

НЕА ТЕА

A$SEMBL у

ASSEM8LY

SEE VIEW

В

SEEVIEWA

-

TEMPERATURE

CONTROl CABLE OFF·HEAT DEFROST

CONTROL

ОААТ

CдBLE

Vlt:w.

Fig. 12 .31 Removing the heater assembIv - 1971 / 73 models (Sec 39) righ1-hand courtesy light 01 1ittedJ, located оп the underside of the ins1rument panel. 17 Aemove the screw attaching the hea1er SUPPO" to the dash panel. ,8 Disconnect the hoses 1rom the hea1er. 19 Working in the engine compartment, disconnect the bIower motor ground wire and remove the five heater assembIy attachment nuts. 20 Aemove the screws attaching the instrument panel to the cowl panel and remove the instrument рапе' right side Ьгасе. 21 Pull the heater assembIy and 1he right side of the instrument рапе' to the геаг and remove the heater а5зетЫу .

HANQ.O.IIO НЕАТЕII

POWE II VENT

1971-73 models 22 Disconnect the two heater hoses from the соге tubes. 23 RemOV8 the right side vent air duct assembIy. It is necessary to remove the glove ЬОХ to gain access to the duct-to-upper cowl attachment screw and the three duct -tо-bIоwег nuts (зее Fig. 12.31 ), 24 Disconnect the то control cabIes from the heater case assembIy. Аетоуе the defrost- to-plenum snap clip. 25 Disconnect the electrical wiring from the resistor assembIy. 26 Undo the 10ur nuts securing 1he heater case to the dash panel mounting studs and гетоуе the heater assembIy.

• ф- ---

Fig. 12.32 Heater bIower

то1ог

removal - 1969/70 models

А" models

27 Installing the heater assembIie5 i5 the reverse of the гетоуа' procedure .

40

Нее1.Г

bIower

то1ог

- removal and in81a1181io"

Aemove the heater assembIy а5 described in Section 39. Aemove the 10ur bIower motor mounting plate nuts, (1ош screws оп later modelsJ and separate the bIower motor 1го т the heater assembIy. 3 I"stallation is the reverse of the гетоуаl procedure (оп later model5 match the alignment holes, see Fig. 12.33).

(5ес

40)

• 41

Неа1ег соге

- removal and refitting

, With the heater removed, as described in Section 39 . proceed as follows : а) 1965-68 model. - геmоуе the retain;ng c!ips, separate the ы

1 2

с)

2

housing and 11ft the соге out 01 the housing 1969-70 models - remove the а;г inlet sealand the eleven retaining clips (see Fig. 12.34), then separate the heater assembIy housing and lift out the heater соге 1971-73 model. - remove the heater соге cover and pad and slide the соге out 01 the case (see Fig. 12.33)

In5tallation is the reverse of the removal procedure .

~-------------------------------------------------------------------uз

BLOWER MOTOR WHEEL,'S,',

ДН О

•

():

,

,

•

DIMPLES CдoSE дoSSEMB L 'f

HEATER

SELF· TAPPING SCREW .~-:-:-....~ #10·12 х 1/2 НЕХ . WASHER НО .

4 REQUIRED

,

SELF· TAPPING SCR EW '10·12.112 НЕХ . WдoSHER НО . .. REQUlRED

Fig . 12.33 Heater bIower motor and core removal1971 / 3 models (Sec 40)

POWER УЕНТ

ONLY

, I

, USE EXPANDING TOOL то REMOVE CLIPS

,

I HEAТER

CORE '--ASSEMBLY

,

12

I

Fig. 12.34 Heater core removal - 1969/70 models (Sec 41)

-

•

Safety first! Regardless of how enthusiasti c you mау Ье about gett1ng оп with the job at hand , take the time t o ensure that your safety is ПО1 jeopardized. А moment' s lack of attention сап result in ап accident . as сап failuгe to observe certain simple safety precautions . The possibility of ап accident wШ always exist, and the following points should nat Ье considered а comprehensive list of all dangers. Rather, they аге intended to make yau aware 01 the risks and to encourage а safety соп­ scious approach to all work you carry out ОП your vehicle.

Essentia/ DOs and DON'Ts DON'T rely оп а jack when working under the vehicle. Always use ар ­ proved jackstands to support the weight of the vehicle and place them under the recommended I;ft ог support po;nts . OON'T attempt to loosen extremely tight fasteners (i.e. wheellug nuts) wh;le the vehic le is оп а jack - it тау fall . OON'T start the engine without first making sше that the transmission is in Neutral (ог Park where applicabIe! and the parking brake is set. OON'T remove the radiator сар from а hot cooling system - let it соо ' ог cover it with а cloth and rele8se the ргеssше gradually. DON'T attempt to dra;n the engine 0;1until уои аге sше;t has cooled to the point that it will not Ьигп уои. OON ' T touch апу part of the engine ог exhaust system until it has cooled sufficiently to avoid burns . OON'T siphon toxic liquids such as gasoline, antifreeze and brake fluid Ьу mouth, ог allow them to remain оп уоиг skin. OON'T inhale brake lining dust - it is potentially hazardous (зее Asbestos belowJ OON'T allow sрШеd 0;1 ог grease to remain оп the 1100г - wipe it ир before someone sl;ps оп it. OON 'T use loose litting wrenches ог other tools which тау slip and . . cause IПJШУ . OON'T push оп wrenches when loose ning ог tightening nuts о г bolts. Always try to pull the wrench toward уои. 11 the situation cal ls for pushing the wrench away , push with ап ореп hand to avoid scraped knuckles if the wrench should slip. OON'T attempt to 1ift а heavy component alone - get someone to help уои. OON'T rush ог take unsale shortcuts to l inis h а job. OON 'Т allow child ren ог animals in ог around the vehlcle while уои аге working оп it. 00 wear еуе protection when using power tools such as а drill, sander, bench grinder, etc. and when working under а vehicte. 00 keep loose clothing and long hair well out of the way 01 moving parts. 00 make sше that апу hoist used has а sale working load ratlng adequate for the job. 00 get someone to check оп уои periodically when working alone оп а vehicle. 00 сапу out work in а logical sequence and make sше that everything is correctly assembIed and tightened. 00 keep chemicals and lluids tightly capped and out of the reach 01 chi ldren and pets. 00 remember that уош vehicle' s sa fety affects that of yoursell and others. If in doubt оп апу point , get professional advice.

Asbestos Certain lriction, insulating , sealing, and other products - such as brake linings, brake bands, clutch 1inings, torque converters, gaskets, etc. - contain asbestos. Extreme саге must Ье taken to avoid inhafation о' dust 'гот such products since;t;s hazardous to health. If in doubt, assume that they do contain asbestos. Fiгe

Remember at а" times that gasoline is highly llаттаЫе. Never smoke ог have апу kind of ореп ltame around when working оп а vehicle. But the risk does not end there. А spark caused Ьу ап electrical short

• •

circuit, Ьу two metal surlaces contacting each otheT, ог even Ьу static electricity built ир in уоиг body undsr certain conditions , сап ignite gasoline vapors, which in а confined space аге highly exptosive. 00 not, under апу circumstances, use gasoline 1ог cleaning parts. Use ап approved safety solvent. Always disconnect the battery ground (-) саЫе at the battery before working оп апу раг! 01 the lиеl system ог electrical systeffi. Never risk spilling fuel оп а hot engine ог exhaust component. It is strongly recommended that а lire extinguisher sUltabIe for use оп lиеl and electrical fires Ье kept handy in the garage ог workshop at а" times . Never try to extinguish а lиеl ог electrical fire with water.

Torch (f/ash/ight in the US) Апу

reference to а "torch " appearing in this manual should always Ье taken to теап а hand -held , battery-o perated electric tight ог llashlight. It OOES NOT mean а welding ог ргорапе torch ог bIowtorch .

Fumes Certain fumes аге highly toxic and сап quickly cause unconsciousness and еуеп death if inha led to апу extent. Gasoline уарог falls into this category, as do the vapors from some cleaning solvents. Апу draining ог рошiпg 01 such volatile fluids shou ld Ье done in а well ventilated агеа.

When using cleaning lluids and solvents, read the instructions оп the container carelully. Never use materials from unmarked containers . Never run the engine in ап enclosed space, such as а garage. Exhaust fumes contain сагЬоп monoxide, which is extremely poisonous. 11 уои need to .run the engine, always do so in the ореп air, ог at least have the геаг 01 the vehicle outside the work агеа. 11 уои аге 10rtunate enough to have the use of ап inspection pit, пеует drain от роиг gasoline and never гип the eng ine while the vehicle is over the pit. The fumes, being heavier than air, will concentrate in the pit with possibIy lethal results.

The battery Never create а spark ог allow а Ьаге light bulb пеаг а battery. They normally give off а certain amount 01 hydrogen gas, which is highly explosive. Always disconnect the battery ground (-) саЫе at the battery before working о п the lие' ог electrica l systems. 11 possibIe , loosen the filler caps ог соуег when charging the battery lTom ап external source (this does not apply to sealed ог maintenancelгее batteries !. 00 not charge at ап excessive rate ог the battery тау burst. Take са г е when adding water to а поп maintenance-lree battery and when carrying а battery. The electrolyte, even when diluted, is уегу corrosive and should not Ье allowed to contact clothing ог skin. Always wear еуе protection when cleaning the battery to prevent the caustic deposits from entering уош eyes .

Mains e/ectricity (househo/d current in the US) When using ап electric power tool , inspection light, etc., which , operates оп household сшгепt, always make sure that the tool is сог­ rectly connected to its plug and that , where necessary , it is properly grounded. 00 not use such items in damp conditions and , again, do not create а spark ог apply excessive heat in the vicinity 01 fuel ог fuel vapor .

Secondary ignition system vo/tage А

severe electric shock сап result from touching certain parts of the ignition system {s uch as the spark plug wiresJ when the engine is гип­ ning ог being cranked, particularly if components аге damp ог the insulat10n is defective. 'П the case of an electronic ignition system, the secondary system voltage i~ much higher and could ргоуе latal.

•

Index А

I t

,

Air cleaner duct and valve аззетЫу te5ting - 58 1ilter element - 58 removaland instal18tion - 58 Air cleaner and duct system, - 58 Air conditioning system - 280 Alternator brushes - 158 descrlption - 157 1ault diagnosls - 158 maintenal1ce -157 removal and Instal18tion - 157 special procedures - 157 Anti1reeze - 51 Automatic transmission band adjustment (FMX) - 125 description - 123 downshi1t саЫе adju5tment - 85 fault diagnosis - 125 11uid level checking -123 intermediate band adjustment (С4 and С6) - 124 kickdown rod adju5tment - 124 lock-rod adjustment - 124 low and геуегзе band 8djustment (С4) - 125 manual shitt linkage adjustment - 123 neutral start switch adjustment - 124 removal and Installatlon - 123 specifications - 106 torque wrench settlngs - 107 towing - 123

гepair,

minor damage - 265

rust - 265 Br.king 8vstem bIeeding the hydraulic system - 139 caliper anchor plate - 143 description - 139 drum-shoes adjustment - 147 drum-shoes removal and inst8118t10" - 144 drum-wheel cylinders overhaul- 146 drum-wheel cylinders removal and installation - 146 fault diagnosis - 152 flexibIe hoses - 140 front disc and hub - 143 front dlsc calipers (1964-1967) - 140 front disc calipers (1968-1973) - 142 !гоп! disc pads 11964-19671- 140 front disc pads (1968-1973) - 141 front drum backplate - 147 master cylinder - 147 parking brake - 151 pedal-149 pressure differential valve cвntraliz8tion - 139 ргеsзuге differential valve гетоуаl and in5t8118tion - 149 геаг drum backplate - 146 specifications - 138 torque wrench setting5 - 139 vacuum servo unit - 151 Bumpers- 278

с C8m,haft геа5зетЫу

в

\

Battery charging - 157 electrolyte repleni5hment - 157 maintenance - 156 гетоуаl and Installatlon - 156 Bodywork back windows - 276 bumpers - 278 ConveгtibIe top hydraulic system - 280 ConvertibIe top lift cylinder - 280 ConveгtibIe top motor and ритр - 278 dents - 265 description - 264 fll11ng and respraying - 265 floor console - 276 in5trument panel pad - 277 malntenance - 264 radiator griНe - 177 repair, major damage - 267

- 35 removal- 28 renovation - 32 C8rbur8tion - warning - 58 C8rburetor adjustments - 64 curb idle and fuel mlxture adjustment - 64 description - 59 1ast Idle speed adju5tment - 68 sвrvicing - 77 specifications - 52 Carburetor (Autolite 2100) adju5tments - 68 description - 59 dismantling and reassembIy - 77 specifications - 52, 53 Carburator (Autolite 43001 adjustments - 71 description - 59 dismantling and reassembIy - 79 specifications - 55 Carburetor (Holley 4150С)

--------------------~----- .

286

•

adjustments - 73

description - 59 dismantling and reassembIy - 79 specifications - 54 Carburetor (Motorcraft 21 00) adjustments - 68

description - 59

Index Inspection - 97 lubrication - 95 reassembIy - 97 removal and Installatlon - 97 Distributor modulator system - 98 Door allgnment - 269

18tch - 269, 272, 275

dismantling and reassembIy - 77

specifications - 54 Carburetor (Motorcraft 4300) adjustments - 71

description - 59 dismantling and reassembIy - 79 specifications - 56 Carburetor( Rochester Quadrajet 4MVI adjustments - 75 description - 59 dismantНng and reassembIy - 81 specifications - 56

Clutch fault diagnosis - 104 judder-105 pedal free-play adjustment - 101 pedal гетоуа' and installation - 103 pilot bush renewal- 104 removal and installation - 104 renovation - 104 slip-105 specifications - 101 spin - 105 sQueal- 104 torque wrench settings - 101 Condenser - 95 Connecting rods reassembIy- 35 removal- 29 renovation - 32 Connecting rod bearing8 reassembIy - 37 renovation - 31 removal- 29 Contact breaker points - 95 Conversion tabIes - 284 Cooling sY8tem description - 46 draining - 47 fault diagnosis - 51 filling - 47 flushing - 47 specifications - 46 torque wrench settings - 46 Crankcase ventilation system - 29 Crankshaft reassembIy - 35 removal- 29 renovatlon - 31 Crankshaft damper installation - 41 removal- 26 Crankshaft геаг oil 8еаl renewal- 62 Cylinder bores renovation - 31 Cylinder heads decarbonisation - 34 dismantling - 26 Installation - 41 . removal with engine in саг - 24 removal with engine out of саг - 26

D Decarbonisation - 34 Distributor contact breaker points - 95 dismantlin9 -97 dwell angle - 95

outslde handle - 276 quarterwindow-274, 275 removal and In5tallation - 269 trim panel- 267 warnlng light 'door ореп' - 269 window-272,274 wi"dow regulator - 272 Drivebelts adjusting - 49 removat a"d i"stallatio" - 50 Driveshaft bal8"Ce - 128 de5cription - 126 fault diagn05is - 128 removal and in5tallatl0" - 126 torque wre"ch settlngs - 126 ,уре-126

universal joints - 127 Dwell angle - 95 Е

Electrical system circuit breakers - 154, 169 descrlption - 156 faultdiagnosis-175 fuses - 154, 169 fuslbIe link - 160 light bulbs - 155 5pec1ficat1on5 - 153 starter relay - 160 torque wrench setting5 - 156 turn si9n81 circult - 163 wiring diagrams - 176-231 Emission control system descriptlon - 85 fault diagnos15 - 89 maintenance and testi"9 - 88 E"ergizer - зее 'Satteгy' Engine ancillary components l"stallatio" - 44 апс111агу components removal- 24 component5 examlnation for wear - 31 description - 19 dismantling - 23 fautt diagn05is - 45 front cover removal - 27 in5tallat1on with manual transmission - 44 installation without transmission - 44 operatlons w ith engine installed - 22 operations with engine removed - 22 геаг plate In5tallation - 41 reas5embIy - 35 removal with automatic transmis5ion attached - 23 removal with manual transmission attached - 23 removal without transmission - 22 specifications - 15 start-up after overhaul- 45 torque wrench settin9s - 19 Exhaust system - 85

F Fault diagno8is automatic transm ission - 125 braking system - 152

•

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~----_.----------------------~--------------------------------------

Index clutch - 104 cooling system - 51 driveshaft - 128

•

м

Main bsarings геаззетЫу

electrical system - 175 ~

287

- 35

emission control system - 89 engine - 45 fuel system - 89

removal- 29 renovation - 3 1 Маiпtепапсе. routine - 1 3

ig"itio" system - 98

Manifold. intake - i"8t8118tio" - 42

manual transmission - 122 геаг axle - 137

Мелuаl transmission - see 'Transmi •• ion. manual'

Models. history

steering - 263 suspension - 263

о

Flywh8S1 i"stallatio" - 41 removal- 27 Flywheel ring gear renov8tion - зз Fuel filter - 59 Fuel pump - 58 Fuel system

description - 56 emission control (Federal regulations) - 56 fault diagnosis - 89 specifications - 52 Fuel tank cleaning and repair - 85

removal and i"5tallatio" - 83 Fua8S - 154. 169

G Generator

(ДС)

- аве 'Alternator'

н

Headlights - 160. 162 Heater - 280, 282 Hood - 267 Ногпа - 168 Hub. front with disc Ьгаkез - 237 with drum brakes - 235

ОН

filt8r - 31

Oil

рап

о' -

2

1nstallation - 41 removal - 27 Oil pump overhaul- 33 reassembIy - 35 removal - 28 р

Piston pins removal- 29 renovation - 32 Piston ringa removal- 29 renovation - 3 1 Pistons reassembIy - 35 removal - 29 renovation - 31

R

Jacking - 7

Radiator - 48 Radio - 173 Аваг axle axleshah bearing (Ьаll bearing type) - 131 axteshatt bearingloit зеаl (taper гоВег bearing type) - 132 axle5hatt 011 seal (Ьаlt bearing type) - 129 axteshatt. removal and installation - 129 description - 129 differential carrier - 132 differential overhaut Iconventional type) - 132 differential overhaul Oimited зliр type) - 136 fault diagnosis - ,37 pinion оН seal- 136 removat and in5tallation - 132 specifi cations - 129 torque wrench settlngs - ,29 Rocker shatt assembIy dismantling - 26 renovation - 34 Routine maintenance - ,3

L

5

Lights bulb specifications -155 front parking and tum signat - 162 front side marker - 162 hazard warning flasher unit - 165 headlight5 - 160, 162 license ptatB - 163 геаг ctuster - 162 геаг side marker - 162 turn signat flasher unit - 165 LuЬгiсапts recommended - 12 Lubricвtion chart - 12 Lubrication system - 29

Spare parts. buying - 6 Spark plugs яепега! information - 97 torque wrench settlngs - 92 Speedometer саЫе - 165 Starter motor - 159 Steering column - 255 column (tilt) mechanism - 256 column upper shatt bearing - 254 description - 234 fault diagnosis - 263 front wheel atignment - 233. 262

I Igпitiоп

system description - 92 fautt diagnosis - 98 servicing and Federal regulations - 93 specifications - 91 timing - 97 Instrument рапеl cluster - 165

J

•

,

,,

Index 1

288

•

-

linkage - 256 specifications - 232

•

torque wrench 58tting5 -

2ЭЗ

wheel- 254 Steering оваг (manuB!) adjustment ОП situ) - 243 o1llevel check - 243 overhaul - 241 removal and 1n5t8118tion - 241 Steering gear (power) checks and adjustments - 243 purnp drivebelt - 243 purnp overhaul- 244 , 247 pump removal and installat10n - 243 start-up procedure after pump overhaul- 247

Steering gear (power - i"t8gr81) ad;uster plug - 252 dismantling - 250 housing-251

rack piston - 252

•

reassembIy - 253 removal and in5t811at1on - 249 stub shaft and rotary valve - 252

Steering

оевг

(power - "0"-i"t8gr811

control valve centering spring - 247 control valve overhaul - 248 control valve removal and 1"st81Iat1o" - 247 cyJinder - 249 cyHnder seal- 249 overhaul - 243 Suspension coil spring - 238 description - 234 fault diagnosis - 263 front shock absorbers - 240 front wheel spindle - 239 lower arm - 238 lower arm strut - 237 гезг shock absorbers - 240 геаг spring - 240 specifications - 232 stabiJizer Ьаг - 237 torque wrench settings - 233 upper агrn - 239 upper arm shaft/bushing - 239 Switch ignition - 168 stoplight - 163 turn signal!hazard flasher - 163 т Теmрегаtще

gauge - 51 Temperature gauge sender uпit - 51 Thermostat - 48 Timing - 97 Timing chsin snd 8prock8t. геаssеmЫу - 39 removal- 27 renovation - 33 Timing соуег Installi"g - 39

Tir8s - 262 Tools- 8 Towing-7,123 Transmission, automatic - .8е •Automatic tran.ml'llon· , Transrnission, manual description - 107 fault diagnosis - 122 removal and installation - 107 specifications - 106 torque wrench settings - 107 Transmission. manuaI13-8p.edl dismantling - 107 input shaft, dismantling - 111 input shaft геаssеmЫу - 113 lock rod - 115 output shaft dismantling - 112 output shaft геа55еmЫу - 113 геа55еmЫу - 113 renovation - 113 5hift linkage adju5tment - 115 Transmission, manuall4-,p88dl dismantling - 115 input shaft - 116, 117 lock rod - 122 output shaft - 117 геаssеmЫу - 119 renovation - 117 5hift control- 120, 122 shift linkage and adjustment - 120, 121 TroubIeshooting - 8е8 'Fault diagn08i.' Trunk - 267

•

•

•

u Universal joints -127

,

v Valve clearancвs - 44 Valvelash adjustment - 42 VaJvelifteгs

removal - 26 renova-tio" - 32 Valves dismantHng - 26 In5tallation - 41 renovation - 33 Vehicle identi1ication numb8ГS - 6 Viscous cooling 18П - 49

w

•

•

•

Water pump - 49 Wheels - 262 Wheel stud - 1 36 Windshield - 276 Wiпdshiеld wssher - 171 Windshield wipers - 170, 171 Wiring diagrams -176-23 1 Wогkiпg 1acilities - 9

•

.-

Common spark plug conditions

•

NORMAL Syтptoтs:

Brown 10 grayish-Ian color and slighl eleclrode wear. Соггесl heal rang e lо г engine and operaling condilions. Recoттendation: When new spark plugs аге inslalled , replace wilh plugs 01 Ihe same heal range.

ТОО НОТ

WORN

Syтptoms:

Blistered, while insulalor, eroded eleclrode and absence of deposits. ResuJts in shoгtened plug life. Recommendation: Check for lhe сопес! plug heal range, оуег­ advanced ignition timing, lean fuel mixture, intake manifold vacuum leaks, sticking valves and insufficient engine cooling .

Symptoms:

Aoundecl electrodes with а 5mall amount 01 deposits оп the firing end. Normal color. Causes

hard starting

,п

damp

ог

cold

weather and роог fuel есопоту. Recoттenda tion : Plugs have Ьееп left 'п the епgiпе 100 long.

Replace with new plugs of the зате heat range. Follow the гее · ommended maintenance schedule.

PREIGNITION

CARBON DEPOSITS Syтptoms:

-

Symptoms: Melted electrodes. Insulators аге white, but тау Ье dirty due 10 misfiring ог flying debris in the combustion chambef. Сап lead to engine damage. Recommendation: Check for lhe сопесl plug heal range, оуег­ advanced ignition timing, lean fuel mixture, insufficient engine cooling and lack of lubrication.

Dry sooty deposits

indicate а rich mixture ог weak igпi­ lion. Causes misfiring, hard star1ing and hesitation. Recommendation: Make $ше the

plug has the соггес! heal range. Check far а clogged aiг filter ог ргоЫет 'п the fuel system ог engine management system. AJso check far i9nil ion system probIems.

ASH DEPOSITS

ЭI AZING Symptoms: Insulator has yellowish, glazed арреагапсе. Indicates that combustion chamber tempeг­ atures have risen suddenly during hard acceleration. Normal deposits mel1 10 foгm а conductive соаtiпg. Causes misfiring а1 high speeds. Recoтm enda tion: Inst~11 new plugs. Consider using а colder plug if driving habits warrant.

HIGH SPEED

Syтptoms: Light encrusted оп the

brown deposits side ог center electrodes ог bolh. Derived fгom oil and/or fuel additives. Excessive amounts тау mask the spark, causing misfiring and hesitation during acceleration. Recommendation: If excessive deposits accumulale оуег а shoгt time ог low mileage, install new valve guide seals 10 prevent seepage of oil into the combustion chambers. Also try changing ga$Oline brands.

DEТONATION Symptom s: Insulators тау Ье cracked ог chipped. ' mргорег gap sel1ing techniques сап also resu!t in а fractured insulator tip. Сап lead 10 piston damage. . Recomтendation: Make sure 1he fuel anti-knock values тее1 engine requiremen1s. Use саге when se1ting the gaps оп new plugs. Avoid lugging the engine.

OIL DEPOSITS Symptoтs: Ьу роог oil

Oily coating caused control. Oil is leaking past worn valve guides ог piston rings in10 lhe combustion chamber. Causes hard staгting, misfiring and hesitation. Recoттendation : Сопес! the mechanical condition with necessary repairs and install new plugs.

•

MECHANICAL DAMAGE Syтptoms:

аАР

BRIDGING

Symptoтs:

Combuslion deposi1s lodge between the electrodes. Н еауу deposits accumulate and bridge the eleclrode gap. The plug ceases 10 fire, resulting in а dead cylinder. Recommenda tion : Locate the faulty plug and гетоуе 1he deposits fгom between the electrodes.

Мау ье

caused Ьу а foreign object in the combustion chamber ог the piston striking ап incorrect reach (100 long) plug. Causes а dead cylinder and could гesull in pis10n damage. Recommendation: Repair Ihe mechanical damage. Аеmоуе the foreign object from the епgiпе and/or instaH the сопес! reach plug.