15-8 GROUP 1 5 - LIGHTING SYSTEM, HORNS AND INSTRUMENTS
EJ REMOVAL AND INSTALLATION
HEADLIGHTS
1. Remove the screws and remove
the headlight trim ring (Fig. 3).
2. Place a band over the head-
light assembly and unhook the spring
from the retaining ring.
3. Remove the retaining ring by
unhooking the ring from the clip lo-
cated directly across the bulb from
the spring hook.
4. Pull the headlight bulb forward
and disconnect the wiring assembly
plug.
5. Plug in the new bulb and place
it in position, locating the bulb glass
tabs in the positioning slots.
6. Hook the retaining ring over
the clip, then over the bulb and se-
cure it with the existing ball-ring
spring.
7. Align the bulb with the wall
screen.
8. Install the trim ring in posi-
tion and install the retaining screws.
PARKING LIGHT
The parking light is shown in Fig.
4. To replace the bulb, remove the
Jens retaining screws and the lens.
TAIL, STOP, AND BACK-UP
LIGHT BULBS
To replace the tail, stop , and/ or
the back-up lights, remove the re-
taining screws and remove the Jens,
FIG. 4-Parking Light-Typical
then remove the bulb.
TACHOMETER LIGHT BULBS
To replace the light bulb in either
the Sun, or the Sprint tachometer, it
is necessary to remove the tachome-
ter from its mounting. In the case of
the Sprint tachometer it is also nec-
essary to remove the tachometer
from its outside housing. The snap-
in bulb socket is then pulled out for
replacement of the bulb.
On the Rotunda tachometer the
bulb is not serviceable.
LICENSE PLATE LIGHT
To replace the bulb, remove the
bezel retaining screw, bezel, and Jens.
DOME LIGHT
ForelRemove the Company,
Publishing two screwsLLC
retaining
the dome light Jens. Remove the lens
Woodbridge,
and VAthe
then replace 22192
bulb.
www.ForelPublishing.com
INSTRUMENT LIGHTS
The instrument panel light bulbs
can be replaced by pulling out the
ind ividual light sockets from the rear
of the instrument panel.
HORNS
Disconnec t the horn wire from the
terminal. Remove the horn mounting
bracket to horn retaining screws and
remove the horn.
To install, mount the horn in posi-
tion, then connect the horn wire to
the horn terminal.
HORN BUTTON
1. Disconnect the horn wire con-
nector, that has a yellow and a yel-
low-green wire in it, under the in-
strument panel, to the left of the
steering column.
2. Press down evenly on the horn
button and turn counter-clockwise
until it lifts out from the steering
wheel.
3. Remove the horn button and
spring.
4. The horn button contacts are in-
tegral with the turn signal switch and
are removed with the switch.
5. Install the horn button spring
and button .
6. Con nect the horn wire connec-
tor under the instrument panel.
 15-9

PART SWITCHES, CIRCUIT BREAKERS, AND

15-3 FUSES

Section Page Section Page

I Description and Operation ... .. .... ...... . . 15-9
Headlight Switch .. .. ...... ... ........... 15-9
Fuse Panel .......... .... .... . .. . ... . ... 15-9
Mechanical Stop Light Switch .... . ......... 15-9
2 Removal and Installation .. .. .. .. ..... .. . . 15-10
Headlight Switch ................... .. ... 15- 10
Headl igh t Beam Selector Switch .. .. ...... .. 15-10
Stop Light Switch .. . .................... 15-10
Dome Light Switch .. ....... ... ......... 15-10
Ignition Switch and Lock Cylinder ... ...... 15-10
Windsh ield Wiper Switch ............. .. .. 15-11
Neutral Start Switch ..... .. ....... .. ..... 15-11
Back-Up Light Switch .................... 15-11

D DESCRIPTION AND OPERATION

Re fer to Wiring Diagram Manual

Forel Publishing Company, LLC
left side cowl panel except that on MECHANICAL STOP LIGHT
Form 7795P-66 for locations of wir- Woodbridge, VA 22192
Fairlane cars it is mounted on the SWITCH
ing harnesses. Schematics are shown www.ForelPublishing.com
brake pedal support. Fig. 2 shows The mechanical stoplight switch
in Group 22 of this manual. differs from the hydraulic switch for-
the fuses, their values and locations.
merly used. The switch assembly is
HEADLIGHT SWITCH installed on the pin of the brake ped-
A combination headlight switch al arm so that it straddles the master
and two circuit breakers is used (Fig. cylinder push rod. The switch assem-
1). The headlight circuit is protected bly is a slip fit on the pedal arm pin
by an 18 ampere circuit breaker and thus the switch assembly moves
for the Comet and F airlane, a 12 with the pedal arm whenever the
ampere circuit breaker for the Fal- brall;e pedal is depressed.
con and the Mustang. The tail, The brake pedal arm pin has a de-
parking, license plate light and horn signed-in clearance with the eye of
circuits are protected by a 15 am- the master cylinder push rod (Fig.
pere circuit breaker . 3). Because of this clearance, when-
. , • -=c
..
ever the brake pedal is pushed for-
ward, the stop light switch contacts,
moving with the pedal arm, are ac-
tually pushed against the end of the

f]l~1.
.. ,
[ -···-e~l.l
master cylinder push rod, through the
switch actuating pin. It is this move-
ment of the switch with respect to

-_
the actuating pin and master cylin-

-
J - ' -
~
....... der push rod th at closes the switch
contacts completing the circuit to the
\
stoplights.
When the brake pedal is released,
FIG. 1-Headlight Switch the spring in the stop light switch re-
FUSE PANEL turns the actuating pin to its normal
FIG. 2-Fuse Valves and position and the circuit to t4e stop
The fuse panel is mounted on the locations-Typical lights opens .
15-10 GROUP 1 5 - LIGHTING SYSTEM, HORNS AND INSTRUMENTS

0 STOP LIGH T
SWITCH ASSEMBLY
0

I STOP LIGHT
I SWITCH SPRING

I
BRAKE PEDAL ARM
I
I ~ BRAKES ARE APPLIED
~ PEDAL MOVEMENT A.
(BRAKES NOT APPLIED)
_..l
_........
'\
\
\

I
-- Kl582-A

FIG. 3 - Mechanical Stoplight Switch Operation

IEJ REMOVAL AND INSTALLATION

Forel Publishing Company, LLC
HEADLIGHT SWITCH
1. Disconnect the battery ground
cable.
2. Remove the control knob and
shaft by pressing the knob release
button on the switch housing (Fig. 1),
with the knob in the fu ll ON posi-
tion. Pull the knob out of the switch.
3. Unscrew the mounting nut, re-
move the switch, then remove the
junction block from the switch.
4. To install the switch , connect
the junction block to the head light
switch, position the switch in the in-
strument panel , and insta ll the
mounting nut.
5. Install the knob and shaft as-
sembly by inserting it all the way in-
to the switch until a distinct click is
heard. In some instances it may be
necessary to rotate the shaft slightly
until it engages the switch-contact
carrier.
6. Connect the battery ground ca-
ble.
HEADLIGHT BEAM
SELECTOR SWITCH
Lay the floor mat back from the
area of tl1e switch, and remove the
Woodbridge, VA 22192
mounting screws (Fig. 4). Discon-
www.ForelPublishing.com
nect the wire terminal block from the
5Witch.
SW ITCH K1070-B
FIG. 4-Headlight Beam
Selector Switch
To install the switch, connect the
terminal block to the switch and in-
stall the switch to the floor. Replace
the floor mat.
STOP LIGHT SWITCH
1. Disconnect the wires at the con-
nector.
2. Remove the hairpin retainer,
slide the stop light switch, the push
rod and the nylon washers and bush-
ing away from the pedal, and remove
the switch (Fig. 5).
3. Position the switch, push rod,
and bushing and washers on the
brake pedal pin, in the order shown
in F ig. 5, and install the hairpin re-
tainer.
4. Connect the wires at the con-
nector, and install the wires in the
retaining clip (Fig. 5).
DOME LIGHT SWITCH
The dome light switch is part of
the headlight switch. It is actuated
by rotating the switch control knob
to the maximum counterclockwise
position. The dome light and head-
li ght switch is replaced as a unit (Fig.
1).
IGNITION SWITCH AND
LOCK CYLINDER
1. Disconnect the negative cable
from the battery.
2. Turn the ignition key to the ac-
cessory position. Slightly depress the
pin shown in Fig. 6, turn the key
counterclockwise, and pull the key
and lock cylinder out of the switch
assembly. If only the lock cylinder is
 PART 1 5-3-SWITCHES, CIRCUIT BREAKERS, AND FUSES 1 5-11

RELEASE- PIN HOLE Kl 176-A

FIG. 6-Typical Ignition Switch

Removal

9. If a new lock cylinder is to be

instaUed, insert the key in the cylin-
der and turn the key to the accessory
position. Place the lock and key in
the ignition switch, depress the pin
slightly (Fig. 6) and turn the key
counterclockwise. Push the lock cyl-
inder into the switch. Turn the key
to check the lock cylinder operation.
10. Connect the battery cable and
check the ignition switch.

WINDSHIELD WIPER SWITCH

Forel Publishing Company, LLC
Woodbridge, VA 22192
www.ForelPublishing.com
FIG. 5-Mechanical Stoplight Switch Assembly
1. Disconnect the battery cable.
2. Remove the wiper switch knob,
bezel nut, and bezel.
3. Pull out the switch from under
the instrument panel. Disconnect the
plug connector from the switch and
remove the switch.
4. Position the switch and con-
nect the plug connector.
5. Position the switch in the in-
strument panel and install the bezel,
bezel nut, and knob.
6. Connect the battery cable and
check the operation of the switch.

to be replaced, proceed to Step 9.
3. Press in on the rear of the
switch and rotate the switch 1/a turn
counterclockwise (as viewed from the
terminal end). Remove the bezel,
switch, and spacer.
4. Remove the nut from the back
of the ignition switch. Remove the
accessory and gauge feed wires from
the accessory terminal of the switch.
Pull the insulated plug from the rear
of the switch.
5. If a new ignition switch is to
be installed, insert a screwdriver into
the lock opening of th e ignition
switch and turn the slot in the switch
to a full counterclockwise position.
6. Connect the insulated plug
with wires to the back of the ignition
switch . Position the accessory and
gauge wires on the ignition switch
stud and install the retaining nut.
7. Position the spacer on the
switch with the open face away from
the switch.
8. Place the bezel, switch, and
spacer in the switch opening, press
the switch toward the instrument
panel and rotate it Vs turn to lock
it in position.
NEUTRAL START SWITCH
See P art 7-2 for replacement of
the neutral start switch on cars
equipped with automatic transmis-
sions.
BACK-UP LIGHT SWITCH
On cars equipped with the steering
column standard shift, the switch is
located on the lower end of the steer-
ing column.
On cars equipped with a shift le-
ver directl y over eit her the standard
or automatic transmissions, the back-
up light switch is located on the
tra nsmission.
15-12

PART INSTRUMENTS
15-4
Section Page
1 Description and Operation ........ ........ 15-12
Gauges ........ ..... .... .. ............ 15-12
Constant Vol tage Regulator ............... 15- 12
Fuel Gauge ..................... . ...... 15-13
Temperature Gauge . . ........... . .... . .. 15-13
Charge Indicator Light-Except
Comet ...... . ....................... 15-13
Charge Indicator Gauge-Comet ... . ....... 15- 13
Oil Pressure Indicator Light-Except Comet .. 15- 13
Oil Pressure Ind icator Gauge-Comet ...... 15-13
Turn Indicator .......................... 15-13
Emergency Warning F lasher ...... . ....... 15-13
Speedometer ........................... 15-13
Windshield Wiper-Comet ................ 15-13
2 In-Car Adjustments and Repairs ........... 15- 15
Windshield Wiper Blade Adjustment .. ...... 15- 15
3 Removal and Installation .............. . .. 15-1 5
I nstrument Cluster-Except Fairlane ..... .. 15- 15
Inst rument Panel Control Identification
Lens-Fairlane .... .. .. . .. . ........... 15-15
Auxiliary Instrumen t Cluster-
Mustang Rall y Pac ............. ...... . 15-1 6
Constant Voltage Regulator-Comet ....... 15-16
Constant Voltage Regu lator-Fairlanc ...... 15-16
Fuel Gauge-Falcon, Mustang ............ 15-16
Fuel Gauge-Comet ..................... 15-16
Forel Publishing
Fuel Gauge- F ai rlane .. .. ............... 15- 17 Company, LLC
Woodbridge,
Fuel Sending Unit .... . .................. 15-17 VA 22192 Assembly-Oscillating Type Two-
Temperature Gauge-Except Comet ........www.ForelPublishing.com
15-17
Temperature Gauge-Comet .............. 15-17
Temperature Sending Unit ................ 15- 17
Oil Pressure I nd icator Gauge-Comet ...... 15-17
Oil Pressure Sending Un it or O il
Pressure Switch ....................... 15-18
Section Page
Charge Indicator Gauge-Comet .... ... ... 15-18
Electric Clock-Fairla ne .... ........ .. ... I 5-18
T urn Indicator Switch ............... ... . 15- 18
T urn I ndicator Flasher ............ . ...... 15- 18
Emergency Warnin g F lasher .. ....... ..... 15- 18
Speedometer-Fairlane ................. .. 15-18
Speedometer-Comet .................... I 5-18
Speedometer-Falcon, Mustang ............ 15- 19
Speedometer Cable ...................... 15-19
Windshield Wiper Switch-Fairlane ..... . .. 15- 19
Windshield Wiper Motor-Except Fairlane .. 15-1 9
Windshield Wiper Motor- Fairlane ........ 15-19
Wiper Pivot Shaft and Link ............... 15-20
4 Major Repai r Operations ... . ............. 15-20
Disassembly-Permanent Magnet T ype
Single or Two-Speed Electric Wiper
Motor .............................. 15-20
Parts Repair or Replacement .............. 15-21
Assembl y-Permanent Magnet T ype
Single or Two-Speed E lectric Wiper
Motor ............................... 15-21
Windshield Wiper Motor P ark Switch
Test and Adjustment-Single and
Two-Speed Permanent M agnet Type ...... 15-2 1
Disassembl y-Osci llating T ype Two-
Speed Electric Wiper Motor ........ .... 15-2 1
Parts Repair or Replacement .............. 15-22
Speed Electric Wiper Motor ............ 15-22
Electro-Pneumatic Governor
and Control Selector Switch-Comet .... . 15-23
Speedometer Diagnostic Procedures ........ 15-23
Speedometer Repair Procedures ............ I 5-23

D DESCRIPTION AND OPERATION

Refer to Wiring Diagram Manual
Form 7795P-66 for locations of wir-
ing harnesses. Schematics are shown
in Group 22 of this manua l.
All of the instruments are electri-
cally operated except the speedome-
ter. Brightness of the instrument pan-
el lights is controlled by a rheostat
on the light ing switch .
GAUGES
The instrument cluster for the Fal-
con, F airlane and Mustang includes
a fuel gauge, temperature gauge,
charge indicator light, oil pressure
indicator light, speedometer, high-
beam ind icator light, and a left and
right-h and turn signal ind icator light.
The instrument cluster for the
Comet includes the same components HEATING
except th at an oil pressure indicator COIL
gauge and a charge indicator gauge COVER
are used instead of ind icator lights. \
There are also separate left-and-
right-hand turn signal ind icator
lights in the instrument panel.
CONSTANT VOLTAGE
REGULATOR
The constant voltage regulator
(Fig. I) used with the fuel, tempera-
ture, and oil gauges maintains an
average value of 5.0 volts at the
gauge terminals. VOLTAGE SUPPLY
The regulator operates by means INPUT TERMINAL
of a bimetallic arm and a heating
coil. When the ignition switch is FIG. 1- Constant Voltage
turned on, the heating coil (Fig. 1) Regulator

heats the bimetallic arm causing it
to bend and break the contacts, dis-
connecting the voltage supply from
the heating coil. The bimetallic arm
then cools and brings the contacts
together again. The making and
breaking of the contacts, causes a
pulsating voltage, with an effective
average value of 5.0 volts to be sup-
pl ied to the gauges. Although these
pulsations are quite rapid, there is
in each gauge a bimetallic arm which
changes temperature quite slowly,
and this assures steady average read-
ings.
As the pulsating voltage would
normaJly cause radio interference, a
radio interference suppression choke
is connected in series with the con-
stant voltage regulator supply wire.
FUEL GAUGE
The fuel gauge consists of a send-
ing unit, located on the gas tank,
and a remote register unit (fuel
gauge) mounted in the instrument
cluster. The remote register unit
pointer is controlled by a bimetallic
arm and heating coil. The send ing
unit is a rheostat that varies its re-
sistance depending on the amount of
fuel in the tank. The rheostat is op-
erated by a float control. As the fuel
level rises or faJls the float control
arm moved by the float, varies the
resistance.
TEMPERATURE GAUGE
T he temperature gauge consists of
a sending unit mounted in the cylin-
der head at the top front on the
V-8 (Fig. 2 or 3), left rear on the
six, and a remote register unit, (tem-
perature gauge) mounted in the in-
strument cluster.
Changes of engine temperature
vary the resistance of the sending
unit which in turn operates the tem-
perature gauge.
CHARGE INDICATOR
LIGHT-EXCEPT COMET
A red alternator ch arge indicator
light is used. This light flashes on if
the battery is discharging and the al-
ternator is not suppl yin g current.
When the ignition switch is closed,
battery current flows through the
charge ind icator light and 15-ohm
parallel resistor, and through the reg-
ulator voltage limiter contacts to the
field.
When the alternator builds up
enough voltage to close the field re-
lay contacts, full voltage is applied
to the field, and the charge indicator
light goes out.
PART 1 5-4 - INSTRUMENTS
OIL PRESSURE SWITCH K1525-A
FIG. 2-Temperature Sender
and Oil Pres~ure Switch-Falcon
and Comet V-8
TEMPERATURE SENDER
Forel Publishing Company, LLC
Woodbridge, VA 22192
www.ForelPublishing.com
DIL PRESSU RE SWITCH K 1627-A
FIG. 3-Temperature and Oil
Pressure Sender-Fairlane 6
CHARGE INDICATOR
GAUGE-COMET
The charge indicator gauge is an
ammeter, which indicates whether
the .battery is being charged or dis-
charged . The am meter is non-adjust-
able and should be replaced if proved
to be defective.
OIL PRESSURE INDICATOR
LIGHT-EXCEPT COMET
A red indicator light flashes on
when the oil pressure is below a safe
value. The light should come on when
15-13
the ignition switch is first turned on,
and it should go out when the engine
comes u p to speed. The light is con-
nected between the oil pressure
switch unit mounted on the engine at
the left rear on the six, above the o il
filter on the V-8 (Fig. 2), and the coil
terminal of the ignition switch.
OIL PRESSURE INDICATOR
GAUGE-COMET
The meter-type oil pressure gauge
consists of a sending unit on the en-
gine above the oil filter on the V-8
(Fig. 3), at the left rear on the six,
and a remote register un it in the in-
strument cluster.
The sending unit operates by vary-
ing resistance according to actua l
oil pressure against it, which in turn
operates the oil pressure gauge.
TURN INDICATOR
The turn indicator uses the dual
filament parking lights as indicator
lights.
The turn indicator flasher is lo-
cated in the back of the instrument
panel, on the steering column brace.
On the Mustang the flasher is
mounted on the front side of the air
duct.
EMERGENCY WARNING
FLASHER
The emergency flasher warning
system is controlled by a combination
switch and flasher assembly. All turn
signal lights can be made to flash
at the same time by closing the
switch of the switch-flasher assembly.
SPEEDOMETER
The speedometer is connected to
the output shaft of the transmission
by means of a flexible shaft, and a
drive gear located inside the trans-
mission. The flexible shaft drives the
speedometer which registers speed in
mil es per hour and also drives an
odometer wh ich records distance
traveled in miles and tenths of a
mile.
WINDSHIELD WIPER-COMET
The Comet wiper provides high
speed (65 to 75 cycles per minute)
constant wiping action, and also in-
termittent low speed (5-30 cycles per
minute), intermittent wiping action.
This low speed operation is based
not on a low speed wiping stroke but
on an adjustable dwell period in the
park position.
The intermittent wiper is operated
through the use of a dual knob. The
o uter or large knob, when in the cen-
 ...
GOVERNOR ELECTRICAL SWITCH GOVERNOR ELECTRICAL SWITCH GOVERNOR ELECTRICAL SWITCH -
UI
I

.a:ii.

Q
;la
0
.,,
c
...
UI
,....I
Ci
.....
~

z
~
V\
-<
Forel Publishing Company, LLC .....
V\
,.,.,
Woodbridge, VA 22192 ~
www.ForelPublishing.com
~
0
:::a
z
V\

>
z
c
z
V\
......
:::a
c:
,.,.,
3::
:::z::
SKETCH 1 START OF INTERMITTENT OPERATION. SKETCH 2 WIPER IN DWELL SKETCH 3 CONTINUOUS WIPER OPERATION
.....
V\
DURING ENGINE ACCELERATION

r-=-=-:-=-=-=.:J LOWERED VACUUM

~~ NORMAL VACUUM
[:;·.;·.,_:!.:/::;:-) ATMOSPHERE

[~~\t',\V\\\\\\\Yd SUPER ATMOSPHERE

K 1633-A

FIG. 4-Electro-Pneumatic Governor For Intermittent Windshield Wiper


ter position, turns the system off.
When turned fully clockwise, the
wiper is in the constant high speed
setting. When turned fully counter-
clockwise, the wiper goes on the in-
termittent lower speed range. The
intermittent wiper action is controlled
by the inner, or small knob.
The intermittent wiper control is
an electro-pneumatic system, a gov-
ernor located in the engine compart-
ment. that allows selection of either
varying dwell between wipe cycles or
continuous wiper action thru applica-
tion of variable opposing vacuum and
pressure within the system.
With the control selector in the in-
strument panel turned to intermittent
wiper control, engine manifold vacu-
um is applied to the upper chamber
of the governor (Sketch I, Fig. 4).
Atmospheric pressure in the lower
chamber then moves the diaphragm
upward. Simultaneous rotation of the
governor valve cam thru the spiral
action of the follower applies mani-
fold vacuum to the diaphragm of the
normally closed electrical switch. The
switch diaphragm is moved down-
EJ IN-CAR ADJUSTMENTS AND REPAIRS
WINDSHIELD WIPER
BLADE ADJUSTMENT
Turn the ignition switch to the ac-
EJ REMOVAL AND INSTALLATION
INSTRUMENT CLUSTER -
EXCEPT FAIRLANE
1. Disconnect the battery cable.
2. Disconnect the speedometer ca-
ble from the speedometer head.
3. Remove the six screws retain-
ing the instrument cluster assembly
to the instrument panel and tilt the
cluster forward.
4. Disconnect the wiring and the
bulb sockets and remove the cluster
assembly.
S. Position the cluster and connect
the wiring and the bulb sockets.
6. Install the instrument cluster as-
sembly to the instrument panel with
the six retaining screws.
7. Connect the speedometer cable
and the battery cable.
8. Check the operation of all
gauges, lights, and signals.
To replace the fuel gauge, tem-
perature gauge, oil pressure gauge,
PART 15-4-INSTRUMENTS
ward compressing the diaphragm
spring and moving the switch into the
park position. The wiper blades then
move to the park position and re-
main there. (Sketch II, Fig. 4).
Rotation of the governor valve
cam that applied vacuum to the gov-
ernor switch also opened the upper
governor chamber to atmosphere.
The compressed diaphragm spring
applies downward pressure to the dia-
phragm creating super atmosphere in
the lower chamber. This is allowed
to bleed off thru a variable orifice
in the control selector. The size of
this orifice is determined by the posi-
tion of the intermittent selector (in-
ner knob) and establishes the length
of wiper cycle dwell (Sketch II, Fig.
4).
As the diaphragm moves down-
ward, the governor valve cam is ro-
tated thru the spiral action of the
cam follower, opening the lower
chamber of the electrical switch dia-
phragm to atmosphere. The com-
pressed diaphragm spring moves the
switch into the closed position, actu-
ating the wiper motor. Simultane-
Forel Publishing Company, LLC
cessory position momentarily, with
the wiper Woodbridge, VA 22192
switch off. After bringing
the pivotwww.ForelPublishing.com
shafts to their park posi-
charge indicator gauge, and speed-
ometer, it is necessary to remove the
instrument cluster assembly.
INSTRUMENT PANEL CONTROL
IDENTIFICATION LENS-
FAIRLANE
1. Disconnect the battery ground
cable.
2. Remove the radio, knobs and
nuts.
3. Disconnect the speedometer ca-
ble.
4. Remove the screws from the
cluster assembly and position it out-
ward.
S. Disconnect the bulbs, constant
voltage regulator and ground wire,
clock and the fuel gauge. Move the
cluster assembly to a bench.
6. Remove the clock knob and the
screws retaining the rear cluster cov-
er which retains the speedometer,
15-15
ously, the rotational movement of
the valve cam applies manifold vac-
uum to the upper chamber of the
governor, thus beginning a new cycle.
If the engine is subjected to sudden
acceleration as in passing, the avail-
able manifold vacuum will be great-
ly reduced. When the vacuum loss
becomes sufficient to allow the elec-
trical switch diaphragm spring to
overcome the vacuum. the switch
will be moved to the closed position
providing continuous wiper opera-
tion. This will continue until the en-
gine has returned to an operating
condition that will provide normal
manifold vacuum. The wipers will
then return to whatever wiper cycle
dwell had been previously selected.
In the same manner as above, un-
der engine acceleration. if any loss
of vacuum or pressure in the inter-
mittent control system occurs due to
a mechanical failure or malfunction,
the wipers will automatically shift to
continuous operation, thereby render-
ing the system fail safe (Sketch III,
Fig. 4).
tions, install the wiper blades so
that they lie flat against the lower
edge of the windshield.
clock. fuel gauge, and bulbs for the
alternator, oil pressure, and hot and
cold water temperature.
7. Remove the screws from the
right side front of the cluster. Re-
move the mask and the lens.
8. Insert and position the new lens
and retaining screws.
9. Position the rear cover assem-
bly to the front of the cluster and
install the retaining screws. Install
the clock knob and screw.
10. Position the cluster assembly
and connect all leads and bulbs.
11. Position the cluster assembly
to the instrument panel and install
the retaining screws.
12. Position the radio to the clus-
ter and install the nuts and bulbs.
13. Connect the speedometer ca-
ble.
14. Connect the battery and check
the operation of all disconnected
parts.
15-16 GROUP 1 5 - LIGHTING SYSTEM, HORNS AND INSTRUMENTS
AUXILIARY INSTRUMENT
CLUSTER-MUSTANG
RALLY PAC
REMOVAL
1. Disconnect the battery ground
cable.
2. Disconnect the wiring. Note the
color code relationships (for correct
assembly later).
3. Remove the mounting clamp
assembly screws below the steering
column and remove the clamp.
4. Remove the RALLY PAC clus-
ter assembly from the steering col-
umn.
INSTALLATION
1. Position the RALLY PAC clus-
ter assembly to the steering column.
2. Position the mounting clamp
and install the retaining screws.
3. Connect the wiring (Fig. 5).
4. Connect the battery ground ca-
ble.
Forel Publishing Company, LLC
VIEW THROUGH INSTRUMENT PANEL
FIG. 5-Rally Pac Wiring Connections
CONSTANT VOLTAGE
REGULATOR-COMET
1. Disconnect the battery ground
cable.
2. Disconnect the speedometer ca-
ble.
3. Remove the instrument cluster
assembly from the instrument panel
and tilt the cluster outward.
4. Disconnect the wires from the
constant voltage regulator.
5. Remove the constant voltage
regulator retaining screw and remove
the regulator and ground wire from
under the same screw.
6. Install the constant voltage reg-
ulator in place with the ground wire
and retaining screw and connect the
electrical leads to the regulator.
7. Install the instrument cluster as-
sembly to the instrument panel and
secure it with screws.
8. Connect the speedometer cable.
9. Check the operation of all dis-
connected parts.
CONSTANT VOLTAGE
REGULATOR-FAIRLANE
1. Disconnect the battery ground
cable.
2. Remove the radio knobs,
mounting nuts and radio.
3. Disconnect the speedometer ca-
ble.
4. Remove the screws retaining
the cluster assembly to the instru-
ment panel. Position the cluster out-
ward.
5. Disconnect the wire leads and
remove the mounting screw from the
Woodbridge, VA 22192
www.ForelPublishing.com
VIEW FROM UNDERSIDE OF INSTRUMENT PANEL
constant voltage regulator and re-
move the regulator.
6. Position the new constant volt-
age regulator, install the mounting
screw and connect the wire leads.
7. Position the cluster assembly to
the instrument panel and install the
retaining screws.
8. Position the radio to the clus-
ter and install the nuts and knobs.
9. Connect the speedometer cable.
10. Connect the battery and check
the operation of all disconnected
parts.
FUEL GAUGE-FALCON,
MUSTANG
1. Remove the instrument cluster
assembly.
2. Remove the six screws retain-
ing the instrument cluster back plate
assembly, and remove the back plate
assembly.
3. Remove the two screws retain-
ing the fuel gauge to the back plate
and remove the gauge.
4. Position the fuel gauge and in-
stall the two retaining screws.
5. Position the back plate assem-
bly and install the six retaining
screws.
6. Install the instrument cluster as-
sembly in the instrument panel.
FUEL GAUGE-COMET
1. Disconnect the battery.
2. Disconnect the speedometer ca-
ble.
3. Remove the screws retaining
the cluster assembly to the instru-
TO
K1573-A
ment panel and position it outward.
4. Disconnect the bulbs, tempera-
ture gauge, fuel gauge, constant volt-
age regulator, and charge indicator
and remove the assembly to a
bench.
5. Remove the screws retaining
the back cover of the cluster to the
front of the cluster. There is no clock
in this cluster. The light for the oil
pressure indicator is in the charge in-
dicator gauge.
6. Remove the nuts retaining the
fuel gauge.
7. Position the new fuel gauge and

install the retaining nuts.
8. Position the rear cover to the
front of the cluster with retaining
screws. The rear cover retains all
gauges and the speedometer head.
9. Position the cluster assembly
and connect all leads and bulbs.
10. Install the cluster assembly to
the instrument panel and secure it
with screws.
11. Connect the speedometer ca-
ble.
12. Connect the battery and check
the operation of all disconnected
parts.
FUEL GAUGE-FAIRLANE
1. Disconnect the battery ground
cable.
2. Remove the radio knobs,
mounting nuts and radio.
3. Disconnect the speedometer ca-
ble.
4. Remove the screws retaining the
cluster assembly to the instrument
panel. Position the cluster assembly
outward.
S. Disconnect the bulbs, constant
voltage regulator, the clock and fuel
gauge. Remove the cluster assembly
to a bench.
6. Remove the clock knob and the
screws retaining the rear cluster
cover.
The cover retains the speedometer,
clock and fuel gauge, also the bulbs
for the alternator charge indicator,
oil pressure gauge and the hot-cold
engine temperature indicator.
7. Remove the screws retaining
the speedometer head to the cover
and four rubber insulators. Remove
the head.
8. Remove the nuts retaining the
fuel gauge, and remove the gauge.
9. Install the new fuel gauge with
mounting nuts.
10. Position the speedometer and
install the retaining screws at the
rear. Install the four rubber insula-
tors in the front.
11. Position the rear cover assem-
bly to the front of the cluster and
install the retaining screws. Install
the clock knob and screw.
12. Position the cluster assembly.
Connect all of the wire leads and
bulbs.
13. Position the cluster assembly
to the instrument panel and install
the retaining screws.
14. Position the radio to the clus-
ter and install the mounting nuts and
knobs.
15. Connect the speedometer ca-
ble.
PART 15-4- INSTRUMENTS
16. Connect the battery and check
the operation of all disconnected
parts.
FUEL SENDING UNIT
1. Remove the fuel from the fuel
tank.
2. Disconnect the fuel gauge send-
ing unit wire from the sending unit.
3. Loosen the hose clamp and dis-
connect the tank line at the sending
unit.
4. Remove any dirt that has ac-
cumulated around the sending unit
so that it will not enter the tank.
S. Turn the sending unit retaining
ring counterclockwise and remove
the unit, retaining ring, and mount-
ing gasket.
6. Clean the fuel gauge sending
unit mounting surface at the fuel
tank.
7. Position the sending unit and
mounting gasket on the fuel tank and
secure with the retaining ring.
8. Connect the sending unit wire
and the fuel tank line.
9. Fill the tank with the fuel re-
moved.
10. Check the fuel gauge opera-
tion and check for leaks.
TEMPERATURE GAUGE
1. Remove the instrument
Forel Publishing cluster
Company, LLC
assembly.
Woodbridge, VA 22192
2. Remove the six screws retain-
www.ForelPublishing.com
ing the instrument cluster back plate
assembly and remove the back plate
assembly.
3. Remove the two screws retain-
ing the temperature gauge to the
back plate and remove the gauge.
4. Position the temperature gauge
and install the two retaining screws.
S. Position the back plate assem-
bly and install the six retaining
screws.
6. Install the instrument cluster as-
sembly in the instrument panel.
TEMPERATURE GAUGE
-COMET
1. Disconnect the battery.
2. Disconnect the speedometer ca-
ble.
3. Remove the screws retaining
the cluster assembly to the instrument
panel and position it outward.
4. Disconnect the bulbs, tempera-
ture gauge, fuel gauge, constant volt-
age regulator, and ammeter and re-
move the assembly to a bench.
S. Remove the screws retaining
the back cover of the cluster to the
front of the cluster. There is no clock
15-17
in this cluster. The light for the oil
pressure indicator is in the ammeter.
6. Remove the nuts retaining the
temperature gauge.
7. Position the new gauge and in-
stall the retaining nuts.
8. Position the rear cover to the
front of the cluster with retaining
screws. The rear cover retains all
gauges and the speedometer head.
9. Position the cluster assembly
and connect all leads and bulbs.
10. Install the cluster assembly to
the instrument panel and secure it
with screws.
11. Connect the speedometer ca-
ble.
12. Connect the battery and check
the operation of all disconnected
parts.
TEMPERATURE SENDING UNIT
t. Disconnect the temperature
sending unit wire from the sending
unit.
2. Prepare the new temperature
sending unit for installation by apply-
ing a small amount of conductive
water resistant sealer C3AZ-19554-
B, to the threads.
3. Remove the temperature send-
ing unit from the cylinder head and
immediately install the new tempera-
ture sending unit.
4. Connect the wire to the tem-
perature sending unit.
S. Start the engine and check the
sending unit operation.
OIL PRESSURE INDICATOR
GAUGE-COMET
1. Remove the instrument cluster
assembly.
2. Remove the six screws retain-
ing the instrument cluster back plate
assembly and remove the back plate
assembly.
3. Remove the two screws retain-
ing the speedometer, the two screws
retaining the speedometer dial to the
back plate, and remove the speedom-
eter assembly.
4. Remove the two nuts retaining
the oil pressure gauge and remove
the gauge.
S. Position the oil pressure gauge
and install the two retaining nuts.
6. Position the speedometer as-
sembly and install the -two speedom-
eter dial retaining screws and the
two speedometer retaining screws.
7. Position the back plate assem-
bly and install the six retaining
screws.
8. Install the instrument cluster
assembly to the instrument panel.
15-18 GROUP 1 5 - LIGHTING SYSTEM, HORNS AND INSTRUMENTS
OIL PRESSURE SENDING UNIT
OR OIL PRESSURE SWITCH
To replace the unit, disconnect the
wire from the terminal. Remove the
unit from the engine. Apply conduc-
tive sealer C3AZ-19554-B to the
threads of the new unit and install
the unit. Connect the wire to the ter-
minal and check the operation of the
unit.
CHARGE INDICATOR
GAUGE-COMET
1. Disconnect the battery.
2. Disconnect the speedometer ca-
ble.
3. Remove the screws retaining
the cluster assembly to the instru-
ment panel and position it outward.
4. Disconnect the bulbs, tempera-
ture gauge, fuel gauge, constant volt-
age regulator, and charge indicator
and remove the assembly to a bench.
S. Remove the screws retaining
the back cover of the cluster to the
front of the cluster. There is no clock
in this cluster. The light for the oil
pressure indicator is in the charge in-
dicator gauge.
6. Remove the nuts retaining the
charge indicator gauge.
7. Position the new gauge and in-
stall the retaining nuts.
8. Position the rear cover to the
front of the cluster and install the re-
taining screws. The rear cover re-
tains all the gauges and the speedom-
eter head.
9. Position the cluster assembly
and connect all leads and bulbs.
10. Install the cluster assembly
to the instrument panel and secure it
with screws.
11. Connect the speedometer ca-
ble.
12. Connect the battery and check
the operation of all disconnected
parts.
ELECTRIC CLOCK-FAIRLANE
1. Disconnect the battery ground
cable.
2. Remove the clock setting knob.
3. Remove the clock push-on con-
nector.
4. Remove the clock screws and
the clock from under the instrument
panel. Handle the clock with care, as
the clock hands are not protected.
S. Position the clock from the un-
derside of the instrument panel and
install the retaining screws.
6. Push on the clock wire connec-
tor.
7. Install the clock setting knob.
8. Connect the battery ground ca-
ble and set the clock hands to the
exact time.
TURN INDICATOR SWITCH
REMOVAL
1. Disconnect the negative
(ground) cable from the battery.
2. Remove the steering wheel hub
and steering wheel retaining nut.
3. Remove the steering wheel
from the shaft.
4. Disconnect the two wire-con-
nector blocks at the dash panel above
the steering column.
S. Remove the wires and terminals
from the connector blocks. This can
be done by depressing the tab on the
wire terminal with an awl, or by in-
serting a ball point pen (refill plas-
tic type) over the bullet pin and pull
the wire and terminal from the con-
nector block. Record the color code
and location of each wire before re-
moving it from the connector block.
Tape the wires together and attach
a piece of heavy cord to the wires to
help pull the wires through the steer-
ing column during installation.
6. Remove the turn indicator
handle from the side of the steering
column.
7. Remove 3 bearing retainer at-
taching screws and remove the bear-
Forel
ing Publishing
retainer andCompany, LLC switch
turn indicator
andWoodbridge, VA 22192 column.
wires from the steering
Disconnect the heavy cord from the
www.ForelPublishing.com
switch wires.
INSTALLATION
1. Tape the ends of the switch
wires together and attach the cord
to the wires.
2. Pull the wires down through
the steering column with the cord,
and position the switch to the steer-
ing column hub.
3. Install the bearing retainer and
attaching screws.
4. Install the turn indicator switch
lever.
S. Press the switch wires into the
connector blocks in their correct lo-
cation recorded during removal. Plug
the connector blocks together with
the mating connector blocks at the
dash panel.
6. Install the steering wheel on the
shaft.
7. Install the steering wheel re-
taining nut and hub.
8. Connect the battery ground
cable and check the operation of the
turn signal switch and horns.
TURN INDICATOR FLASHER
Disconnect the wires from the
flasher unit terminals and pull the
flasher from its retaining clip. Ob-
serve the color code and number on
the cover of the flasher. Be certain
to replace it with a new flasher with
the same color code and number on
the cover.
EMERGENCY WARNING
FLASHER
Pull the flasher from the retaining
clip, and disconnect the wires (Fig.
6).
SPEEDOMETER-FAIRLANE
1. Disconnect the battery ground
cable.
2. Remove the radio knobs,
mounting nuts, and radio.
3. Disconnect the speedometer ca-
ble.
4. Remove the screws retaining
the cluster assembly to the instru-
ment panel. Position the cluster as-
sembly outward.
S. Disconnect the bulbs, constant
voltage regulator and its ground
wire, the clock and the fuel gauge.
6. Remove the cluster assembly to
a bench.
7. Remove the clock knob and the
screws retaining the rear cluster cov-
er. The cover retains the speedome-
ter, clock, fuel gauge, the bulbs for
the alternator charge indicator, oil
pressure, and the hot and cold en-
gine temperature indicators.
8. Remove the screws retaining
the speedometer head to the cover
and the four rubber insulators. Re-
move the speedometer head.
9. Position the speedometer and
install the retaining screws at the
rear. Install the four rubber insula-
tors.
10. Position the rear cover assem-
bly to the front of the cluster. In-
stall the retaining screws. Install the
clock knob.
11. Position the cluster assembly.
Connect all leads and bulbs.
12. Position the cluster assembly
to the instrument panel. Install the
retaining screws.
13. Position the radio to the clus-
ter and install the mounting nuts and
knobs.
14. Connect the speedometer ca-
ble.
15. Connect the battery ground ca-
ble and check the operation of the
disconnected parts.
SPEEDOMETER-COMET
1. Disconnect the battery ground
cable.
2. Disconnect the speedometer ca-

STEERING COLUMN
TO FRONT OF
VEHICLE
15583- EMERGENCY WARNING-WIRING,
SWITCH AND FLASHER ASSEMBLY
FIG. 6-Emergency Warning Flasher
ble.
3. Remove the screws retaining
the cluster assembly to the instru-
ment panel. Position the cluster as-
sembly outward.
4. Disconnect the bulbs, and wir-
ing from the temperature gauge,
fuel gauge, constant voltage regula-
tor and charge indicator. Remove the
assembly to a bench.
S. Remove the screws from the
cover retaining the back portion of
the cluster assembly and separate it
from the front portion.
6. Remove the screws retaining
the speedometer and remove the
speedometer head.
7. Position the new speedometer
head and install the retaining screws.
8. Position the back cover of the
cluster to the forward portion and
install the retaining screws. The back
cover houses all of the gauges and
the speedometer head.
9. Connect all wire leads and
bulbs in the cluster assembly.
10. Position the cluster assembly
to the instrument panel and install
the retaining screws.
11. Connect the speedometer ca-
ble.
12. Connect the battery ground ca-
ble and check the operation of all
disconnected parts.
SPEEDOMETER-FALCON,
MUSTANG
1. Disconnect the battery ground
cable.
2. Disconnect the speedometer
cable.
3. Remove the instrument cluster
assembly.
4. Remove the six screws retain-
ing the instrument cluster back plate
PART 15-4-INSTRUMENTS
SWITCH AND FLASHER
LOCATION AND MOUNTING
(TYPICAL)
,,:::::::::::::::::::::::::::::::::::::::::::::::.
t
/
) assembly from the instrument panel.
/K1578-B
assembly and remove the back plate
assembly.
5. Remove the two screws retain-
ing the speedometer, the two screws
retaining the speedometer dial to the
back plate, and remove the speedom-
eter assembly.
6. Position the speedometer and
install the two speedometer dial re-
taining screws and the two speedom-
eter retaining screws.
7. Position the back plate assem-
bly and install the six retaining
screws. Forel Publishing Company, LLC
8. InstallWoodbridge,
the instrumentVAcluster
22192as-
sembly to the instrument panel.
www.ForelPublishing.com
9. Connect the speedometer cable,
avoiding sharp bends.
10. Connect the battery ground
cable.
SPEEDOMETER CABLE
To replace the speedometer drive
cable, disconnect the cable housing
from the speedometer, and pull the
cable out of the housing. Wipe off
all of the old lubricant. Lubricate
the new cable with cable lubricant
BSA-19581-A (do not over lubri-
cate), insert it all the way into the
housing, and twist it slightly to make
sure that the squared drive is
engaged in the speedometer driven
gear. If a speedometer cable is bro-
ken, it will be necessary to disconnect
both ends of the cable housing in
order to remove the broken sections.
Tighten the mounting bolt to 3-4 1/2
foot-pounds torque (Fig. 7).
The speedometer driven gear is
held on to the speedometer cable
housing by a retainer clip. When re-
placing the driven gear, make cer-
tain that the gear is secure by placing
the gear in position before inserting
15-19
the retainer clip through the gear
slots.
WINDSHIELD WIPER SWITCH
-FAIRLANE
1. Disconnect the battery ground
cable.
2. Remove both control knobs
and disconnect the washer.
3. From the lower edge of the
cluster remove the retaining screws
from the switches. Disconnect the
electrical leads and remove the switch
4. Remove a screw and separate
the wiper and washer switches from
each other including the plastic bar
between the switches.
5. Assemble the wiper and wash-
er switches to each other including
the plastic bar so that when the
washer switch is turned on the wip-
ers will start.
6. Connect the electrical leads to
the assembly and install it to the in-
strument panel.
7. Install the control knobs and
connect the wiper washer.
8. Connect the battery ground ca-
ble.
WINDSHIELD WIPER MOTOR
-EXCEPT FAIRLANE
1. Disconnect the harness connec-
tor from the wiper motor.
2. Remove the three bolts retain-
ing the wiper motor and mounting
bracket assembly to the dash panel.
Lower the assembly and disconnect
the wiper links at the motor. Remove
the motor and bracket assembly.
3. Transfer the mounting bracket
with grommets to the new motor.
4. Position the motor and bracket
assembly and connect the wiper links
to the motor.
5. Position the motor and bracket
assembly to the dash panel and in-
stall the three retaining bolts.
6. Connect the harness connector
to the wiper motor.
7. Connect the battery and check
the operation of the wiper motor and
the park position of the wiper blades.
WINDSHIELD WIPER MOTOR
-FAIRLANE
1. Disconnect the wiper links drive
arm from the wiper motor drive shaft
(under the instrument panel).
2. Disconnect the wiring leads
from the motor.
3. Remove the wiper motor
mounting bolts and remove the mo-
tor.
4. Apply sealer around the edge of
the new motor mounting bracket and
15-20 GROUP 1 5 - LIGHTING SYSTEM, HORNS AND INSTRUMENTS

7. Check the op eration of the wip-

MOUNTING
CLIP
SPEEDOMETER
FIG. 7-Speedometer Driven Gear Retainer and Mounting
around each bracket bolt hole. Posi-
tion the motor to the dash and install
the mounting bolts.
5. Attach the wiring leads to the
er and adjust the park · position if
necessary.
'
WIPER PIVOT SHAFT AND
LINK
1. Remove the windshield wiper
blade and arm assembly.
2. Remove the pivot shaft retain-
ing nut, bezel and gasket.
3. D isconnect the wiper link from
the motor and remove the link and
pivot shaft assembly.
SPEEDOME TER
DRIV EN GEAR 4. Position the link and pivot shaft
CABLE 17271 assembly on the cowl and wiper mo-
tor. Connect the link to the motor.
K 1629-A 5. Install the pivot shaft to the
cowl and install the gasket, bezel,
and retaining nut.
motor. 6. Install the wiper blade and arm
6. Position the wiper links drive assembly.
arm on the motor driveshaft and in - 7. Check the pivot shaft and link
stall the mounting nut. operation.

D MAJOR REPAIR OPERATIONS

DISASSEMBLY-PERMANENT 1. Remove the gear cover retain- tainer.
MAGNET TYPE SINGLE OR ing screws, ground terminal and cov- 3. Remove the idler gear and pin-
TWO-SPEED ELECTRIC er (Fig. 8). ion and thrust washer.
WIPER MOTOR 2. Remove the gea1 and pinion re- 4. Remove the motor through
Forel Publishing Company, LLC
Woodbridge, VA 22192
www.ForelPublishing.com
OUTPUT ARM

ARMATURE SHAFT
END PLAY SPRING

GEAR
COVER

AND SWITCH
ASSEMBLY
FOR SINGLE SPEED r ,
MOTOR
GROUND
TERMINAL
I
MOTOR HOUSING A.ND
MAGN ET ASSEMBLY

K 1632-A

FIG. 8-Disassembled Single or Two-Speed Wiper Motor- Permanent Magnet

Type
 PART 15-4-INSTRUMENTS 15-21

bolts, motor housing, switch terminal 7. Apply Sun Prestige grease to justment (Figs. 8 and 10).
insulator sleeve, and armature. Do the ball bearing in the end of the Remove the motor thru bol ts and
not pound the motor housing magnet armature sha ft. Position the arma- remove the motor cup and armature.
assembly as the ceramic magnets ture shaft in the gear housing and Rotate the output shaft until the
may be damaged. remove the brush retracting wires. park switch lower contacts are firm-
5. Mark the position of the output 8. Holding the armature in posi- ly closed as shown.
arm with respect to the output shaft , tion, install the terminal insulating Rotate the adjusting screw clock-
for assembly. Remove the output sleeve, motor housing and magnet wise until the pa rk swi tch lower con-
arm retaining nut, output arm, spring assembl y, and through bolts. Seal the tacts just open.
washer, fiat washer, output gear- area where the terminal insulator
shaft assembly, thrust washer, and sleeve sea ts against the motor and Rotate the adjusting screw coun-
parking switch lever and parking gear housings. terclockwise one full turn.
switch lever washer. 9. Apply Sun Prestige grease to C heck the bridge to assure that
6. Remove the brushes and brush the worm gear and idler gear, and the legs are contacting the brush
springs. install the id ler gear, thrust washer plate when the lower contacts are
7. Remove the brush plate and and reta iner. closed.
switch assembly, and remove the 10. Apply a generous amount of Insta ll the armature, motor cup
switch contact to parking lever pin Sun Prestige grease to the area and thru bolts.
from the gear housing. around the end of the armature
DISASSEMBLY-OSCILLATING
shaft. Install the gear housing cover
PARTS REPAIR OR TYPE TWO-SPEED ELECTRIC
and ground terminal.
REPLACEMENT WIPER MOTOR
All parts on both the single-speed WINDSHIELD WIPER MOTOR The two-speed electric motor may
and two-speed wiper are replaced PARK SWITCH TEST AND be disassembled for service of the
and not repaired. ADJUSTMENT-SINGLE AND drive mechanism parts.
TWO-SPEED PERMANENT 1. Remove the gear housing cover
ASSEMBLY-PERMANENT
MAGNET TYPE plate and gasket (Fig. 11 ).
MAGNET TYPE SINGLE
OR TWO-SPEED ELECTRIC With jumper wires connected as 2. Remove the output shaft re-
WIPER MOTOR shown in Fig 9, the motor should tainer and spacer washer.
1. Install the parking switch lever move to the park position. If it does, 3. Remove the crankpin bearing
washer. the motor is all right and the fau lt retainer and remove the spacer wash-
2. Install the parking switch lever lies in th e pa nel switch or wir ing. If er and cam return spring assembly.
on the gear and pinion shaft with the the motor does not park, proceed 4. Remove the arm and link as-
wit h th e follow in g park switch ad- sem bly.
cam rider pointing toward the gear Forel Publishing Company, LLC
housing output shaft hole. Make cer- Woodbridge, VA 22192
tain that the lever bottoms against
the casting. www.ForelPublishing.com
3. Apply a film of Sun Prestige
grease to the output gear teeth and
shaft bearing surface. Insert the shaft
in the bearing. M ake certain that
the parking switch lever is clear of
the cam and gear assembly.
4. Place the spacer washer and
spring washer on the shaft, position
the output arm on the shaft in the
marked position from which it was
removed, and install the mounting
nut.
5. Position the brush springs and
brushes in the holders and wrap wire
around them to hold them in the
fully retracted position. Push the in-
sulated brush connector onto the
switch terminal.
6. Place the switch-contact to
parking-lever pin in the gear hous-
ing. Position the brush plate assem-
bly to the housing and install the
mounting screws.
Make the park switch contact
points adjustment covered under
Windshield Wiper Motor Park Switch K 1630 A
Test and Adjustment--Single and
Two-Speed Perma nent Magnet Type FIG. 9-Windshield Wiper Motor Park Switch Test--
in this section. Single-Speed
15-22 GROUP 1 5 - LIGHTING SYSTEM, HORNS AND INSTRUMENTS

PARTS REPAIR OR
REPLACEMENT
All parts on both the single-speed
and the two-speed electric wipers
are replaced and not repaired.

ASSEMBLY-OSCILLATING
TYPE TWO-SPEED ELECTRIC
WIPER MOTOR
1. Tighten the motor cover. Ad-
just the motor shaft end play to
BRIDG E 0.000-0.005 inch by turning the shaft
LEGS
stop screw. Measure with a feeler
gauge between the stop screw and
the motor shaft.
2. Install the input gear shim on
the input gear shaft and install the
gear in the housing. Adjust the end
play to 0.005 to 0.010 inch by add-
ing or removing shims under the in-
put gear retainer. Install the retain-
er.
3. Install the output gear on the
output shaft. Make sure that the gear
is bottomed on the shaft.
- OUTPUT SHAFT 4. Install the output shaft and gear
assembly into the housing with the
gear teeth facing the motor. Install
K 1631 ·A one spacer washer to the outside end
of the output shaft and assemble the
FIG. 10-Windshield Wiper Motor Park Switch Adjustment wiper arm lever to the output shaft,
with the linkage studs facing away
from and above the shaft. Secure the
Forel Publishing Company, LLC lever with a lock washer and out.
S. Place the bearing cam on the
Woodbridge, VA 22192 GEAR crankpin with the small diameter
HOUSING COVER
www.ForelPublishing.com portion of the cam facing outward.
6. Install the arm and link assem-
bly to the bearing cam. As the arm
is placed on the shaft, the gears must
be meshed and the link which is riv-
eted to the arm must be installed to
the output shaft at the same time.
Proper gear indexing is obtained
when the bottom tooth of the arm
and gear segment will be in mesh
with the bottom valley of the output
TESTING CONNECTIONS
TO PARK
shaft gear.
B TERMINAL TO VOLTAGE SOURCE 7. Install the output shaft spacer
C TERMINAL TO Blue AND Red CAM RETURN - , , washer and retainer. Check the end
Yellow TO White Block TO GROUND SPRING ASSEMBLY
play of the output shaft (0.005-0.010
TO OP ERATE AT HIGH SPEED TO OPERATE AT LOW SPEED
Yellow TO VOLTAGE SOURCE Red AND Yellow TO VOLTAGE SOURCE
inch). Remove or install spacer
Blue TO White Block TO GROUND Blue TO White Block TO GROUND washers under the shaft retainer to
B AND C TERMINALS B AN D C TERMINALS NO CONNECTION adjust the end play.
AND Red NO CONNECTION K1090-D
8. Install the cam return spring
FIG. 11-Two-Speed Wiper Motor-Oscillating Type assembly.
9. Install the bearing spacer and
S. Remove the craokpio bearing and spacer, and remove the output retainer. If the retainer cannot be in-
cam. shaft and gear assembly from the stalled, one or more coils of the
6. Remove the input gear retainer housing. spring clutch are probably out of
and outer spacer shim, and remove 9. The output gear may be re- place. lf the bearing has excessive
the input gear and inner spacer moved from its shaft by tapping with end play on the craokpin, the pro-
shim. a fiber hammer. Be careful not to jection of the bearing may ride out
7. Remove the wiper arm lever damage the end of the shaft. of the semi-circular slot in the end
nut and lock washer. The worm drive gear and armature plate. Add spacer washers under the
8. Remove the wiper arm lever assembly is not serviced. retai ner if necessary.

10. Apply generous amounts of
Sun Prestige grease to all moving
parts. Install the gear housing cover
plate.
When operating the unit on the
bench, do not place hands or fingers
between the wiper lever and the case,
or inside the gear housing, as con-
siderable power is developed by the
gear reduction.
ELECTRO-PNEUMATIC
GOVERNOR AND CONTROL
SELECTOR SWITCH-COMET
The electro-pneumatic governor
and the control selector switch are
serviced as assemblies only. Should
any internal component become de-
fective the complete assembly must
be replaced.
In the event of suspected partial
or total blockage of internal pas-
sages, light air pressure may be ap-
plied in an attempt to remove the
cause of blockage.
Although the vacuum hoses are an
integral part of the wiring harness
assembly, individual hoses may be re-
placed if required.
SPEEDOMETER DIAGNOSTIC
PROCEDURES
Speedometer system complaints are
generally the result of a visible or
audible defect in the system. It is im-
perative that the specific defect be
determined prior to attempting any
physical repairs to preclude unnec-
essarily disassembling system compo-
nents. The following suggestions are
intended to aid in quick and accurate
system problem diagnosis.
VISIBLE DEFECTS
Slight Needle Waver or
Severe Needle Fluctuation
(No Noise)
1. Loose cable nut.
2. Defective speedometer head.
PART 1 5-4- INSTRUMENTS
3. Bent cable core at attaching
nut.
4. Kinked or pinched cable hous-
ing.
5. Excessive grease in speedome-
ter head.
6. Defective speed control regula-
tor.
Inoperative
1. Broken cable core.
2. Defective drive and/ or driven
gear.
3. Defective speedometer head.
AUDIBLE DEFECTS
Clicking or Ticking (With
Needle Waver), Grinding
or Ringing
1. Loose cable nut.
2. Defective drive and/ or driven
gear.
3. Defective speedometer head.
4. No lube on cable.
SPEEDOMETER REPAIR
PROCEDURES
LOOSE CABLE A TT ACHING
NUTS
1. Cable nuts should be tightened
with pliers to approximately 18 to 25
in-lbs.Forel Publishing Company, LLC
2. CableWoodbridge,
nuts shouldVA 22192
start and run
up freely by hand for at least three
www.ForelPublishing.com
to four turns.
3. A loose cable nut can cause a
bent cable core. Tightening will not
always correct the problem.
DEFECTIVE SPEEDOMETER
HEAD
Before removing a speedometer
head, disconnect the cable at the
head and insert a short section of ca-
ble core in the head. Rotate the sec-
tion of core to check for any drag-
ging or noise. The speedometer shaft
should turn freely and evenly.
15-23
DEFECTIVE CABLE CORE
AND HOUSING
1. To check for a kinked cable
core remove and wipe dry. Lay the
core out straight on a flat surface
and roll it back and forth. Any kinks
or damage will be seen. Then take
an end in each hand, allowing core
to hang in approximately a 9-inch
loop. Rotate both ends to be sure
core turns evenly.
2. Routing of the cable housing is
particularly important where the ca-
ble leaves the speedometer head. The
optimum routing would provide that
the cable and housing take virtually
no change of direction for at least
a length of 8 inches from the speed-
ometer head.
3. When installing a new cable
and housing it is necessary that the
new assembly be guided and routed
properly to eliminate any kinks.
4. Proper lubrication of the cable
core is accomplished by a light ap-
plication of B5A-19581-A lubricant
after the cable has been wiped clean.
A light film is all that is required.
DEFECTIVE DRIVE AND
DRIVEN GEARS
1. A score nicked or gouged driv-
en gear is usually indicative of a de-
fective drive gear on those vehicles
that have the drive gear integral
with the transmission output shaft.
The output shaft should be carefully
inspected for imperfections and re-
placed if necessary.
2. A driven gear with two or
three adjoining teeth badly scored is
indicative of improper assembly pro-
cedure. The gear should be inserted
in the transmission while simultane-
ously turning the drive shaft. This
will insure initial gear engagement
and prevent gear damage. Force
should never be used.
3. Whenever a drive gear is re-
placed, a new driven gear should al-
so be installed, regardless of its ap-
parent condition.
15-24

PART SPECIFICATIONS
15-5
BULB CHART
Candela© Trade
Unit or Wattage Number
Headlight No. 1 (Inner or Lower) 37.5 W. 4001
Headlight No. 2 (Outer or Upper) 37.5/50 w. 4002
Headlight (Falcon-Mustang) 40/50 w. 6012
Fog Light (Mustang) 35 w. 4415
Front Turn Signal/Parking 32 c. 1157
Rear Turn Signal and Stop/Tail 32 c. 1157
License Plate 4 c. 1155
Back-Up Lights (Falcon Sdn) 32 c. 1156
Back-Up Lights (Falcon Sta. Wag.) 32 c. 1076
Back-Up Lights (Mustang) 21 c. 1142
Spot Light 30W. 4405
Luggage Compartment 6C. 631
Luggage Compartment (fairlane) 15 c. 93
Cargo Light (Wagon-Comet> 15 c. 1003
Engine Compartment (Comet) 15 c. 93
Dome Light 15 c. 1003
Warning Lights
Oil and Generator 2 c. 1895
Park Brake (Comet-Mustang) 1 c. 257
Park Brake 2 c. 1895
Seat Belt (fairlane) 1.6 c. 257
Seat Belt (Comet-Falcon) 2 c. 1895
Emergency Flasher 2 c.
Forel Publishing Company, LLC 1895
Alternator Woodbridge, VA 22192 2 c. 1895
Turn Signal (Inst. Panel) 2 c. 1895
Illumination
www.ForelPublishing.com
Instruments 2 c. 1895
Clock 2 c. 1895
Heater Control 2 c. 1895
Hi-Beam Indicator '1 2 c. 1895
Speedometer 2 c. 1895
Glove Compartment 2 c. 1895
Glove Compartment (Mustang Console) 1.5 c. 1445
Courtesy Light (Ins. Panel) 6 c. 631
Radio Pilot Light (f airlane) 2 c. 1892
Radio Pilot Light (Mustang) 1.9 c. 1891
Radio Pilot Light (Falcon) 2 c. 1891
Radio Dial (Comet) 2 c. 1895
Arm Rest Courtesy (f airlane) 6 c. 631
Courtesy Light (front Door-Comet> 4 c. 1155
Courtesy Light (Fast Back-Mustang) 15 c. 1003
Courtesy Light (falcon Conv.) 6 c. 631
Ash Receptacle (f airlane) 1.5 c. 1445
Courtesy Light (Mustang Console) 3 c. 1816
Clock (Mustang Rally Pac) 3 c. 1816
Tachometer (Mustang-Rally Pac) 2 c. 1895
Automatic Transmission Control 2 c. 1895
Map Light 6 c. 631
©Candela is the new international term for candlepower
 PART 15-5-SPECIFICATIONS 15-25

CIRCUIT PROTECTION

Falcon
Comet Fairlane Mustang
FUNCTION LOCATION RATING TYPE RATING TYPE RATING TYPE
Dome Courtesy-Map Cargo Fuse Panel 7¥2 SFE 7¥2 SFE 7¥2 SFE
Tail-Park License Light Switch 15 C.B. 15 C.B. 15 C.B.
Stop Light Light Switch 15 C.B. 15 C.B. 15 C.B.
Clock Fuse Panel 7¥2 SFE 7¥2 SFE 7¥2 SFE
Back-up Fuse Panel 14 SFE 14 SFE 14 SFE
Turn Signals (act as a circuit breaker)
Radio Fuse Panel (Acc. Socket) 14 SFE 14 SFE 14 SFE
Heater Fuse Panel 14 SFE 14 SFE 14 SFE
Heater and PRNDL dial Fuse Panel Heater Socket 14 SFE
Cigar Lighter Fuse Panel 14 SFE 14 SFE 14 SFE
Cigar Lighter and Emergency Warning Flasher Fuse Panel Cigar Lighter Socket 20 SFE 20 SFE 20 SFE
Tachometer Fuse Panel (Dome Socket) 71/2 SFE 7¥2 SFE 7¥2 SFE
Convertible Top Between starter relay & Safety Safety Safety
Junction Block Link Link Link
Power Window-Power Seat On Starter Relay 20 C.B. 20 C.B. 20 C.B.
Overdrive Clips to overdrive relay 20 SFE 20 SFE 20 SFE
Seat Belt Warning Fuse 14 SFE 14 SFE 14 SFE
Windshield Washer Panel 14 SFE 14 SFE
(Two speed wiper) Acc.
Windshield Washer Socket 14 SFE 14 SFE 14 SFE
(Single speed wiper)
Windshield Washer Wiper Switch 12 C.B.
(Two speed wiper)
Windshield Wiper Wiper Switch 6 (S. Sp.l C.B. 6 (S. Sp.l C.B. 5 (S. Sp.l C.B.
7 (2 Sp.l C.B. 7 (2 Sp.l C.B. 12 (2 Sp.l C.B.
(Falcon)
7 lntermitten1
Light-Instrument Panel Fuse Panel 2¥2 AGA 2¥2 AGA 2¥2 AGA
Light-Instrument Cluster Instrument 2¥2 AGA 21/2 AGA 2¥2 AGA
Light-Clock LP Socket 2¥2 AGA 21/2 AGA 2¥2 AGA
Light-Tachometer Connected into 2¥2 AGA 2112 AGA 2¥2 AGA
Light-Ash Receptacle 15 C.B. Forel Publishing Company, LLC 2¥2 AGA 2¥2 AGA 2¥2 AGA
Light-PRNDL Dial Light Switch 2¥2 AGA 2¥2 AGA
Light-PRNDL Dial (Console Only) Woodbridge, VA 22192 14 SFE
Fuse Panel Acc. Socket 14 SFE
Light-Luggage Compartment Fuse Panel www.ForelPublishing.com 7¥2 SFE 7¥2 SFE 7¥2 SFE
Light-Door Open Warning Fuse Panel 7¥2 SFE
Light-Glove Box Fuse Panel 71/2 SFE 71/2 ~ft 71/2 SFE
Light-Spotlight In Line 7¥2 SFE 7¥2 SFE 7¥2 SFE
Light-Headlights Light Switch 18 Comet C.B.
12 Falcon C.B
Emergency Warning Flasher Fuse Panel 14 SFE 14 SFE 14 SFE
Horns Light Switch 15 C.B. 15 C.B. 15 C.B.
Air Conditioner (I ntegratedl On lgn. Switch 25 C.B. 25 C.B. 25 C.B.
Back Light Control At Starter Relay 20 C.B. 20 C.B.
Economy Air Conditioner In Line 15 AGC 15 AGC 15 AGC
Motor Windshield Wiper Circuit C.B. C.B. C.B.
Motor Convertible Top Breaker C.B. C.B. C.B.
Integral
Motor Power Window With · C.B. C.B. C.B.
Motor Power Seat Motor C.B. C.8. C.B.

SPEEDOMETER CABLE
I Mounting Clip bolt Torque 3-4¥2 ft. lbs.
 16-1

VENTILATING, HEATING, GROUP

AND ACCESSORIES 16
PART 16-1 PAGE PART 16-3 PAGE
VENTILATING SYSTEM AND AIR CONDITIONING-SELECTAIRE ... 16-20
HEATER ............. ..... ... . . 16-1
PART 16-4
PART 16-2 RADIO . . .... . .. .. ..... .. ... .... 16-26
AIR CONDITIONING-FORD . . ...... 16-10
PART 16-5
SPECIFICATIONS . ............. . .. 16-29

PART
VENTILATING SYSTEM AND HEATER
16-1
Section Page
Desc ription and Operation ................. 16-1
Ventilating and H eatin g System- Comet,
Falcon and Fairlane ... .... .... ......... 16- 1
Ventilating and Heat ing System-Mustang .. .. 16-2
2 Diagnosis and Testing ... . . ......... . .. ... 16-6
Ve ntilating and Heatin g Trouble Diagnosis
Guide . . . .. .. ..... .. ........ .... ...... 16-6
Heater Current Draw Test ........ . ........ 16-6
Loose Motor Fan Test ..... . .. . ........... Forel Publishing Company,
16-6
Blower Switch Test ................. . ..... IWoodbridge,
6-6
Pl ugged Heater Co re Test ...... ............www.ForelPublishing.com
I 6-6
3 Common Adjustments and Repairs .. ... . ... . 16-6
Ventilating System ....... .. . . ..... . ...... 16-6
Heating System .......... . .. . ............ 16-6
Control Adjustme nts-Mustang ........... 16-6
Bowden Cable Adjustments- Comet,
Falcon and Fairlane .................. 16-7
Section Page
Heater Hose Rout ing ............ .. ..... 16-7
Heater Hose Replacement ............... 16-7
Bleeding Air From Heater Core .......... 16-7
4 Removal and Installation .................. 16-7
Heater- Mustang . . ........... . ... . ...... 16-7
H eater Core-Mustang . . .. .. . .......... . .. 16-8
Heater Control Assembly-Fairlane ........ 16-8
Heater Control Assembly-Falcon .......... 16-8
LLC
Heater Control Assembly-Comet .......... 16-8
VADischarge
22192 A ir Registers ............ .. .... 16-8
Defroster Nozzles-Comet, Falcon and
Fai rlane ...... ... ............ .... ..... 16-8
H eate r Core Assembl y-Comet,
Falcon and Fairlane .. ...... ........ . .. 16-8
Blower Motor and Wheel Assembly-
Comet, Falcon and Fairlane ............. 16-8
H eater Blower-Mustang . ........ . ....... 16-8
Defroster Nozzles-Mustang ....... .. .. . .. 16-9

-
Blower Motor Electrical C ircuit-
Comet, Falcon and Fairlane .......... .. 16-7 Blower Switch- Mustang ... . . . ....... . .... 16-9

D DESCRIPTION AND OPERATION

VENTILATING AND HEATING
SYSTEM-COMET, FALCON
AND FAIRLANE
The 1966 heater is a blend a ir
system con nected to an opening in
the right vent air duct. The entire
heater assembly is located under the
instrument panel and it is necessary
to remove the right air vent duct and
heater case assembly to service ma-
jor components of the heater assem-
bly (Fig. I).
Outside air is drawn into the ve-
hicle from the cowl through the
right air duct, into the blower hous-
ing, forced through. and/ or around
the heater core, mixed, and then dis-
charged through the outlets in the
discharge a ir register or defroster
outlets (Fig. 2).
The air temperature is controlled
by the position of the temperature
air va lve, or door, loca ted between
the blower and heater core in the
heater housing. As the temperature
lever is moved from LOW to HIGH;
a Bowden cable moves the temper-
ature door in the heater housing
from min imum heat to full heat po-
sition to modulate the air flow
through a nd / or around the heater
core. The air through the core ·and
the air through the bypass chamber
is then mixed as it enters the plenum
chamber.
A heater a ir valve, referred to as
the heat-defrost door, is located in
the plenum chamber to control the
discharge a ir between heat and de-
frost, and close off all air in the OFF
position. The heat-defrost lever ac-
tuates a Bowden cable connected to
the heater air valve in the plenum
chamber. Air fl ow through the ple-
num is directed, as required by the
operator, through th e discharge air
outlets in the plenum, in the heat
position; or up to the windshield in
the defrost position. T he air flow
can also be modulated by sett ing the
controls in any position between
heat and defrost.
A single defroster nozzle leads to
16-2 GROUP 16- VENTILATING, HEATING, AND ACCESSORIES

REFER TO FIGURE 6
VIEW i3 FOR COMET
NOZZLE

RIGHT AIR
VENT DUCT

HEAT POSITION SEE FIGURE 6 VIEW A K 1644- A

FIG. 1-Heater Assembly-Comet, Falcon and Fairlane

DEFROSTER OUTLETS
Forel Publishing Company, LLC
www.ForelPublishing.com
DISCHARGE
REGISTER
FIG. 2-Heater Air Flow (Modulated)-Comet, Falcon and Fairlane
two slots in the forward instrument
panel crash pad.
Three speeds are provided for the
blower fan with a four position
switch in the control assembly and a
resistor assembly located to the right
of the heater core in the heater
housing. The resistor in the blower
motor circuit controls the low and
medium blower speeds.
vers and the blower switch (Fig. 4).
Woodbridge, VA 22192 The Comet heater controls are lo-
cated to the left of the steering col-
umn in the lower instrument panel
area. The dial for the Caliente and
Cyclone models are illuminated with
one bulb; the Capri and 202 model
does not have an illuminated dial
(Fig. 5).
In order to provide adequate air
distribution on all vehicles, two air
distribution register assemblies are
provided. All vehicles equipped with
K 1643-A consoles or economy air condition-
ing is equipped with a register that
distributes the air to the lcf t and
The nomenclature for the Fairlane right of the tunnel area. The register
heater controls is located on the for standard vehicles has air outlets
lower right side of the instrument across the face of the register and a
cluster, and the horizontal control small outlet on the lower left end
levers are directly below on the low- (View A, Fig. 9).
er lip of the instrument panel (Fig.
VENTILATING AND HEATING
3). SYSTEM-MUSTANG
The Falcon control, located on
the right side of the cluster assem- VENTILATING SYSTEM
bly, contains two vertical slide le- Two manually operated doors lo-
 PART 16-1 - VENTILATING SYSTEM AND HEATER
~.,_--BOWDEN CA3LE
FIG. 3-Heater Controls-Fairlane
~~-;;./.f!..--TEMPERA TURE
FIG. 4-Heater Controls-Falcon
cated under each end of the instru-
ment panel allow fresh air to enter
TEMPERATURE CONTROL
K 1646-A
Forel Publishing Company, LLC
Woodbridge, VA 22192
CONTROLwww.ForelPublishing.com
LEVER
K 1647-A
the passenger compartment. The
right door is open to the cowl inlet
16-3
only when the HEAT lever is in the
up position. The position of the fresh
air doors deflects the air as desired.
HEATING SYSTEM
The fresh air heater is designed to
function in conjunction with the
right duct of the fresh air ventilating
system. The heater assembly couples
to an outlet provided in the right
cowl assembly. A door in the duct
and two doors in the heater housing
are operated by controls located on
the instrument panel, allowing the
selection of outside air for ventila-
tion or heating (Figs. 6 and 7).
The defroster control lever oper-
ates a valve in the heater plenum
chamber. Push the lever downward
for proportionately more air to the
defroster registers.
The PUSH FOR TEMP lever op-
erates the blend-air valve in the
heater blower housing. The blend-air
door controls the amount of air fl.ow
through the heater core. Any inter-
mediate position of the blend-air
door allows both cool and heated air
to be mixed in the plenum chamber
for lower than maximum tempera-
tures.
The PUSH FOR HTR lever oper-
ates a door in the right incoming air
duct. When the lever is in the up po-
sition air from the cowl grille enters
the passenger compartment through
an opening under the right side of
the instrument panel. A manually
operated door closes the opening, or
deflects air as desired. Pushing the
lever downward allows air to enter
the heater blower inlet duct.
To operate the blower motor,
move the top lever from the center
OFF position. Moving the lever to
the left will give high speed opera-
tion, and moving it to the right will
give low speed operation (Fig. 8).
16-4 GROUP 16-VENTILATING, HEATING, AND ACCESSORIES

CONTROL ASSEM8L Y- 18549

(UNLIGHTED SHOWN)
CONTROL ASSEMBLY -185J9
(LIGHTED-NOT SHOWN)

HEAT DEFROST
LEVER

K 1648-A

FIG. 5-Heater Controls-Comet

DEFROSTER
CONTROL
Forel Publishing Company, LLC
Woodbridge, VA 22192
www.ForelPublishing.com

Kl 555- A

FIG. 8-Heater Controls-

Mustang

FIG. 6-Heater System-Mustang

HEATER CABLE

FIG. 7-Heater Control Cables-Mustang

 PART 16-1 - VENTILATING SYSTEM AND HEATER 16-5

REGISTER FOR VEHICLES EQUIPPED

STANDARD REGISTER ASSEMBLY FOR VEHICLES WITH CONSOLE ECONONY A/C
WITHOUT CONSOLE OR ECONOMY A/C

DISCHARGE REGISTERS

VIEW A

Forel Publishing Company, LLC

Woodbridge, VA 22192
www.ForelPublishing.com

VIEW B

- _
kl
.__...._

)I -
- - ~- -- .,.

SECTION BB
K1645-A

FIG. 9-Air Distribution Registers-Types

16-6 GROUP 16- VENTILATING, HEATING, AND ACCESSORIES

B DIAGNOSIS AND TESTING

VENTILATING AND HEATING TROUBLE DIAGNOSIS GUIDE

1. Burned out fuse or loose wires 6. Improperly connected heater

to the heater blower. hoses.
2. Defective motor ground, or de- 7. Plugged beater core, or air
fective blower motor. outlet.
INSUFFICIENT OR NO
3. Fan loose on motor shaft, or 8. Improperly installed or defec-
HEAT
motor stalled. tive engine thermostat.
4. Defective heater blower switch. 9. Incorrectly installed and ad-
5. A kinked, clogged, or collapsed justed control cables.
water hose. 10. Air leaks in the body.

1. Improperly adjusted defroster zle, or obstructed defroster openings

control cable, or disconnected de- at windshield.
INSUFFICIENT OR NO
froster hose. 4. Defroster hoses not properly
DEFROSTING
2. Binding defroster valve. attached at plenum.
3. Plugged or loose defroster noz-

1. Incorrectly adjusted blend-air

TOO MUCH HEAT
valve.

TESTING Current draw should be to specifica-

Refer to Wiring Diagram Manual
Form 7795P-66 for locations of wir-
ing harnesses. Schematics are shown
in Group 2 of this manual.
The following tests may be made
on the heater: Burned out fuses,
loose wire connections, defective
wires, collapsed hoses, loose defros-
ter hoses and air leaks in the body
may be determined by visual inspec-
tion of the parts.
HEATER CURRENT
DRAW TEST
This test will determine if the
blower motor is defective. Connect
a 0-50 ammeter as shown in Fig. 10.
The blower motor will operate in-
dependently of the control switch,
and the current drawn by the motor
will be indicated on the ammeter.
tion.
LOOSE MOTOR FAN TEST
TO AMMETER Turn on the heater switch, and
NEGATIVE LEAD listen for the sound of the motor. If
+ only a hum is heard, the fan is loose
on the motor shaft.
Forel Publishing Company, LLC
GROUND WIRE BLOWER SWITCH TEST
Woodbridge, VA 22192
TO AMMETER Substitute a known good blower
www.ForelPublishing.com
POSITIVE LEAD
switch for the suspected switch.
PLUGGED HEATER CORE
TEST
Start the engine and temporarily
remove the outlet hose from the
heater core (the hose that leads to
the water pump). Very little or no
Kl 173-C flow of water from the core outlet
indicates that the core is plugged.
FIG. 10-Heater Motor Current Make certain that water is being sup-
Draw Test plied to the core inlet.

EJ COMMON ADJUSTMENTS AND REPAIRS

VENTILATING SYSTEM HEATING SYSTEM seated against the spacer.

Bowden cable operated vents and
air inlets are adjusted so that the
vents are tightly closed when the
control knobs are all the way in.
Loosen the Bowden cable retaining
screw at the vent control arm, move
the cable housing back and forth un-
til the vent is closed when the knob
is 1/rn to 11s inch from the in position,
then tighten the retaining screw.
CONTROL ADJUSTMENTS-
MUSTANG
To assure maximum temperature
the following temperature control
adjustments should be used.
1. Insert a 1/s -inch spacer be-
tween the temperature control lever
(center lever) and the bottom of the
slot. Move the lever down until it is
2. Loosen the control cable re-
taining clip (at either end of the
cable).
3. With the temperature control
damper crank (heater assembly)
held tightly in the full heat position,
tighten the control cable retaining
clip screw.
4. Remove the spacer from the
control head and check the lever
 PART 16-1 -VENTILATING SYSTEM AND HEATER
Red
Blue
HEATER
RESISTOR
FIG. 11-Blower Motor Circuit-Comet, Falcon and Fairlane
travel. All overtravel (springback)
should appear at the bottom of the
lever travel.
BOWDEN CABLE
ADJUSTMENTS-COMET,
FALCON AND FAIRLANE
Temperature
Adjust the temperature Bowden
cable at the heater case (Figs. 1 or
2), with the temperature door crank
arm in the far left position and the
temperature control lever on HI.
Provide approximately 1/s inch clear-
ance between the lever and edge of
the slot for proper adjustment.
Heat and Defrost
Adjust the heat-defrost Bowden
cable at the heater case by aligning
the crank arm (Figs. 1 or 2), with
E] REMOVAL AND INSTALLATION
HEATER-MUSTANG
Most of the heater repairs can be
performed with the heater assembly
lying on the car floor. Therefore,
the following procedure will not re-
move the heater assembly from the
car. The heater core or plenum re-
placement procedures contain the
additional required steps to remove
the heater assembly from the car.
REMOVAL
1. Drain the cooling system.
2. Remove the glove box.
3. Disconnect the three control
cables.
4. Disconnect the defroster hoses
at the heater plenum.
HEATER
SWITCH
f IJSE
Black-Green Stripe
K 1651-A
the locating dart directly below the
crank arm on the case. With the
crank arm in this position, the heat-
defrost door is in a horizontal posi-
tion for maximum heat.
The Bowden cables can also be
adjusted at the control assembly
(Figs. 4, 5 and 9).
BLOWER MOTOR ELECTRICAL
CIRCUIT-COMET, FALCON
AND FAIRLANE
ForForel
the blower motorCompany,
circuit wir-
Publishing LLC
ing diagram refer to Figure 11 or
Woodbridge, VA 22192
the Wiring Diagram Manual Form
www.ForelPublishing.com
7795P-66.
HEATER HOSE ROUTING
Care must be taken when servic-
ing the hoses to insure a smooth kink
free installation for maximum heat-
ing (Fig. 12).
5. Disconnect the heater hoses at
the water pump and the carburetor
heater. Remove the heater hoses
from the retaining clips. On 8-cylin-
der models remove the hose from
the choke clip (Fig. 12).
6. Disconnect the wires at the
heater motor and remove the
ground-wire-to-dash panel retaining
screw.
7. Remove the heater and motor
assembly retaining nuts from the
dash panel.
8. Disconnect the fresh air inlet
rubber boot, pull the heater assem-
bly from the dash panel and lay the
heater assembly on the floor.
16-7
HEATER HOSE REPLACEMENT
To replace a heater hose, drain
the coolant, remove the hose, cut a
new hose to the same length as the
old hose, install the hose, and replace
the coolant. Make certain that the
heater hoses do not come in contact
with any part of the exhaust system.
After the coolant has been re-
placed, bleed the air from the heater
core.
BLEEDING AIR FROM
HEATER CORE
Remove the hose at the outlet
connection of the heater core (hose
that leads to the water pump). Al-
low any trapped air to flow out.
When a continuous flow of coolant
is obtained, connect the hose to the
core.
INSTALLATION
1. Position the heater assembly to
the dash panel and install the retain-
ing nuts.
2. Connect the heater motor wires
to the wiring harness, and connect
the heater motor ground wire to the
dash panel with the retaining screw.
3. Connect the heater hoses and
install the hose retaining clips.
4. Connect the fresh air inlet
boot.
S. Connect the defroster hoses to
the heater plenum.
6. Connect and adjust the three
cables to the heater, and install the
glove box.
16·8 GROUP 16- VENTILATING, HEATING, AND ACCESSORIES
FIG. 12-Heater Hose Routings-Six and Eight Cylinder Engines
7. Fill the cooling system, and
check the system for leaks.
Forel
8. Bleed the system.
HEATER CORE-MUSTANG
1. Remove the heater assembly
and lay the assembly on the car
floor.
2. Remove the clips retaining the
heater housing halves together and
separate the halves.
3. Lift the heater core from the
heater housing chamber. On console
equipped cars it may be necessary to
remove the heater from the car.
4. Position the heater core in the
forward half of the heater housing,
assemble the housing, and install the
retaining clips. If a 2-inch core is
used, transfer the adapter from the
old core to the new core.
S. Position the assembly on the
car floor.
6. Install the heater assembly.
7. Refill and bleed the cooling
system and check for leaks.
HEATER CONTROL ASSEMBLY
-FAIRLANE
To remove the control assembly,
remove the three control knobs and
remove two control mounting screws
from the face of the instrument pan-
el, then lower the control from un-
der Publishing
the panel Company,
and disconnect
LLC the
Bowden cables.
Woodbridge, VA 22192
The blower switch is located to
www.ForelPublishing.com
the left of the two control levers and
retained with one screw in the face
of the lower instrument panel (Fig.
4).
HEATER CONTROL ASSEMBLY
-FALCON
To service the controls, remove
the three knobs, remove two upper
screws in the control bezel and two
lower mounting nuts behind the in-
strument cluster. Lower the control
assembly and disconnect the two
Bowden cables and blower switch
wiring (Fig. 5).
HEATER CONTROL ASSEMBLY
-COMET
To remove the control assembly,
remove the knobs and spanner nuts
from the headlight and wiper
switches and lower the control as-
sembly from under the instrument
panel, then disconnect the Bowden
cables, light bulb, and wiring.
DISCHARGE AIR REGISTERS
The discharge air registers can be
removed from the heater assembly
if necessary (View A, Fig. 9).
DEFROSTER NOZZLES-COMET,
FALCON AND FAIRLANE
The Fairlane and Falcon have a
common type nozzle; the nozzle for
the Comet is unique due to the wid-
er space between the two openings
in the instrument panel.
1. Remove the glove box.
2. Remove the defroster nozzle
retaining clip screw (Figs. 2 and 3).
3. Remove the defroster nozzle
retaining nuts; two on the Fairlane
and Falcon, and four on the Comet.
4. Lower the nozzle down and
out from under the panel on the
Fairlane and Falcon; remove the
Comet nozzle through the glove box
opening.
HEATER CORE ASSEMBLY-
COMET, FALCON AND
FAIRLANE
The heater core is mounted in the
heater case in a diagonal position in
the center of the case and is serviced
through an opening in the back plate.
With the heater assembly out of the
vehicle, simply remove four screws
from the cover plate and pull the
core from the housing (Fig. 13 ).
The core is mounted in the heater
housing with butyl rubber pads on
each end to insure a snug fit.
BLOWER MOTOR AND WHEEL
ASSEMBLY-COMET, FALCON
AND FAIRLANE
To remove the blower motor and
wheel assembly, it is necessary to re-
move the right air vent duct and the
heater case assembly. The blower
motor and wheel assembly is
mounted to the forward right side of
the heater case in the blower scroll
and attached with four screws to the
back plate (Fig. 13).
HEATER BLOWER MOTOR-
MUSTANG
1. Remove the heater assembly
and lay the assembly on the car
floor.
2. Remove the blower motor and
bracket to the blower housing retain-
ing screws and remove the blower
assembly.
3. Loosen the blower cage set
screw and remove the blower cage
from the motor.
4. Remove the b I o w e r motor
mounting plate from the motor.
 PART 16-1 -VENTILATING SYSTEM AND HEATER
ALIGNMENT
DIMPLES
SELF· TAPPING SCREW -42127-SB
"10-12x1/2 HEX. WASHER HD.
4 REQUIRED
Kl650-A
FIG. 13-Heater Blower Motor and Core Assemblies-Comet, Falcon
and Fairlane
Forel Publishing Company, LLC
Woodbridge, VA 22192
www.ForelPublishing.com
16·9
5. Install the b l o w e r motor
mounting plate to the new motor.
6. Install the blower cage and
tighten the set screw.
7. Install the heater motor and
bracket to the blower housing.
8. Install the heater assembly.
DEFROSTER NOZZLES-
MUSTANG
1. Remove the defroster outlet
register retaining screws and remove
the register.
2. Disconnect the defroster hose
at the plenum.
3. Remove the defroster nozzle
retaining clips and remove the nozzle
assembly.
4. Transfer the retaining clips to
the new defroster nozzle assembly.
5. Install the defroster nozzle to
the instrument panel.
6. Install the defroster outlet reg-
ister.
7. Connect the hoses to plenum.
BLOWER SWITCH-
MUSTANG
1. Loosen the screw in the knob.
2. Disconnect the wiring.
3. Remove one screw holding the
blower switch to the control head as-
sembly, and remove the switch.
16-10

PART AIR CONDITIONING-FORD

16-2
Section Page
Description and Operation .. ... ..... ... .. 16-10
Receiver Unit . ... . ........ ..... ... .... . 16- 10
Evaporator Unit .. . .. .. . ....... . ... . . ... 16- 10
Expansion Valve ....... ..... . . ... . ...... 16-11
Compressor Unit ....... . ... . ............ 16-11
L iqu id Sight Gl ass .................... .. 16-11
Magnetic Clutch .... ...... .. ... .. ...... 16-11
Thermostatic Swi tch . . . . .. . ............. . 16- 11
Service Valves ................. . ..... . .. 16- 11
2 Diagnos is and T esting ....... .... .... .... 16-1 2
A ir Conditioning Diagnos is Guide .. .. .. .. . 16-12
Checking For Leaks .................... 16-12
Use of Sight Glass ... ....... ... . ........ 16-13
Checkin g System Pressures ........... . ... 16-13
Interpreting Abnormal System Pressures .. .. 16-13
Thermostatic Switch T est ............... . 16-14
Magnetic Clutch .... .. . ....... ... ... . .. . 16-14
Blower Motor .. ..... . .. ............ . . .. 16-14
Expansion Valve . .. . ......... . ..... . ... . 16-14
Compressor Volumetric Efficiency T est . .... 16-14
3 Common Adjustments and Repairs .. .. .... 16-14
Safety Precautions ........ . . .. ... ... . ... 16-14
Section Page
Discharging the System . . .. . ..... . ... . .. 16-1 5
Evacuatin g th e System ....... . ... . . . . . ... 16-15
M ak in g a P artial Charge .... . .... .. . .... . 16-15
M akin g a Comple te C ha rge ......... . . .. .. 16-16
C hargin g From Small Con tai ners ... . .. . ... 16-16
Compressor Oil Level Check ..... ... . .... 16-16
Isolating The Compressor .......... . .. ... 16-1 6
4 Removal and fnstall ation .... .... . . ....... 16-17
E vaporator ............... . .. . . ........ 16-17
Condenser ..... . . ... ... ..... ........... 16-17
Compressor ... . .. . . . ....... ... . .. .... .. 16-1 7
Compressor Components .. . . ........ .. . . . 16-17
Valve Plate .. . .. . . . . ........... .... .. . . 16-17
Crankshaft Seal .. . .... ....... .. . . .. .. .. 16-18
Expansion Valve .. . ....... ...... . .. . .. .. 16-1 8
Thermostatic Switch . . . . . ........ . .. .. .. . 16-18
A ir Conditioner Blower Motor .. ....... . .. 16-19
Belt . ..... . . ..... ... . .... .... . .. . .. .. . 16- 19
Clutch ..... .. ..... . .. . . ........ . .... . . 16- 19
5 C lea nin g and Inspection .. ... . ... . .. . ... .. 16-1 9
Compressor . . . . . . .. . . . . .. . ..... . .... . .. 16- 19

D Forel Publishing Company, LLC

DESCRIPTION AND OPERATION
Refer to Wiring Diagram Manual
Form 7795P-66 for locations of wi r-
ing harnesses. Schema tics are shown
in Group 22 of this manual.
The Ford air conditioner is used
on the Falcon and Fa irlane (Fig. 1).
Woodbridge, VA 22192
cooling system. Besides these major
www.ForelPublishing.com
cooling components there is a liquid
sight glass, an oil separator (integral
wi th the compressor), a cooling unit
thermosta tic switch, and a blower
assembly.
liquid Refri gerant -12 under pressure
in a combination receiver and dehy-
dra tor (Fig. 2). The pressure in the
receiver normally varies from about
80 to 300 psi, depending on the sur-
rou nd ing ai r temperature and com-
pressor speed.
T he dehyd rator serves the purpose
of removing any traces of moisture
that may have accumulated in the
system. Even small amounts of mois-
ture will cause an air cooling unit to
ma lfu nction. A fus ible plug is
screwed into the receiver. This will
release the refrigerant before the
refrigerant temperature exceeds
2 12 °F .

FIG. 1-Ford Air Conditioner
The M ercury air conditioner is used
on the Comet. The Selectai re is
available on the F ai rlane. A ll units
use a receiver, an expansion valve,
an evaporator, a com pressor, and a
condenser. These parts are the stand-
ard units which are used in any air
Kl 559-A
Fig. 2 shows an air conditioning
system in schematic form . Arrows
indicate the direction of refrigerant
ft ow.
RECEIVER UNIT
The air cooling system stores the
EVAPORATOR UNIT
When the coolin g system is in op-
era tion, the liquid Re fri gerant-12
flows from the combination receiver
and dehyd rator unit thro ugh a flexi-
ble hose to the evaporator (Fig. 2)
where it is allowed to evaporate at
a reduced pressure, to cool the evap-
orator.
Passenger compartment air is
blown th rough the evapora tor fins
and is thus cooled by the evaporator.
 PART 16-2-AIR CONDITIONING-FORD
~ HIGH PRESSURE LIQUID
~ LOW PRESSURE LIQUID
[?;E§{;J HIGH PRESSURE GAS
~ LOW PRESSURE G AS
OUT TO REC EIVER-~
FIG. 2-Air Conditioning System
EXPANSION VALVE
The rate of refri gera nt evapora-
tion is controlled by an expansion
valve (Fig. 2) which allows only
enough refrigerant to flow into the
evaporator to keep the evaporator
operating efficiently, depending on
its hea t load.
T he expansion valve consists of
the valve a nd a temperature sensing
capillary tube and bulb. The bulb is
clamped to the outlet pipe of the
evaporator. T hus the valve is con-
trolled by evaporator o utlet temper-
ature.
The rest ricting effect of the ex-
pansion va lve at the evaporator
causes a low pressure on the low
pressure side of the system of 12 to
50 psi, depending on the surrounding
air tempera ture and compressor
speed.
COMPRESSOR UNIT
The evaporated re frigerant leav-
ing the evaporator (now in the form
of a gas) at a pressure of 12 to 50
psi is pumped by the compressor, lo-
cated on the engine (Fig. 3), into
the top of the condenser, located in
front of the rad iator.
The compressor ma intains a pres-
sure on its high pressure side of from
80 to 300 psi, depending on the sur-
round ing air temperature and com-
pressor speed.
As the now hea ted and com-
pressed refrigerant gas flows down
K1231-B
Forel Publishing Company, LLC
Woodbridge, VA 22192
www.ForelPublishing.com
FIG. 3-Compressor Installed
through the condenser, it is cooled
by air passing between the secti ons
of the condenser. The cooled , com-
pressed refrigerant gas condenses to
liquid refrigerant which then flows
in to the receiver.
LIQUID SIGHT GLASS
A liquid sight glass is mounted in
the high pressure refrigerant line be-
tween the receiver and the expansion
valve (Fig. 2). The sight glass is
used to check whether there is
enough liquid refrigera nt in the sys-
tem.
MAGNETIC CLUTCH
l t is necessa ry to control the
amount of cooling that the system
produces . To accomplish this, the
16-11
compressor is electrically cut in and
out of operation by the use of a
magnetic clutch pu ll ey mounted on
the compressor cranksha ft (Fig. 2).
T he magnetic clutch is controlled by
a thermostatic switch which has its
temperature sensing tube inserted in
the fins of the evaporator core.
THERMOSTATIC SWITCH
The thermostatic switch controls
the operation of the compressor by
controll ing the compressor magnetic
clutch. The temperature sensing tube
of the switch is placed in contact
with the evaporator fins. When the
temperature of the evaporator be-
comes too cold, the ther mostatic
switch opens the magnetic clutch
electrical circuit, disconnecting the
compressor from th e engine. When
the temperature of the evaporator
rises to the upper lim it at which the
thermostatic swi tch is se t, the ther-
mostatic switch closes and energizes
the magnetic clutch. This connects
the compressor to the engine, and
cooling action begins again.
When the ignit ion switch is off or
the cooling control thermostatic
switch is in the off posi tion, the mag-
netic clutch is not energized, and the
compressor can not operate.
Wh en the ign ition switch is on
(engine running), and the cooling
control is in the cooling range, the
magnetic c lu tch is energized , the
compressor is connected to the en-
gin e a nd the cooling system is in op-
eration.
The thermostat ic switch may be
ad justed to maintain an average
evaporator tempera ture of from
30 °-60°F . T he thermostatic switch
operating differential temperature a t
any one setting is 6°F.
SERVICE VALVES
T he service valves on the com-
pressor are used to test and serv ice
the cooling system (F igs. 4 and 5).
Th e high pressure serv ice valve,
moun ted at the outlet to the com-
pressor , a llows access to the high
pressure side of the system for at-
taching a pressure gauge, or a serv-
ici ng hose.
The low pressure valve, mounted
a t the inlet to the compressor, allows
access to the low pressure side of the
system fo r a ttaching a pressure
gauge or a ser vicing hose.
Both service valves may be u sed
to shut off the rest of the system
from the compressor during com-
pressor service.
16-12 GROUP 16-VENTILATING, HEATING, AND ACCESSORIES
FIG. 4 - Low Pressure Service FIG. 5-High Pressure Service
Valve Gauge Port Valve Gauge Port
EJ DIAGNOSIS AND TESTING
AIR CONDITIONING-DIAGNOSIS GUIDE
INSUFFICIENT OR 1. Inoperative magnetic clutch.
NO COOLING 2. Inoperative blower, motor, or
switch.
3. Obstructed air passages.
Forel PublishingJoss
4. Complete Company,
of chargeLLC (No
foamWoodbridge,
in sight glass
VAat22192
system start-
up).www.ForelPublishing.com
5. Partial Joss of ch arge (Contin-
uous foam in sight glass after start-
up).
6. Service valves improperly set
(should be maximum counterclock-
wise).
NOISY COMPRESSOR 1. Loose, torn or misaligned belt.
2. Loose or slipping clutch .
3. Foreign material or damaged
.COMPRESSOR VIBRATION 1. Broken or loose moun ting
bracket.
TESTING the center position. Both gauges
Obstructed air passages, broken should now show approximately 60
belts, disconnected or broken wires, to 80 pounds pressure at 75°F. If
loose clutch, loose or broken mount- very little or no pressure is indi-
ing brackets may be determined by cated, leave the vacuum pump valve
visual inspection of the parts. closed, open the Refrigerant-.1 2 tank
valve, and set the low pressure mani-
CHECKING FOR LEAKS fold gauge valve to the counterclock-
Attach the manifold gauge set wise position. T his opens the system
(Fig. 6). Leave both manifold gauge to tank pressure.
valves at the maximum clockwise Check all connections, and the
position. Set both service valves at compressor shaft seal for leaks, using
7 . Compressor defective, or loose
or broken compressor belt.
8. A / C thermostat defective.
9. Clutch lead disconnected or
broken.
10. Expansion valve inoperative
-stays open or closed.
11. P lugs left in compressor under
service valve (both gauges ind icate
the same pressure).
12. Moisture in system.
parts in compressor.
4. Compressor loose on bracket.
2. Loose clutch.
3. Loose belt.
a flame type leak detector (Fig. 7).
Follow the directions with the leak
detector. The smaller the flame the
more sensitive it is to leaks. There-
fore, to insure accurate leak indica-
tion keep the flame as small as possi-
ble. The copper elemen t must be red
hot. If it is burned away, replace the
element. Hold the open end of the
hose at each suspected leak point for
two or three seconds (Fig. 8). T he
flame will normally be almost color-
 PART 16-2-AIR CONDITIONING-FORD
FIG. 6-Manifold Gauge Set
DETECTOR
UNIT
Kl 548-A
FIG. 7-Flame Type leak
Detector
FIG. 8-Checking for leaks
less. The slightest leak will be indi-
cated by a bright color to the flame.
Be sure to check the manifold gauge
set and hoses for leaks as well as
the rest of the system.
If the surrounding air is contami-
nated with refrigerant gas the leak
detector will indicate this gas all the
time. Good ventilation is necessary
to prevent this situation. A fan, even
in a well ventilated area, is very
helpful in removing small traces of
refrigerant vapor.
USE OF SIGHT GLASS
When observing the sight glass for
foam, run the engine at 1500 rpm
with the thermostatic switch control
lever set for maximum cooling, and
the blower on high. Foam in the
sight glass indicates an undercharge
of refrigerant. Check the system for
leaks, repai r if necessary and charge
the system with the proper amount
of Refrigerant-12.
No foam in the sight glass will in-
dicate either a full charge or a com-
plete loss of refrigerant. Clean the
sight glass. If the system is fully
charged, the sight glass will be per-
fectly clear. If the system is com-
pletely empty of refrigerant, the sight
glass will look oily and will not be
as clear as when refrigeran t is flow-
ing through it.
When the compressor is not op-
erating and when the system is com-
pletelyForel Publishing
charged, Company,
an occasional LLC
large
bubble of Woodbridge,
Refrigerant-12VAvapor
22192will
normallywww.ForelPublishing.com
be seen in the sight glass.
Under conditions of extremely
high temperatures occasional foam
or bubbles may appear.
CHECKING SYSTEM
PRESSURES
The pressures developed on the
high pressure and low pressure side
of the compressor indicate whether
the system is operating properly.
Attach the manifold gauge set
(Fig. 6). It will not be necessary to
attach the Refrigerant-12 tank un-
less refrigerant is to be added to the
system. Set both manifold gauge
valves at the max imum clockwise or
closed position. Set both service
va lves at the center position .
Check the system pressures with
the engine running at 1500 rpm, all
controls set for maximum cooling,
and the front of the car a t least five
feet from any wall.
The actua l pressures indicated on
the gauge will depend on the tem-
perature of the surrounding ai r and
the humidity. Hi gh air temperatures
along with low humidity, will give
higher system pressures. The lowest
16-13
figures given are for an ambient
(surround ing air) temperature of
75 °F. , 50 % r elative humidity.
The low pressure gauge should in-
dicate a pressure of from 12 to 50
pounds. The high pressure gauge
should indicate a pressure of six or
seven times the low pressure or 80
to 300 pounds.
At idle speed and a surrounding
air temperature of 100° to 110°F.,
the high pressure may go as high as
300 pounds or more. If it becomes
necessary to operate the air condi-
tioner under these conditions, keep
the high pressure down with a fan
directed at the condenser and radi-
ator.
INTERPRETING ABNORMAL
SYSTEM PRESSURES
Low Pressure Below Normal,
High Pressure Normal
These pressures indicate a restric-
tion between the receiver and the
expansion valve or between the ex-
pansion valve and the low pressure
service valve. If the low pressure is
actually a vacuum , the expansion
valve is probably closed tightly. Shut
the system down and allow it to
warm to room temperature. Start
the engine and if the evaporator will
now become cool, the expansion
valve was frozen because of mois-
ture in the system. Release the re-
frigerant , replace the dryer-receiver
assembly, check for leaks, then evac-
uate and charge the system .
Whenever the system has been
opened three times the receiver dry-
er should be replaced as a precau-
tion against internal icing of the ex-
pansion valve.
Check the system between the re-
ceiver outlet and the low pressure
service valve for restrictions, by feel-
ing all of the connections and com-
ponents. Any portion that is cold to
the touch or th at frosts up, with the
pressures as indicated here, is re-
stricting the refrigerant flow.
Low Pressure Above Normal,
High Pressure Normal
Observe both pressu re gauges. If
the low pressure is above normal
(12 to 50 pounds) and the high pres-
sure is at or near normal (80 to 300
pounds), the expansion valve is not
operating properly. This condition
may cause the compressor to receive
slugs of liquid and thus to be very
noisy. Also, the suction side of the
compressor and the cran kcase and
head will be colder than normal and
will frost up.
16·14 GROUP 16-VENTILATING, HEATING, AND ACCESSORIES
The expansion valve will allow
too much liquid refrigerant to flow
to the compressor if it is defective
or, if the temperature sensing ele-
ment is not making close contact
with the evaporator outlet pipe.
Make sure that the element is se-
curely clamped to the outlet pipe,
and properly covered.
High Pressure Below Normal,
Low Pressure Above Normal
If the two pressures are equal or
within 30 pounds of each other, the
compressor may be defective. Per-
for m a compressor volumetric effi-
ciency test. Repair or replace the
compressor as needed.
High Pressure Above Normal
High compressor head pressures
are caused by an overcharge of re-
frigerant, condenser air passages
clogged, a restriction between the
condenser inlet a nd the receiver, or
high surrounding air temperatures.
High head pressures are generally
evidenced by a noisy compressor.
Discharge excess refrigerant until
foam is seen in the sight glass (sys-
tem operating at 1500 engine rpm),
then add Y2 pound of refrigerant.
THERMOSTATIC SWITCH
TEST
The switch must be removed for
this test. Move the switch arm to the
coldest temperature setting by hold-
ing the arm against the stop nearest
LOW
PRESSURE --~
SERVICE
VALVE CAP
REMOVED
FIG. 9-Voltmetric Efficiency Test
to the vacuum actuator. At room
temperature the switch should be
closed. Use a self powered test light
EJ COMMON ADJUSTMENTS AND REPAIRS
SAFETY PRECAUTIONS
The refrigerant used in the air
or an ohmmeter connected to
switch leads to check whether or
the switch is closed. Release
switch arm. The switch should
open.
MAGNETIC CLUTCH
Disconnect the magnetic clutch
wire at the bullet connector, and
connect it to the negative lead of an
ammeter. Connect the positive lead
of the ammeter to the battery posi-
tive terminal. The magnetic clutch
should pull in with a distinct click
and the current reading on the am-
meter should be to specification.
Make certain that the brushes and
brush slip rings are clean and free of
oil or grease.
BLOWER MOTOR
Disconnect the blower motor wire
at the bullet connector, and connect
it to the negative lead of an a mme-
ter. Connect the positive lead of the
ammeter to the battery positive ter-
minal: The motor should operate and
the reading on the ammeter should
be to specification.
EXP ANSION VAL VE
Remove the expansion valve from
the evaporator. Connect the Refrig-
erant-12 supply hose to the expan-
sion valve inlet with a suitable adapt-
Forel Publishing
er. Open Company,
the refrigerant LLC valve
supply
Woodbridge,
slightly. VA 22192
Refrigerant gas should come
www.ForelPublishing.com
STANDARD QUICK COUPLER !f.i
SAE FEMALE X !/.i SAE MALE
m6-20 THREAD)
ALTER FLAT TO PROVIDE 0.125
WALL THICKNESS
K1332-B
out of the expansion valve outlet. If
no gas comes out of the outlet, the
temperature sensing element has lost
conditioner system is Refrigerant-12.
Refrigerant-12 is nonexplosive, non-
the its charge and the expansion valve
not must be replaced.
the
be
COMPRESSOR VOLUMETRIC
EFFICIENCY TEST
Malfunction of the compressor
can be isolated by checking the com-
pressor volumetric efficiency with a
special tool. M ake the test with the
car in a clean dry a tmosphere.
Run the engine at 1500 rpm with
all controls at maximum cooling fo r
at least 10 minutes. Adjust the en-
gine idle with a tachometer to ex-
actly 515 rpm with the compressor
cl utch engaged. Turn the engine off
and set the cooling control to the
OFF position. Isolate the compres-
sor, then remove both h igh and low
pressure service valve gauge port
caps, allowing the gas in the com-
pressor to escape.
Attach the special tool (calibrated
orifice with gauge attached) to the
high pressure service valve gauge
port (Fig. 9). Start the engine. En-
gage the magnetic clutch for 15 sec-
ond intervals, by moving the cooling
control from the OFF position to
the maximum cooling position, and
observe the maximum gauge pres-
sure at the end of each 15 second
interval. Be sure to allow the gauge
pressure to drop to zero between the
15 second intervals. Stop the engine.
A good compressor wi ll bring the
pressure to 200 psi in 15 seconds. If
the pressure does not come up to
200 psi, in 15 seconds, clean the
compressor intake screen. If the in-
take screen is clean, remove and in-
spect the valve plate. Most of the
failures to come up to the 200 psi
specification will be caused by small
foreign particles under the valve
plate leaves or a defective valve
plate. Clean the valve plate and as-
semble it to the compressor using
new gaskets. If this does not effect
a cure, replace the valve plate or the
compressor as required.
If no further work is to be done
on the system after making the vol-
umetric efficiency test, disconnect
the orifice tool and gauge, evacuate
the compressor and connect it back
into the system.
infl ammable, noncorrosive, has prac-
tically no odor, and is heavier than
-
PART 16- 2-AIR CONDITIONING- FORD
ai r. Although it is class ified as a safe
refrigerant, certain precautions must
be observed to protect the parts in-
vo lved and the person who is work-
ing on the unit. Use only Refriger-
ant-12.
Liqu id Refri gerant-12, at normal
atmospheric pressure and tempera-
tures, evaporates so quickly that it
tends to freeze anything that it con-
tacts. For this reason, extreme care
m ust be taken to prevent a ny liq uid
refrigerant from coming in contact
with the skin and especially the eyes.
Refr igerant- 12 is readily absorbed
by most types of oil. It is therefore
recommended that a bottle of sterile
mineral oil and a q uantity of weak
boric acid soluti on be kept nearby
when servicing the ai r conditioning
system. Should any liquid refrigerant
get in to the eyes, use a few drops of
mineral oil to wash them ou t, then
wash the eyes clean wi th the weak
boric acid solution. Seek a doctor's
aid immed iately even though irrita-
tion may have ceased .
Always wear safety goggles when
servicing any part of the refrigerat-
ing system.
The Refri geran t- 12 in the system
is always under pressure. Because
the system is tightly sealed, heat
applied to any part wou ld cause this
pressure to build up excessively.
To avoid a dangerous explosion,
never weld, use a blow torch, solder,
stea m clean, bake body finishes, or
use any excessive amount of heat on,
or in the immediate area of, any patt
of the air cooling system or refriger-
ant supply tank, while they are
closed to the atmosphere whether
filled with refrigerant or not.
T he liquid refrigerant evaporates
so rapidly that the resulting refri ger-
ant gas will disp lace the air sur-
rounding the area where the refri g-
erant is released. To prevent possi-
ble suffocation in enclosed areas, al-
ways discharge the refrigerant from
an air cooling syste m into the gar-
age exh aust collector. Always main-
tain good ventilation surround ing the
work area. If the car is to be under-
coated, make certain that the under-
coating does not plug the evaporator
drain tubes.
Although Refr igerant- 12 gas, un-
der norma l conditions, is non-poison-
ous, the discharge of refrigerant gas
near an open flame ca n produce a
very poisonous gas. T his gas will also
attack all bright meta l surfaces. This
poisonous gas is generated in small
quantities when the flame-type leak
detector is used . Avoid inhaling the
fumes from the leak detector. Make
certain that Refrigerant-12 is both
stored and installed in accordance
with all state a nd local ordinances.
When admitting Refrigerant-1 2
gas into the cooling un it, always
keep the tank in an upright position.
If the tank is on its side or upside
down, liquid Rcfrigerant-12 wi ll en-
ter the system a nd damage the com-
pressor. In surrounding air tempera-
tures above 90°F ., prolonged engine
idle will result in excessively high
compressor pressures.
DISCHARGING THE SYSTEM
Discharge th e refrigerant from the
system before replacing any part of
the system, except the compressor.
T o discharge the system, connect
the manifold gauge set to the system
(Fig. I 0). Do not connect the mani-
fo ld center connection hoses to the
Forel Publishing Company, LLC
Woodbridge, VA 22192
www.ForelPublishing.com
l ow Pressure Gouge
TO REFRIGER ANT SUPPLY AND VACUUM PUMP
FIG. 10-Charging the Air Conditioning System
Re frigerant-12 tank, or vacuum
pump. Place the open end of these
hoses in a garage exhaust outlet. Set
the high pressure manifold ga uge
va lve at the maxi mum counterclock-
wise or open posi tion. Open th e high
pressure service valve a slight
amount (Fig. 5), and allow the re-
frigerant to discharge slowly from
the system.
Do not allow the refrigerant to
rush out, as the oil in the compres-
16-15
sor will be forced out along with it.
EVACUATING THE SYSTEM
A tt ach the manifold gauge set, a
tank of Refr igera nt-12 and a vacu-
um pump to the system (Fig. 10).
M ake certain th at the Refrigerant-
12 tank valve is tightly closed. Set
both service valves to the mid-posi-
t ion. Open both manifold valves. Re-
lease any pressu re in the system.
Open the vacuum pump valve and
run the pump unt il the low pressure
gauge reads at least 25 inches, and
as close to 30 inches of vacuum as
possible. Conti nue vacuum pump op-
erat ion for 20 to 30 minutes to boil
a ny moisture out of the system.
C lose the pump valve. Turn off the
pump .
MAKING A PARTIAL CHARGE
Attach the manifold gauge set
H IGH PRESSURE SERVICE VALVE
Kl 557- A
(Fig. 10). Open both manifold
valves. Close the vacuu m pump
valve. Open the Refrigerant-12 tank
valve. Purge the air from the high
pressure hose by loosen ing the high
pressure hose at -the service valve,
for a few seconds. Tighten the con-
nection and set the hi gh pressure
mani fo ld gauge va lve at the maxi-
mum clockwise position . L oosen the
low pressure gauge hose slight ly a t
t he low pressure service valve, fo r a
16-16 GROUP 16- VENTILATING, HEATING, AND ACCESSORIES
few seconds, to purge the air from
the hose. Tighten the connection. Set
both service valves at the center po-
sition (Fig. I 0).
Run the engine at 1500 rpm with
all controls at the maximum cold
position. Charge the system until all
foam disappears from the sight glass,
and then add 1/.i pound of Refriger-
ant-12. Shut the Refrigerant-12 tank
valve.
It may be necessary to place the
Refrigerant-12 tank in a container
of hot water at about 150°F. to
force the gas from the tank during
charging.
Never heat the Refrigerant-12
tank with a torch. A dangerous ex-
plosion may result.
Set both service valves at the
maximum counterclockwise position.
Remove the gauge set, and cap the
service valve gauge ports and valve
stems.
MAKING A COMPLETE
CHARGE
Check for leaks first, release the
pressure, then evacuate the system .
Leave both service valves at the
mid-position a nd the vacuum pump
valve closed. Leave the low pressure
manifo ld gauge valve at the maxi-
mum counterclockwise or open po-
sition. Set the high pressure manifold
gauge valve at the maximum clock-
wise or closed position. Set all con-
trols to the maximum cold position.
Open the Refrigerant-12 ta nk
valve. Run the engine at 1500 rpm.
Charge the system until the sigh t
glass is clear of foam, then add an
additional 'l"i pound of refrigerant.
During the charging, the high
pressure may build up to an exces-
sive value. This can be caused by an
overcharge of refrigerant, or an
overheated engine, in combination
with high surrounding temperatures.
Never a llow the high pressure to ex-
ceed 240 pounds while charging.
Stop · the engine, determine the
cause, and correct it.
After the proper charge has been
made, close the Refrigerant-1 2 tank
valve, and check the system pres-
sures for proper operation. Set both
service valves at the maximum coun-
terclockwise position. Remove the
gauge set, and cap the service valve
gauge ports a nd valve stems.
CHARGING FROM SMALL
CONTAINERS
Refrigerant-1 2 is available in one-
pound cans. A scale is not necessary
if these small containers are used in-
stead of a tank.
Attach the hose, that would nor-
mally attach to the large tank (Fig.
10), to the special valve that is pro-
v ided for the small cans. Close the
valve (maximum clockwise position)
and follow the procedure for leak
testing, evacuating and charging the
system as previously given.
For charging, attach a one-pound
can of Refrigerant-12 to the special
valve, and open the valve. Keep the
can in an upright position. When the
can is empty (no frost showing),
close the valve, remove the empty
can, attach a new one, and open the
valve again. Kl 544- A
Charge the system until the sight
glass clears of foam then add an ad- FIG. 11-0il level Check
ditional 1:t"i pound of refrigerant. Es-
timate the 'l"i pound weight by ob-
serving the frost line on the one- shaft. If add it ional oil is needed in
pound can. the compressor, add Suniso 5 or
Check the system pressures, set Capella E refrigerator compressor
both service valves at the maximum oil, or equivalent.
counterclockwise position. R emove If more than "Vs inch of oil is in-
the gauge se t, and cap the service dicated, as might happen if a new
valve gauge ports and valve stems. compressor is installed and oil al-
ready in the system is pumped back
to the compressor, draw out the ex-
COMPRESSOR OIL cess oil until the proper quantity is
LEVEL CHECK
indicated.
Under normal conditions when Replace the oil fi ller plug, then
the aiPublishing
Forel r cooling system
Company,is operating
LLC evacuate and connect the compressor
satisfactoril y the compressor oil lev- back into the system. Be sure to
Woodbridge, VA 22192
el need not be checked. There is no check th e compressor filler opening
www.ForelPublishing.com
place for the oil to go except inside for leaks.
the sealed system. When the car is
first started some of the oil will be
pumped into the rest of the system. ISOLATING THE COMPRESSOR
After 15 minutes of operation, most T his procedure is used when check-
of th e oil is ret urned to the compres-
ing the compressor oil level and
sor crankcase.
when it is desired to replace the com-
Check the compressor oil level
pressor without losing the refriger-
only if a portion of the refrigerant
ant charge.
system is being replaced or if there
To isolate the compressor fro m the
was a leak in the system and the re-
system, turn both the high and the
frigerant is being replaced.
low pressure service valves to the
Check the oil after the system has
been charged and has been operating extreme clockwise position. Loosen
the cap on the high pressure service
at an engine speed of 1500 rpm for
valve ga uge port, and allow the gas
J 5 minutes in 60°F. surrounding air
to escape until the compressor is re-
temperature or above. Turn off the
lieved of refrigerant pressure.
engine, and isolate the compressor.
Loosen the cap a small amount
Remove the oil fill er plug from the
only, and do not remove it until the
compressor, insert a flattened Ys -
pressure is completely relieved.
inch diameter rod (Fig. 11), in the
oil filler hole until it bottoms. The To connect the compressor back
rod should show "Vs inch of oil on into the system, evacuate the com-
Tecumseh compressors and ~ inch pressor at the high pressure service
of oil on York compressors. This is valve gauge port, close the vacuum
equ ivalent to 11 ounces on T ecum- pump valve, turn both service valves
seh and 10 ounces on York. It may to the maximum counterclockwise
be necessary to rotate the compres- position, and cap the high pressure
sor crankshaft sligh tly (by hand) so service valve gauge port and service
that th e dip rod will clear the crank- valve stems.
 PART 16-2-AIR CONDITIONING-FORD
EJ REMOVAL AND INSTALLATION
EVAPORATOR
REMOVAL
1. Discharge the refrigerant fro m
the system.
2. Disconnect the two w ires from
the unit, demount the evaporator as-
sembly, and set the unit on the car
floor.
3. Disconnect t h e refrigerant
hoses. On some models it may be
necessary to remove the assembly
from the car before going further.
4. Remove the front panel, covers
and the expansion valve from the
unit. (See Expansion Valve Removal
and Installation.)
5. Remove the thermostatic sw itch
temperature sensing tube from be-
tween the evaporator fins, remove the
evaporator-to-base mounting screws
and remove the evaporator from the
base.
INSTALLATION
1. Attach the old expansion valve
to the new evaporator and leak test
the connection by capping the outlet
of the evaporator and using a suit-
able reducing connector from the
valve inlet to a tank of Refrigerant-
12.
2. Position the evaporator on the
base and install the two evaporator-
to-base mounting screws.
3. Push the thermostatic switch
sensing tube into the same relative
position at a bout the center of the
evaporator, but if the same core is
being used position the sensing tube
between the next two fins for good
temperature conduction. Install the
covers and fron t panel.
4. Attach the refrigerant lines and
leak test the connec tions.
5. Mount the assembly, connect
th e two wires, leak test, evacuate
and charge the system.
CONDENSER
1. D ischarge the refrigera nt from
the system.
2. Remove the fron t grille lo radi-
ator support bracket, and the hood
latch.
3. Disconnect the refrigerant lines
from the condenser and receiver.
Remove the condenser mounting
screws and remove the condenser re-
ceiver assembly. On the Mustang a
special arrangement is used where
the radiator retaining studs are p art
of the condenser.
4. Position and mount the new
condenser, remove the protective
plugs, attach the refrigeran t lines and
install the grille to radiator support
bracket and hood latch.
S. Check for leaks, evacuate and
charge the system.
COMPRESSOR
REMOVAL
1. Isolate the compressor (see
Common Adjustments and Repairs in
this part). Disconnect the two service
valves and hoses from the compres-
sor (Fig. 12). E nergize the clutch
and loosen and remove the clutch
mounting bolt.
2. Install a %-11 bolt in the clutch
drive shaft hole. With the clutch still
energized, tighten the bolt 10 loosen
the clutch from the shaft. Disconnect
Forel Publishing Company, LLC
Woodbridge, VA 22192
www.ForelPublishing.com
FIG. 1 2-Compressor- Service
Valves Removed
the clutch wire at the bullet con-
nector.
3. Loosen the belt, remove the
belt and the clutch, and then remove
the mounting bolls and th e compres-
sor.
4. W it h the compressor on the
work bench, remove the key from
the shaft.
INSTALLATION
Before install ing the compressor,
see Cleani ng and Inspection in this
pa rt.
1. Mount the clutch on the shaft
a nd install the mounting screw _and
washer finger-tight. Place the com-
pressor on the mounting bracket and
install the four mounting bolts.
2. Connect the clutch wire, ener-
16-17
gize the clutch and torque the clutch
mounting bolt to specification. H the
new compressor was shipped with a
bolt and washer in the end of the
crankshaft, remove and discard the
bolt and use a bolt with a nylon insert
in it. Install and adj ust th e drive bell.
3. Making sure that the protective
rubber pl ugs have been removed, in-
stall the service va lves on the com-
pressor using new seals. T ighten the
service valve outs to specification.
Do not over-tighten the nuts. The
ROTO -LOK service valves can be
rotated slightly on their seat without
breaking the high pressure seal. Th is
is not an indication of a loose valve.
Leak test the compressor, then evac-
uate it and connect it back into the
system.
4. Check the oil level in the com-
pressor and add or remove oil if
necessary.
COMPRESSOR COMPONENTS
All compressor removal and instal-
lation operations, except belt rep lace-
ment, can be p erformed only after
the unit has been isolated from the
rest of the system. (See Common
Adj ustmen ts and Repairs in this part.)
VALVE PLATE
Removal
1. Isolate the compressor and dis-
con nect the service valves. Remove
the 12 head bolts.
2. Remove the cylinder head and
valve plate from the top of the com-
pressor body (Fig. 13). Do not tap or
hit the head with any hard tool , as
damage co uld resu lt (York compres-
sors are made of aluminum).
3. Remove and d iscard all gaskets,
and be sure to clea n gasket shreds
from a ll gasket surfaces. Exa mine the
cylinders and top of the pistons, par-
ticularl y in case of va lve breakage.
If there are score marks, replace the
compressor assembly.
4. If the cylinders and pisto ns are
in good condit ion, check the va lve
plate and valve reeds fo r damage.
If the valve assembly is in good con-
dition, it can be used again. If the
va lve pla te is damaged, install the
entire replacement kit which includes
the valve pl ate , valve reeds, and the
two gaskets (Fig. 13).
S. When the valve plate assembly.
is re-used, wash it in clea n solvent
and dry in dry air. Check the oil for
dirt. If the system is not clean, re-
place the oil.
16-18 GROUP 16- VENTILATING, HEATING, AND ACCESSORIES
SERVICE VAL VE
PLATE-TO-HEAD GASKET
VALVE PLATE ASSEMBLY
PLATE-TO-BODY GASKET
SEAL KIT ASSEMBLY
Forel Publishing Company, LLC
Installation
1. Starting with the valve plate
gasket, assemble the parts in the or-
der shown in Fig. 13. Insert the cylin-
der head bolts carefully to avoid
damaging the gaskets. Before as-
sembly apply a film of new refrigera-
tion oil to both sides of both gaskets.
2. Tighten all bolts finger-tight,
then torque the bolts ~ turn at a
time to specification. Then tighten the
remaining bolts in a sequence so that
those diagonally opposite are evenly
tightened to the required torque.
3. Connect the compressor into
the system. Check the oil level in the
compressor, and add or remove oil
if necessary. (See Cleaning and In-
spection.)
CRANKSHAFT SEAL
REMOVAL
1. Isolate the compressor, loosen
and remove the belt.
2. Remove the clutch and remove
the Woodruff key (on some six cyl-
inder engine installations it will be
necessary to loosen the compressor
mounting bolts and slide the com-
pressor back slightly).
SERVICE VALVE SEALS
STUD WASHER
CRANKCASE BODY
3. Carefully remove all accumu-
Woodbridge, VA 22192
lated dirt and foreign material from
www.ForelPublishing.com
the seal plate and surrounding area
of the compressor, and position a
small drain pan beneath the seal
plate.
4. Remove the seal plate bolts,
and remove the plate and gasket. Do
not mar the sealing surfaces, or the
polished shaft surface.
5. Remove the carbon seal ring
and seal housing assembly from the
crankshaft. A disassembled view of
the crankshaft seal assembly is in-
cluded in Fig. 13.
6. Clean all old gasket material
from the seal plate and the compres-
sor. Make certain that the shaft, the
seal plate and the compressor gasket
surfaces are completely clean before
installing the new seal.
INSTALLATION
1. Lubricate the new shaft seal
parts in clean compressor oil. and
position the seal assembly on the
crankshaft, with the carbon ring
toward the seal plate.
2. Position the new gasket on the
compressor, center the crankshaft in
the seal plate and install the seal
plate.
3. Torque the bolts to specifica-
tion.
4. Make certain that there are no
burrs or dirt on the compressor shaft.
Then install the key, and the clutch.
5. If the compressor was moved,
reposition it and tighten the mount-
ing bolts, then install the belt and
adjust the tension.
6. Check the oil level (see Com-
mon Adjustments and Repairs).
EXPANSION VALVE
REMOVAL
1. Discharge the refrigerant from
the system. Disconnect the two wires
from the unit, demount the evapo-
rator assembly, and set the unit on
the car floor. Disconnect the refrig-
erant hoses. On some models, it may
be necessary to remove the assem-
bly from the car before going further.
2. Remove the expansion valve
protection shield.
3. Carefully slit the insulation cov-
ering the temperature bulb and re-
move the temperature bulb clamp.
Then disconnect the valve from the
inlet pipe and remove the valve.
INSTALLATION
1. Connect the new valve to the
inlet pipe, and leak test the connec-
tion by capping the outlet end of the
evaporator and using a suitable re-
ducing connector from the valve in-
let to a tank of Refrigerant-12. Po-
sition the temperature bulb to the
outlet pipe, and install the bulb
clamp. Be sure that the bulb, pipe,
and clamp are clean and that the
clamp is tight. Go over these parts
with fine sandpaper to assure this.
2. Wrap the insulating material
around the temperature bulb, pipe.
and valve, and position the rubber
seal over the pipe connections.
3. Install the expansion valve pro-
tection shield.
4. Connect the refrigerant hoses
and leak test the connections.
5. Mount the assembly. connect
the wires, leak test, evacuate and
charge the system.
THERMOSTATIC SWITCH
The thermostatic switch is mounted
to the air conditioner front register.
Remove the three register to evapo-
rator case screws. Pull the register
from the case and pull the sensing
tube from the evaporator fins. Re-
move the wires and the knob from
the switch and remove the switch.
 PART 16-2 -AIR CONDITIONING-FORD
AIR CONDITIONER BLOWER
MOTOR
REMOVAL
1. Disconnect the battery ground
cable.
2. Remove one screw and the
shield from the right hand lower
side of the evaporator case.
3. Remove the cover plate mount-
ing screw and the cover plate at the
left hand side of the evaporator case.
4. Remove the mounting screws
from the register panel, and remove
the panel from the evaporator case.
Care should be taken not to dam-
age the temperature sensing tube
when drawing it from between the
fins of the evaporator.
S. Remove the bolts which retain
the evaporator case to the lower in-
strument panel, and lower the evapo-
rator to the floor.
6. Remove the mounting bracket
from each side of the evaporator,
and remove the ground wire from
the left hand side.
7. Remove the clips which con-
nect the upper and lower halves of
the evaporator case, and lift off the
upper half of the case.
8. Disconnect the blower wire at
the connector.
9. Remove the blower retaining
screws and remove the blower motor
assembly from the evaporator case.
(It will be necessary to lift the evap-
orator core slightly to allow removal
of the blower motor wire.)
1O. Remove the blower cages,
mounting bracket, and the insulator
pad.
D CLEANING AND INSPECTION
COMPRESSOR
On compressor clutch installa-
tions, carefully remove any burrs or
dirt that· may be on the compressor
shaft. The shaft must be dry and
INSTALLATION
1. Install the blower cages,
mounting bracket and insulator pad.
2. Lift the evaporator core slightly
to allow positioning of the blower
motor wire, and position the blower
in the evaporator case.
3. Connect the blower wire at the
connector.
4. Position the two halves of the
evaporator case, and install the con-
necting clips.
S. Install the mounting bracket to
each side of the evaporator, and in-
stall the ground wire on the left hand
side.
6. Position the evaporator to the
lower instrument panel and install
the mounting bolts.
7. Position the register panel near
the evaporator and insert the sensing
tube between the fins of the evapo-
rator. For best results the sensing
tube should be inserted in between
the next two fins from where it was
originally withdrawn. This assures a
more positive contact and more exact
transfer of temperature changes. In-
stall the mounting screws.
8. Position the cover plate to the
left hand side of the evaporator
case and install the mounting screw.
9. Position the shield to the lower
right hand
Forelside of the Company,
Publishing ·evaporatorLLC
case and install the retaining screw.
Woodbridge, VA 22192
10. Connect the battery ground
cable. www.ForelPublishing.com
It may be necessary in the case of
console equipped cars to remove the
evaporator assembly from the car in
order to remove the blower motor.
brightly polished. Then install the
key in the shaft.
When the compressor is disassem-
bled, completely clean all surfaces of
gasket shreds and foreign objects.
If the compressor shaft seal is
16-19
BELT
8-CYLINDER
1. Loosen the idler pulley, then
remove the belt.
2. Place the new belt in position,
and slide the compressor toward the
outside of the car and carefully
align the belt. Then tighten the four
mounting bolts.
3. Adjust the belt tension to spec-
ification, using the idler pulley.
6-CYLINDER
1. Loosen the alternator mounting
and adjusting screws, and swing the
alternator toward the center of the
car until the old belt can be removed.
2. Install the new belt and adjust
to specification.
3. Tighten the alternator mount-
ing and adjusting screws. Some en-
gines have a means of adjusting the
belt with a vertical lock screw.
CLUTCH
1. Loosen the belt.
2. Energize the clutch and loosen
and remove the clutch mounting bolt.
3. Install a % -11 bolt in the clutch
drive shaft hole. With the clutch
still energized, tighten the bolt to
loosen the clutch from the shaft,
then remove the magnetic clutch.
For clearance on some installations,
it is necessary to loosen the compres-
sor mounting bolts and slide the com-
pressor back slightly.
4. Install the clutch, the clutch
mounting bolt, and the washer.
5. Energize the clutch, and torque
the bolt to specification.
being replaced, inspect the compres-
sor internally and clean out dirt or
chips as required.
When installing a new control
assembly or parts, inspect for dirt
and foreign objects.
16-20

PART AIR CONDITIONING-SELECTAIRE

16-3
Section Page
Description and Opera tion .......... .......... 16-20
Comet, Falcon and Fairlane SelectAire Air
Conditioning and Heating System . ... ...... 16-20
Controls . ............. ... ................ . 16-21
Air Velocity .... ........ . ...... . .. . ........ 16-21
D ischarge Air ......... .. .................. 16-22
A/C -Heater Electrica I System ............. ... 16-22
2 Removal and Installa tion .. . .................. 16-24
Section Page
Hea ter Air Cond itioner Assemb ly ............ 16-24
Evaporator Core ........................... 16-24
Hea ter Core ............................... 16-24
Expansion Va lve . . .............. ........... 16-24
Blower M otor Switch .. ........ . ............ 16-25
Blower Motor .......... . .................. 16-25
A/C-Heat Door Vacu um Actuator ... ........ 16-25
Heat-Defrost Door Vacuum Actuator ........ 16-25

D DESCRIPTION AND OPERATION

( NORM) O< (OUTS IDE ) COMET, FALCON AND
FAIRLANE SELECTAIRE AIR
CONDITIONING AND
HEATING SYSTEM
VACUUM ACTUATOR T he SelectAire a ir conditioning
A/ C - HEAT DOOR
and hea ting assembly is contained
ent irely in one case under the instru-
ment panel.
Ou tside ai r is d rawn in from the
cow l through the outside ai r door
in to the right vent duct, into the
Forel Publishing Company, LLC blower scroll, forced th rough the eva-
pora to r core, through and/ or around
Woodbridge, VA 22192 the heater core then mixed and dis-
www.ForelPublishing.com charged through either the A/ C air
duct or through the heat-defrost
plenum a ir outlet, depending on the
( RECIRC.) K 1684 ·A
position on the control setting (Figs.
FIG. 1 -Comet, Falcon and Fairlane A/C-Heater l and 2).
The temperature door is located to
Air Flow-NORM-OUTSIDE-RECIRC the left of the evaporator core and to
the rear of the heater core in the left
side of the case.
The A/ C-heat d oor is located in
the left rear corner of the case, and
\, th e heat-defrost door is in the plenum
chamber attached to the rear face of
the case assembly.
VACUUM ACTUATOR A single defroster nozzle leading
A/C - HEAT DOOR to two openings in the instrument
panel is attached d irectly in the
plenum chamber with a clip. T he
Comet defroster nozzle is un ique in
des ign; the Fairlane and Falcon are
th e same.
The A/ C registers located in the
lower instrument panel are located;
VACUUM ACTUATOR
one to the far left; one to the fa r
HEAT - DEFROST
ODOR righ t; and a double register in the
center.
K 1804· A The Fairlane and Falcon registers
are barrel type registers that can be
m oved up and down and the vertical
FIG. 2-Comet, Falcon and Fairlane A/C-Heater Air Flow-HEAT vanes are positioned by moving a
 PART 16-3-AIR CONDITIONING-SELECTAIRE 16-21

horizontal wheel within the assem-

bly. The Comet registers are posi-
tioned by moving a swivel knob or
lever in the center of the registers
that control both horizontal and ver-
tical vanes in the assembly.
TEMPERATURE AIR The blower motor and wheel as-
BLEND LEVER sembly is located in the blower scroll
immediately forward of the right
vent duct assembly. The evaporator
core is located in a diagonal position
in the center of the case; and the
heater core in a diagonal position in
the lcf t side of the case.
Vacuum actuators that operate the
. ""' A/C ·HEATER - normal-recirc door in the right vent,
AIR DISTRIBUTION and the A/ C-heat door, are con-

,~ONTROL
trolled by a vacuum selector on the
LEVER------·---.. control head assembly.

CONTROLS
The air temperature is controlled
by the location of the temperature air
blend lever in the control assembly
(Figs. 3, 4 and 5). As the lever is
moved from cool to warm, a Bow-
den cable moves the (temperature
blend door) from maximum cooling
K 1814-A
position to minimum cooling posi-
tion. A vacuum switch on the control
FIG. 3-Comet A/C-Heater Control Assembly assembly is actuated to supply vac-
uum to close the water valve when
the temperature lever is in the maxi-
mum cool setting and the A/C-heat-
Forel Publishing Company, LLC er. air distribution control lever is in
Woodbridge, VA 22192 either A/C position. See the A/C-
www.ForelPublishing.com Heater Control Setting Chart, Table
BLOWER MOTOR 1, and the Vacuum Schematic m
Fig. 6.
Air distribution is controlled by
the A/C-heater lever in the control
panel assembly and the blower switch
setting. The lever actuates a vacuum
selector switch on the control assem-
TEMPERATURE AIR bly which in turn operates vacuum
actuators at the outside or recirculat-
ing air door in the right vent duct;
the A/C-heat air-blend door in the
case, and the heat-defrost door in the
plenum chamber.
The blower switch must be on to
engage the compressor clutch for air
con<litioning. With the A/C-heater
control lever in either air condition-
ing position, the air conditioner heat
door is in the air conditioning posi-
tion (vacuum) and pressure is applied
to the compressor clutch switch to
YELLOW
close the circuit and engage the
clutch.

AIR VELOCITY
K 1850- A
Three speeds are provided for the
blower fan with a four position
switch in the control assembly and a
FIG. 4-Falcon A/C-Heater Controls resistor assembly located in the blow-
16-22 GROUP 16- VENTILATING, HEATING, AND ACCESSORIES
FIG. 5-Fairlane A/C-Heater Controls
er housing. The resistor in the blower
motor circuit controls the low and
medium blower motor speeds.
DISCHARGE AIR
An A/C floor cooler tube located
at the lower rear corner of the duct
is used to discharge cold air to the
center of the left front floor area. A
deflector on the tube can be posi-
tioned manually for driver comfort.
The two outboard registers can be
VACUUM RESERVOIR
/-
CHECK VALVE
t
WATER VALVE
YELLOW
"'--it---+---!--+-+--+--+-.. SWITCH ON CONTROL
DASH PANEL
TO FALCON-COMET SELECTOR - - - - -
TO FAIRLANE SELECTOR - - - - -
FIG. 6-Comet, Falcon and Fairlane A/C-Heater Vacuum Schematic
over the tunnel or to the windshield
defroster nozzle, depending on the
location on the heat-defrost door
within the plenum.
A/C-HEATER ELECTRICAL
SYSTEM
The A/ C heater electrical circuit
is protected by a 25 ampere circuit
breaker and consists of the blower
switch on the control assembly,
blower motor, blower motor resistor,
A/C thermostatic switch, clutch
switch and compressor clutch sole-
noid (Fig. 7).
K 1851 -A
closed by a push-pull knob and lever
that actuates the balanced door be-
hind the registers. On the Fairlane
and Falcon the knob is located below
the registers on the lower lip of the
instrument panel. The Comet control
knob is located in the instrument
panel at the inboard side of each out-
board register.
The plenum chamber located on
the left rear face of the case assem-
bly distributes heated air to the floor
Forel Publishing Company, LLC
Woodbridge, VA 22192
www.ForelPublishing.com
RED
BLACK
BLUE
WHITE /'· .
WATER VALVE V~CUUM\..
HEAD ASSEMBLY
VACUUM SELECTOR ON
CONTROL HEAD ASSEMBLY
- -
K 1852-A
 PART 16-3 -AIR CONDITIONING - SELECTAIRE 16-23

TABLE 1 -SELECTAIRE CONTROL SETTING CHART

FUNCTIONAL CONTROL LEVER POSITION
A/C HEAT

RECIRC
NORM
OR OFF NORM
OR DEF
OR I
OUTSIDE HEAT DEFROST
OPEN TO Ut'tN IU Ul'tN TO
A OUTSIDE RECIRC OUTSIDE RECIRC
OPEN TO OUTSIDE
I NV
R
REC IRC v NV v
A/C A/C POSITION
v NV
D HEAT
0
0 HEAT NV
HEAT
POSITION
I DEFROST
POS~ION
R DEFROST NV
CLUTCH ON
OFF
SWITCH SEE WIRING DIAGRAM
BLOWER OFF
ON-L-M-H ON-L-M-H ON-RECIRC ON-L-M-H
SWITCH OFF-RAM AIR CONDITION OFF-RAM AIR
WATER COOL OPEN VACUUM SWITCH BY-PASSED
VALVE MOD BY SELECTOR SWITCH CIRCUIT
VACUUM CLOSED
SWITCH WARM NV
COOL CLOSED v SELECTOR SWITCH CIRCUIT
WATER MOD OPENS WATER VALVE BY
VALVE OPEN NV CLOSING OFF VACUUM NV
WARM
T COOL ALL COLD AIR BY-PASSES OUTS! DE Al R BY-PASSES
E HEATER CORE HEATER CORE
M COLD AIR PASSES OUTSIDE AIR PASSES
p MOD THRU AND AROUND THRU AND AROUND
D HEATER CORE THEN MIXED HEATER CORE THEN MIXED
0 ALL COLD AIR PASSES OUTSIDE AIR PASSES
0 WARM THRU HEATER CORE THRU HEATER CORE
R
L-LOW V-VACUUM
M-MEDIUM NV-NO VACUUM
H-HIGH MOD-MODULATED
Forel Publishing Company, LLC
Woodbridge, VA 22192
www.ForelPublishing.com

HEATER BLOWER
WIRING COLOR CODE
MOTOR
257 YELLOW 25 AMP.

268 RED ~IT BREAKER

~
269 BLUE
270 BLACK YELLOW STRIPE
359 BLACK IGNITION SWITCH
348 GREEN
257

19A885 ASSY.

COMPRESSOR CLUTCH
CONTROL SWITCH
BLOWER SWITCH
MUST BE ON TO
ENGAGE CLUTCH
359

~
A/C COMPRESSOR CLUTCH

CLUTCH CONTROL SWITCH

VACUUM CONTROLLED

K 1853-A

FIG. 7-Comet, Falcon and Fairlane A/C-Heater Wiring Diagram

16-24 GROUP 16- VENTILATING, HEATING, AND ACCESSORIES
EJ REMOVAL AND INSTALLATION
HEATER AIR CONDITIONER
ASSEMBLY
REMOVAL
1. Partially drain the cooling sys-
tem.
2. Discharge the air conditioning
system.
3. Disconnect the heater hoses at
the dash and remove the weather
seal pads.
4. Unwrap the insulation from the
sensing bulb and unclamp the bulb.
Disconnect the receiver to evapora-
tor hose at the dash panel. Leave the
expansion valve attached to the hose.
Remove the weatherseal at the dash.
5. Disconnect the evaporator to
compressor hose at the dash panel.
6. Remove the glove box liner.
7. Remove the right hand fresh
air duct from the cowl upper panel.
Remove the vacuum line from the
vacuum actuator and remove the
actuator.
8. Disconnect the wires from the
resistor block and thermostatic
switch.
9. Disconnect the three plenum to
instrument panel air ducts from the
plenum and position them out of
the way.
Forel Publishing Adiustment-Except
10. Disconnect the vacuum line
from the heat-defrost door vacuum
actuator.
11. Remove the defroster plenum
and vacuum actuator as an assembly.
12. Remove the instrument panel
upper and lower support and remove
the speaker grille.
13. Remove the speaker retaining
screws and position the speaker out
of the way.
14. Remove the defroster nozzle.
15. Remove the evaporator case
drain hose clamp and drain hose at
the dash.
16. Cover the floor mats and re-
~ove th~ .4 nuts retaining the heater
a1r cond1tloner assembly to the dash.
Pull the assembly from the dash and
rest it on the car floor.
17. Disconnect the wire from the
thermostatic switch.
18. Disconnect the temperature-
blend door actuating Bowden cable
and the vacuum line at the A/C-heat
door vacuum actuator.
19. Position the front seat all the
way back, turn the bottom of the as-
sembly toward the rear of the car
and remove the assembly from the
car.
INSTALLATION
1. Position the assembly under the
instrument panel resting it on the
floor.
2. Connect the thermostatic switch
wire (left top of plenum).
3. Connect and adjust (as shown
in Fig. 8), the temperature-blend
door Bowden cable.
ADJUSTING NUTS
CAM PLATE LOCATING PIN
K 1805- A
FIG. 8-Temperature-Blend Door
Bowden Cable Company,
LLC
Mustang
Woodbridge, VA 22192
www.ForelPublishing.com
4. Connect the vacuum line at the
A/C-heat door vacuum actuator.
5. Position the heater-air condi-
tioner assembly to the dash and in-
stall the mounting nuts.
6. Install the defroster nozzle, the
speaker and speaker grille.
7. Install the instrument panel
upper and lower supports.
8. Install the defroster plenum
and connect the red vacuum line to
the heat-defrost door vacuum actu-
ator.
9. Connect the wires to the resistor
block and thermostatic switch.
10. Install the right hand fresh air
duct and the vacuum actuator and in-
stall the white vacuum line to the
actuator.
11. Install the glove box liner and
install the 3 plenum to instrument
panel air ducts.
12. Position the rubber seals and
connect the heater hoses.
13. Install the evaporator case
drain hose.
14. Connect the compressor-to-
evaporator hose at the dash and in-
stall the expansion valve temperature
sensing bulb.
15. Connect the receiver to eva-
porator hose at the dash and install
the seal and temperature bulb insula-
tion.
16. Fill the cooling system.
17. Leak test, evacuate and charge
the air conditioning system.
18. Check the operation of the
system.
EVAPORATOR CORE
1. Remove the heater air-condi-
tioner assembly (in this section), and
place it on a bench.
2. Remove the thermostatic switch
from the evaporator.
3. Separate the heater housing
from the plenum.
4. Remove the evaporator core
from the housing.
5. Transfer the mounting bracket
and rubber pad to the new evapor-
ator.
6. Install the evaporator in the
plenum.
7. Position the plenum to the
housing and install the mounting
screws, clips, resistor block wires
and seal and retainer.
8. Install the heater-air condi-
tioner assembly (in this section).
HEATER CORE
1. Remove the heater air condi-
tioner assembly (in this section), and
place it on a bench.
2. Separate the heater housing
from the plenum.
3. Slip the heater core out of the
p:enum.
4. Transfer the heater core seal
from the old core to the new core.
5. Slip the new core with seal into
the plenum.
6. Install the plenum to the heater
housing. Connect the wires at the
resistor block, and install the seal
and retainer at the evaporator tubes.
7. Install the heater-air condi-
tioner assembly (in this section).
EXPANSION VALVE
1. Discharge the air conditioning
system.
2. Remove the insulation and re-
move the sensing bulb from the com-
pressor to evaporator line.
3. Disconnect the expansion valve
from the evaporator and disconnect
the valve from the valve to con-
denser line.
 PART 16-3-AIR CONDITIONING-SELECTAIRE
4. Position and connect the new
valve to the evaporator.
S. Connect the condenser to valve
line to the valve.
6. Install and insulate the sens-
ing bulb.
7. Leak test, evacuate and charge
the system. Check the system opera-
tion.
BLOWER MOTOR SWITCH
1. Remove the air conditioning
plenum to center register air duct.
Disconnect the plenum to right regis-
ter air duct at the plenum and posi-
tion it out of the way.
2. Remove the switch knob. Re-
move the switch mounting screw re-
taining the switch to the control
assembly and lower the switch.
3. Disconnect the wires from the
switch and remove the switch.
4. Connect the wires to the new
switch and install it in the control
assembly.
S. Install the two air ducts.
6. Install the switch knob and
check the operation of the switch.
BLOWER MOTOR
1. Remove the glove box.
2. Remove the right hand fresh
air duct and vacuum actuator as-
sembly. Disconnect the vacuum line
from the actuator and position it out
of the way.
3. Disconnect the plug from the
resistor block and remove the resis-
tor block.
4. Remove the blower motor
cover and remove the motor and
blower wheel.
S. Remove the blower wheel and
install it on the new motor.
6. Install the motor and wheel
and ground wire in the heater case.
Install the blower cover.
7. Install the resistor blo.::k to
the plenum and connect the wires.
Check the blower operation.
8. Install the fresh air duct and
vacuum actuator.
9. Install the glove box.
A/C-HEAT DOOR VACUUM
ACTUATOR
1. Remove the glove box liner.
2. Remove the vacuum line at the
actuator, and remove the defroster
plenum chamber.
3. Remove the instrument panel
lower and upper support.
4. Remove the speaker grille, the
speaker mounting screws, and posi-
tion the speaker out of the way.
5. Remove the defroster nozzle.
Forel Publishing Company, LLC
Woodbridge, VA 22192
www.ForelPublishing.com
16-25
6. Disconnect the AIC plenum to
right hand register air duct at the
plenum and position it out of the
way.
7. Disconnect the vacuum line
from the actuator, remove the act-
uator mounting screws, disconnect
the actuator to door lever arm at the
lever and remove the actuator.
8. Install the new vacuum actua-
tor and connect the actuator arm
and vacuum line.
9. Connect the right hand regis-
ter air duct.
10. Position and install the de-
fro:;ter nozzle.
11. Install the speaker and speaker
grille.
12. Install the instrument panel
upper and lower support.
13. Connect the red vacuum line
to heat-defrost door vacuum actua-
tor.
14. Install the glove box liner.
HEAT-DEFROST DOOR
VACUUM ACTUATOR
The defrost door vacuum actuator
may be replaced after first removing
the defroster plenum from the heat-
er assembly.
After installing the new actuator,
check its operation for full travel
of the air door.
16-26

PART RADIO
16-4
Section Page
Description and Operation ................ 16-26
Cars and Radio Types ................... 16-26
2 Diagnosis and Testing ................... 16-26
Radio Diagnosis Guide .................. 16-26
3 Common Adjustments and Repairs ........ 16-27
Push Button Adjustment-Comet, Falcon
and Fairlane ......................... 16-27
Section Page
4 Removal and Installation ................. 16-27
Radio Receiver ......................... 16-27
Antenna-Comet, Falcon, and Fairlane ..... 16-27
Front Speaker-Falcon and Fairlane ....... 16-28
Rear Speaker ........................... 16-28
Interference Suppression ................. 16-28

D DESCRIPTION AND OPERATION

CARS AND RADIO TYPES On the Comet and Mustang, a
band selector switch is provided for
Car Manufacturer Model selection of either the AM or the FM
and Type No. broadcast band. The five push but-
tons can be preset to select five AM
stations or five FM stations or any
Comet Philco AM 6TPE combination thereof, however, the
Bendix AM-FM F6TBG push buttons cannot be used to
change from one broadcast band to
Falcon Philco AM 6TPD the other. The band selector switch
must first be positioned to the de-
Fairlane Philco AM 6TPO sired band before selecting stations
with the push buttons. When select-
ing stations with the manual tuning
Mustang Philco AM 6TPZ control, the band (AM or FM) in
Forel Publishing Company, LLC
use is controlled by the band selector
The antenna is mounted on the On Woodbridge,
all cars exceptVA
the22192
Comet the push switch, if the band selector switch is
right fender. A rear seat speaker is www.ForelPublishing.com
buttons on the AM-FM radio may be set to AM, the manual tuning con-
available. The radios have push but- divided between AM and FM sta- trol (right hand knob) will select
ton tuning as well as manual tuning. tions. AM stations.

EJ DIAGNOSIS AND TESTING

RADIO DIAGNOSIS GUIDE

NO RECEPTION 1. Burned out fuse. substitute a known good antenna and

2. Defective antenna.
3. Shorted speaker lead or defec-
tive speaker.
4. Reversed battery polarity.
Make certain that voltage is avail-
able at the A lead (12 volts), then
speaker.
Be sure to tum off the radio re-
ceiver before removing or installing
the speaker.
If the radio still will not play, re-
move the receiver for a major repair.

NOISY OR ERRATIC NOISY RECEPTION-ENGINE 3. Receiver not properly grounded

RECEPTION NOT RUNNING to the instrument panel.
1. Loose connections.
NOISY RECEPTION-CAR IN
NOISY RECEPTION-ENGINE MOTION
RUNNING 1. Loose or broken lead-in cable.
1. Defective suppression equip- 2. Loose or defective radio an-
ment. tenna.
2. Suppression condensers not 3. Defective wheel static collector.
properly grounded.

CONTINUED ON NEXT PAGE


RADIO DIAGNOSIS GUIDE-(Continued)
DISTORTED OR GARBLED
SOUND
WEAK RECEPTION
NO SOUND FROM
ONE SPEAKER
TESTING
Tests for any of the components
in the radio system may be made by
substituting known good parts. In
the case of an antenna or speaker,
EJ COMMON ADJUSTMENTS AND REPAIRS
PUSH BUTTON ADJUSTMENT-
COMET, FALCON AND
FAIRLANE
Turn the radio on, and allow it to
warm up for 15 minutes. Extend the
antenna to a height of approximately
33 inches.
AM PUSH BUTTONS
Place the band selector switch to
the AM position. Pull out the push
button to be set to unlock the push
button mechanism. The letters AM
must appear at the top of the push
button face. If the letters FM appear,
a REMOVAL AND INSTALLATION
RADIO RECEIVER
REMOVAL
To remove the radio receiver,
proceed as follows:
1. Pull the radio control knobs
off and remove the nuts and washers
retaining the radio to the instrument
panel.
2. Disconnect the antenna lead at
the right side of the radio (at the
back of the AM-FM radio).
3. Disconnect the speaker lead.
4. Disconnect the radio lead wire
and the pilot light wire from the
quick disconnects.
S. Remove the radio support
bracket to radio retaining nut.
PART 16-4-RADIO
1. Voice coil rubbing on center
pole piece of speaker magnet.
2. Torn speaker cone.
3. Foreign material on cone.
1. Poor adjustment of the antenna
trimmer (AM only).
2. Beyond normal reception dis-
tance from station (FM only).
1. One speaker defective.
2. Wiring to dead speaker defec-
it will not be necessary to remove
the suspected antenna or speaker.
Disconnect the antenna or speaker
at the radio and plug in the known
good unit. Check the antenna with
pull the push button out approxi-
mately 1 /to inch further until the push
button is free to rotate and rotate
the push button 180° to the AM po-
sition. Carefully tune in the desired
AM station with the manual tuning
Forel Publishing Company, LLC
knob. After the station is clearly
Woodbridge,
tuned in, push the buttonVAstraight
22192 in
www.ForelPublishing.com
until it stops and then release it. Re-
peat this procedure for the remain-
ing buttons.
FM PUSH BUTTONS
Place the band selector switch to
the FM position. Pull out the push
6. Remove the radio assembly
from the instrument panel.
INSTALLATION
1. Position the radio to the instru-
ment panel, and then install the
washers and retaining nuts at the
knob shafts. Be sure that the radio
mounting stud enters the support
bracket.
2. Install the radio support
bracket retaining nut. Torque all
mounting nuts to specification.
3. Connect the antenna lead to
the radio.
4. Connect the radio speaker lead.
S. Connect the radio power lead
and the pilot light lead.
16-27
4. Bent or twisted speaker
mounting.
Be sure to tum off the radio re-
ceiver before removing or installing
the speaker.
3. Defective antenna. If FM re-
ception is poor, be sure that the an-
tenna is at 30 to 32 inch height be-
fore trying a new antenna.
tive. Operate the fader to determine
the speaker at fault.
the car outside of the garage. Plug
the antenna lead into the antenna
socket in the radi"9, and extend the
antenna wand through the open
window of the car.
button to be set to unlock the push
button mechanism. The letters FM
must appear at the top of the push
button face. If the letters AM ap-
pear, pull the push button out ap-
proximately 1 /10 inch further until
the push button is free to rotate and
rotate the push button 180° to the
FM position. Carefully tune in the
desired FM station with the manual
tuning knob. After the station is
clearly tuned in, push the button
straight in until it stops and then re-
lease it. Repeat this procedure for
the remaining buttons.
6. Install the radio control knobs.
7. Check the radio operation.
ANTENNA-COMET, FALCON
AND FAIRLANE
1. Disconnect the antenna lead
from the side of the radio receiver
(at the back of the AM-FM radio).
Tie a string to the end of the an-
tenna lead.
2. Remove the antenna cap, four
screws, and remove the antenna as-
sembly.
3. Tie the string to the new an-
tenna lead.
4. Position the antenna assembly
 16-28 GROUP 16- VENTILATING, HEATING, AND ACCESSORIES

in the opening, put the spacer in
position on the antenna and install
the antenna.
5. Pull the antenna lead through
the opening and route the lead un-
der the glove box and connect the
lead to the radio.
FRONT SPEAKER-FALCON
AND FAIRLANE
1. Disconnect the speaker wires
from the radio receiver.
compartment. On the station wagon denser is an internal part of the al-
the speaker is mounted on the left terference suppression items used on
rear trim panel. Remove the trim denser, and wheel static collectors
panel to replace the speaker. are also used. A constant voltage
regulator choke and a hood bonding
INTERFERENCE SUPPRESSION clip are used on the Comet only. In-
Interference suppression items are terference suppression items used on
shown in Fig. 1. An alternator con- the Fairlane are shown in Fig. 2.
INNER HUB CAP

2. Remove the glove box.

3. Remove the speaker retaining
nuts and remove the speaker through
the glove box opening.
SPRING ASSEM&j<~',
WHEELSTATIC I 111 I
COLLECTOR '1 i 1

4. Install the new speaker through 18938 - A I -- - ----~

the glove box to the instrument ----A-Tu '-=---
·:·
panel and secure it with retaining I

--~~
nuts.
5. Connect the speaker leads to 8 CYL. INSTALLATION
the radio and check the radio opera- BEND COTTER KEY AWAY
tion. FROM SPINDLE CENTER
HOLE SO IT WILL NOT
6. Install the glove box. INTERFERE WITH
STATIC COLLECTOR

REAR SPEAKER K 1494 .c

The rear seat speaker is accessible

for replacement from the luggage FIG. 1-Radio Interference Suppression-Except Fairlane

/.·
Forel Publishing Company,
r~~-\
LLC .L l
BEND COTTER KEY AWAY FROM
Woodbridge, VA 22192 SPINDLE CENT ER HOLE SO IT
I ii WILL NOT INTERFERE WITH
www.ForelPublishing.com
Ii STATIC COLLECTOR
ii
il
ti I

.30
LOCATION OF R.H. HOOD I ~~:~~ ~~'C~:c~L;o~
•",~:~,. •~@;;}~/""'~
11

~~ ~
BONDING STRAP L.H. SYM. OPP.

CONDENSER - 18832 - A
lil
l H ; 'I
INSTALLATION OF RADIO CONDENSER i II
ON BOTTOM OF VOLTAGE REGULATOR ASSEMBLY INSTALLATION OF STATIC COLLECTOR
6 & 8 CYLINDER CYL. ENGINES
FOR 6 & 8 CYLINDER ENGINES
Kl560-C

FIG. 2-Fairlane Radio Interference Suppression

 16-29

PART SPECIFICATIONS
16-5
AIR CONDITIONER COMPRESSOR
Blower Motor Air
Current Draw Heater Conditioner Torque (ft-lbs)
at 12 Volts Location York
High Speed 6-8 Amps 6.5-7.5 Amps Cylinder Head 14-18
Medium Speed 4-6 Amps 4.5-5.5 Amps Front Seal Plate 13-17
Low Speed 2-4 Amps 3.0-4.0 Amps Service Valves (Rotolock)
I
35-Max.
Mounting Bolts 14-17
CIRCUIT
PROTECTION SFE 14 Fuse 3AG 15 Fuse Oil Filler Plug 18-22
Location Fuse Panel In Line Clutch Mounting Bolt 15-22

RADIO CURRENT DRAW Base Plate 7-11

Back Plate 7-10
1 Amp Max. at 12 Volts Oil Capacity- 3AI inch (10 ounces)
Use Suniso #5, or Capella E
MOUNTING TORQUE (in-lbs)
Radio to Instrument Panel 30
Support Bracket Screw and Nut 30 DRIVEN BELT TENSION
Antenna Mounting Nut 15
Between Fan Pulley and Air Conditioner Compressor
All Engines ..................................... New 120-15(
MAGNETIC CLUTCH CURRENT DRAW Forel Publishing Company, LLC Usecl<D 90-120

1-2 Amperes at 12 Volts Woodbridge, ©Belt

VA 22192operated for a minimum of 10 minutes is considered a used
belt.
www.ForelPublishing.com
 17-1

BODY, DOORS GROUP

AND WINDOWS 17
PART 17·1 PAGE PART 17·3 PAGE
G ENERAL BO DY SERVICE ... 17-1 DOORS, WIN DOWS, TAILGATE
A ND DECK LID ........... . . . 17-30
PART 17-2
FRONT SH EETMETA L, BUMPERS,
EXTERIO R M O ULDINGS .......... 17-1 1

PART GENERAL BODY SERVICE

17-1
Section P age
I Diagnosis and Testing . .......... . . .. ......... 17-1
Dust and Wa ter Leaks ... . .............. ... . 17-1
2 Common Adjustments and Repairs . .. .......... 17-1
Types of Sealer and Application . . ........... 17-1
Body Alignment ...... ........ . ............ 17-3
Section Page
Paint Refinishing .. . ...... . .. ........ ...... 17-4
3 Cleaning and Inspection ...................... 17-8
Care of Wood Grain Paneling ........ ..... .. 17-9
4 Hoisting ................................ . ... 17-1 0

D DIAGNOSIS AND TESTING

DUST AND WATER LEAKS
Sealer locations should be consid-
ered when checking for dust or water
leaks. T he forward motion of the car
creates a slight vacuum within the
body, particularly if a window or
ventilator is panially open. Any un-
sealed small opening in the lower
section of the body will permit air
to be drawn into the body. If dust is
present in the air, it will follow any
path taken by the air from the point
of entry into the passenger and lug-
gage compartments. Opening the
ventilator air ducts will equalize
these pressures. Dust accumulates in
the rocker panel. and may eventually
work its way to the kick-up or the
rear body pillar, and follow the con-
tour of the wheelhouse into the lug-
gage compartment.
To eliminate dust leakage, deter-
mine the exact point at which the
dust enters. The point of entry is
often deceptive in that the
Forel Publishing dust may
Company, LLC
enter at one point, then follow the
Woodbridge, VA 22192
passages formed by interior trim to
www.ForelPublishing.com
another point.
· Under certain conditions, water
can enter the body at any point
where dust can enter. Any considera-
tion of water leakage must take into
account all points covered under
dust leaks.
To determine the exact location of
a dust leak, it may be necessary to
remove the following trim from the
car :
1. Cowl trim panel.
2. Quarter trim panel.
3. Rear seat back and seat cush-
ion.
4. Luggage compartment floor
mats, spare wheel, and side trim
panel.
S. Center pillar trim on 4-door
models.
6. Scuff plates.
After removing the trim, the loca-
tion of most leaks will be readily
evident. The entrance of dust is usu-
ally indicated by a pointed shaft of
dust or silt. Seal these leaks, and road
test the car on a dusty road to make
sure that all leaks are sealed.
After the road tests, check for indi-
cations of a dust pattern around the
door openings, cowl panel, lower
part of the quarter panel, and in the -
luggage compartment.
Sometimes leaks can be located by
putting bright lights under the car,
with the above components removed,
a nd checking the interior of the
body joints and weld lines. T he light
will show through where leaks exist.

EJ COMMON ADJUSTMENTS AND REPAIRS

TYPES OF SEALER
AND APPLICATION
The all-purpose sealers described
below have been selected for service
use. The method and points of appli-
cation are given under each sealer
type.
CAULKING CORD A B19560-A
This sealer has a plastic base with
an asbestos filler, is heavy bodied,
and is commonl y known as perma-
gum. 1t is used on spotweld holes,
around moulding clips, or between
two surfaces not properly sealed by
a gasket. Apply the sealer with a
putty knife.
 c

42.76-
SEDANS

28.38 42.30-
MODEL-
STATION
WAGON
Q
166.76- MODEL-SEDANS _.,
173.52- MODEL-STATION WAGON
0
c.,,
...
~
I
l...,..___ _ _ _ _ _ _ _ 58.50---------------35.50-----..---------68.92-MODEL-SEDANS - - - - - - - - - =
0
c
75.88- MODEL-STATION WAGON :<
PLAN
Forel VIEW
Publishing Company, LLC c
Woodbridge, VA 22192 0
0
www.ForelPublishing.com
NOTE: DIAGONAL DIMENSIONS MUST BE EQUAL , ::IC
""'
DIMENSIONS UNDER 100" HAVE A >
:z:
VARIATION OF ±0.06• EXCEPT AS
NOTED BY ASTERISK.
c
UPPER SUSPENSION REAR MOUNTING HOLE DIMENSIONS OVER 100" HAVE A :E
VARIATION OF ± 0.12 •. z
c
UPPER SUSPENSION *VARIATION OF ±0.02' ALLOWED. 0
:E
""'
REAR BUMPER MOUNTING HOLE

10.80 MODEL -
IDLER ARM BRACKET MOUNTING HOLE (R.H. SIDE) SEDANS
9.30 MODEL-
STATION

SIDE VIEW N1361-A

FIG. 1-Comet and Falcon Underbody Dimensions

 PART 17-1- GENERAL BODY SERVICE
33.40
FRONT BUMPER
MOUNTING HOLE 12.04
REAR ATTACHING HOLE
FOR IDLER ARM MOUNTING
TRIM CEMENT C2AZ-19C525-A
This cement is recommended for
instrument panel safety cover and
body panel plastic water shield in-
stallation. It is also useful for repair
or replacement of other vinyl and
rubber trim.
RUBBER CEMENT SA-19552-B
This quick-drying, strong adhe-
sive material is designed to hold
weatherstripping on doors, bodies,
deck lids, cowl ventilators, and the
surrounding metal. Windows and
windshields which are set in rubber
can be effectively sealed against
leakage by flowing cement into the
affected areas.
Clean all grease, dirt, and old
sealer from the surfaces to be ce-
mented. For best results, apply a
medium coat of cement to both sur-
faces, allow it to dry until tacky,
and press both surfaces firmly to-
gether.
Sil.ICON LUBRICANT
COAZ-19553-A (JELLY) AND
COAZ-19553-C (SPRAY)
This lubricant is to be used on the
door window weatherstrips. It is rec-
HOISTING PADS
II II
II II
II II
a--i\<in'
II II
II :: 109.47
...--lHr'
II II
II::
43 00 II 11 46.36
. ~:::
DATUM LINE
Forel Publishing Company, LLC
ommendedWoodbridge,
that siliconeVA lubricant
22192
www.ForelPublishing.com
be applied to the upper weather-
strips at every regular lubrication
period. Its use makes the doors
easier to close, avoids weatherstrip
squeaks, retards excess weatherstrip
wear from chafing between the
door glass upper frame and the
weatherstrip, and helps to retain
door window alignment by reduc-
ing friction between the glass frame
and rubber weatherstrip.
BODY ALIGNMENT
Servicing the unitized body should
present no unusual difficulties or
necessitate additional equipment
other than that required for the
conventional frame and body repair.
The application of heat and the use
of heavy-duty jacks must be care-
fully controlled because of the dif-
ference in the gauge of the metal
in the sub-frame of a unitized body
and the stress points developed in a
single welded unit construction. It
is possible to pull damaged areas
back into alignment with the use
of light-weight jacks and hydraulic
equipment without heating the
metal.
17-3
? ----------n
---::~~;;~";~~~~~~~/~~~~~~~=~~~=
I
II 11
II
~
,Al
II M
:: . 87.71-STATIONWAGON
± .09
II
II
81.62-SEDAN
42.10
II
II
II,1
11•
T
::1
REAR BUMPER MOUNTING HOLE
Rl205-B
Rough out badly damaged areas
before taking measurements for
squaring up a body. If necessary,
remove the glass from the damaged
area to prevent damage. In severe
cases reinforcement brackets and
other inner construction may have
to be removed or cut to permit
restoration of the outer shell and
pillars without excessive strain on
the parts. Straighten, install, and se-
cure all such parts in place before
attempting to align the body.
In cases of severe or sharp bends,
it may be necessary to use heat.
Any attempt to cold-straighten a
severely bent bracket may cause
ruptures of the welds and may also
cause cracks in the bent part. Never
heat the area more than a dull red.
CHECKING BODY FOR
MISALIGNMENT
To align or square up a body, take
two opposite diagonal measurements
between pillars. Use a measuring
tram for these measurements. Take
the measurements between reference
points such as crease lines or weld
joints which are diagonally opposite
each other on the two pillars being
17-4 GROUP 17 - BODY, DOORS AND WINDOWS
measured. Since all measurements
should be made from the bare metal,
remove all interior trim from the
checking points.
In some cases, it is difficult to ob-
tain proper body alignment when
repairing a body that is damaged
on both sides. In these cases, hori-
zontal and vertical measurements
can be taken from a body of the
same body style. Once these basic
dimensions are taken and established
on the damaged body, alignment can
be made by diagonal measurements
taken from points on the two pillars.
Do not attempt to correct any
serious misalignment with one jack-
ing operation. This is particularly
true if other sections of the body
also require aligning. Align each
section proportionately until the
proper dimensions are obtained.
Door openings are checked in the
same manner as the body. Horizon-
tal, vertical, and diagonal checking
points are established on all four
sides of the door opening that is
being measured.
CHECKING UNDERBODY FOR
MISALIGNMENT
The dimensions of the underbody
must be restored in the repair of
major body damage, to provide cor-
rect front and rear wheel geometry
(Figs. I, 2 and 3). All the dimen-
sions are detailed to the center line
of existing holes in the underbody
assembly. Once the frame and sus-
pension members are aligned, the
balance of the repair can be per-
formed.
PAINT REFINISHING
PAINT DAMAGES AND
PROCEDURES FOR REPAIR
Paint Repairs on Galvanized
Metals. Jf for any reason it becomes
necessary to perform paint repairs on
galvanized rocker panels or any
other galvanized steel surfaces, care
must be exercised in preparing the
bare galvanized surface to properly
accept paint, and the best possible
paint products must be employed
to insure satisfactory adhesion to the
metal and to give a good color match
with acceptable durability. Most of
the approved paint suppliers for re-
finishing materials agree on the pro-
cedure for metal preparation but use
different primer recommendations.
The methods involving the use of
DuPont Preparakote and Ditzler Zinc
Dust Primer are indicated here and
it is important that either one be
employed exactly as directed. No
short cuts nor any inter-mixing
should be attempted.
MET AL PREPARATION FOR
GALVANIZED STEEL
1. Strip, sand-off or otherwise re-
move all paint from the affected
galvanized steel panel.
2. Wire-brush or steel-wool the
entire metal surface and remove all
grease or oil by wiping with a clean
solvent.
3. Wipe the panel using a clean
cloth or sponge with Lithoform No.
2 (Distributed by the Neilson Chemi-
cal Division of Amchem Products,
Inc.) or Bonderite No. 34 (Distrib-
uted by Parker Rustproof). The work
should be kept completely wet for at
least three minutes and the metal
should be thoroughly etched. If any
bright metal remains the treatment
should be repeated.
4. Rinse the area with clean water
and blow off with compressed air.
5. The dried surface must be
primed immediately. Then succeed-
ing coats and color as required must
be applied according to vendor's di-
rections. Examples such as the Du-
Pont and Ditzler systems are given
as follows:
SYSTEM FOR USING DUPONT
Forel Publishing Company, LLC
PREPARAKOTE
Woodbridge, VA 22192
1. Spray Preparakote over prop-
www.ForelPublishing.com
erly prepared metal. Force-dry with
radiant heat or air-dry overnight.
This primer must be dried hard
enough to sand wet or dry.
2. Sand the Preparakote very care-
fully, preferably with No. 400 paper
so as to avoid cutting through to bare
metal. Blow off and tack clean.
3. Spray two coats of No. 22 clear
sealer and allow to air-dry for thirty
minutes.
4. Spray on matching Acrylic Lac-
quer as directed. Then air-dry or
force-dry until the lacquer is hard
enough to be polished.
5. Polish the lacquer as recom-
mended by supplier.
SYSTEM I~OR USING
DITZLER ZINC DUST
PRIMER
1. Prime the galvanized area with
DPE659 Zinc Dust Primer. This is
a two-component product and the
zinc must be carefully mixed with
the vehicle as directed. A recom-
mended film thickness of one mil
may be recoated with a lacquer base
primer surfacer such as DZL3200 in
about twenty minutes. Do not sand
DPE659.
2. Spray primer surfacer DZL3200
reduced as directed to a film thick-
ness of about two mils.
3. After drying the primer surfacer
about thirty minutes, carefully sand
with No. 360 or No. 400 silicon car-
bide paper, wet or dry, so as not to
cut through the zinc dust primer
coat. Blow off and tack clean.
4. Spray matching Duracryl lac-
quers as directed and after drying
rub and polish as required.
All material coatings may be
force-dried. Careful manipulation is
recommended.
Acrylic Enamels. Acrylic enamels
exhibit better hardness, mar resist-
ance and gloss retention in metallic
colors than the ordinary enamels.
Acrylic enamels also possess the
property of good polishability.
Following are recommended re-
pair procedures for acrylic enamels:
Repair By Polishing. Repair of
minor dirt or fallout, sags, mars,
scratches, dry spray, overspray, and
orange peel can be accomplished by
machine or hand polishing or by
both sanding and polishing without
the necessity of repainting. Repairs of
this type should apply to an entire
panel while spot repairs should be
attemped only in isolated areas.
The suggested polish repair pro-
cedure consists of:
1. Remove the defect by oil sand-
ing with 600 grit paper, using water
or mineral spirits as a lubricant.
2. Apply a white or light colored
medium grit machine polishing com-
pound (Sno-Flake No. 16 or equiva-
lent) to the painted surface with a
brush.
3. Polish the entire panel surface
using an 1850 rpm wheel and a car-
pet pad (approximately %-inch nap)
or lambswool pad.
4. Buff the surface with a clean
lambswool pad.
Normally, acrylic enamels do not
need polishing to improve their gloss;
however, the foregoing procedure
can be used to restore the original
luster to the film after weathering,
or to improve the surface smooth-
ness of the finish on the entire car.
Repair By Repainting. Acrylic
enamels can be repaired by repaint-
ing with either conventional air dry-
ing or low bake enamels, or with
acrylic lacquers. When repainting
metallic colors, it is recommended
that acrylic lacquer be used since a
better color match can be obtained;
 "-~-" 37.62
61.55
43.00

~
a'.P ...
~

...
l-+----------73.78 48.50 46.50-----------~
...
'I
I

PLAN VIEW C")

m
:z:
m
NOTE: DIAGONAL DIMENSIONS MUST BE EQUAL. ~
DIMENSIONS UNDER 100" HAVE A VARIATION ,...
>
OF :t 0.06" EXCEPT AS NOTED BY ASTERISK.
Forel Publishing Company, LLC
DIMENSIONS OVER 100" HAVE A VARIATION
=
0
c
Woodbridge,
OF :t 0.12".VA 22192 -<
www.ForelPublishing.com V'\
•vARIATION OF.!. 0.02" ALLOWED. m
~
UPPER SUSPENSION REAR MOUNTING HOLE <
;::::;
m

REAR SPRING
REAR HANGER HOLE

10.68 8.14
1 1

...
BASELINE
SIDE VIEW
N 1391-A

'I
FIG. 3-Mustang Underbody Dimensions I
VI
17-6 GROUP 17 - BODY, DOORS AND WINDOWS
both the original finish and the re-
pair can be polished to provide the
same luster, and the air dry acrylic
repair lacquer will provide better
durability in service than air dry
enamels. Do not use Nitrocellulose
lacquers for exterior repairs.
When using any one of the three
types of repair materials over acry-
lic enamel, remove all traces of wax,
polish or grease with a gocxl silicone
remover such as DL-60-3721-A. It
is extremely important that a thor-
ough sanding of the original finish
be accomplished using No. 400 grit
paper. Care should be exercised to
insure that all surfaces, including
edges and areas adjacent to applied
mouldings, are thoroughly sanded in
order to provide adhesion of the re-
pair top coat. Areas sanded to the
base metal (cut through) should be
treated with an acid cleaner such as
Metalprep (distributed by Amchem
Products Inc.). Follow the directions
of the supplier as stated on the con-
tainer.
After sanding, proceed with the
application of a primer surfacer re-
duced according to the supplier's
recommendations to any bare metal
spots that have been exposed. After
the recommended air dry time, sand
the primer surfacer with No. 400
grit paper before application of the
repair material. The lacquer or
enamel used should be reduced as
recommended by its supplier.
PAINT DEFECTS AND REPAIR
PROCEDURES
Listed here are some of the ab-
normal paint conditions that may be
encountered (Fig. 4). It is very im-
portant to identify the paint condi-
tion correctly so that the proper
repair procedure may be followed.
For each of the following paint con-
ditions described, the recommended
repair procedure will be indicated.
BLISTERING
Blistering is the formation of bub-
bles or pin points on the surface of
the finished work. Unless inspected
by a magnifying glass, this condition
is very hard to identify. In some in-
stances, this complaint may be con-
fused with dirt in the paint. To
verify blistering, prick the suspected
areas, and note whether a hole exists
under the bubble. This condition is
caused by rust, moisture, or oil be-
tween the coats, metal not properly
cleaned, or uneven temperatures
between the metal and the paint
being sprayed.
Acrylic Enamel. Repair by re-
painting (color coat). Priming pro-
cedure must first be followed if
defect is due to poor metal prepara-
tion.
CHECKING
Line checking has the appearance
of thin, straight lines criss-crossing
each other. These lines may be from
one-half inch to four inches or long-
er, increasing in length as the finish
ages.
Acrylic Enamel. Refinish panel.
(Color coat-primer if damaged.)
CHIPPING AND
STONE BRUISES
Chipping occurs when the surface
of the finish coat of paint has been
broken by a sharp blow, and small
particles of paint have flaked off.
Frequently, stone bruises result in
chipping.
Acrylic Enamel. Refinish panel.
Paint may be spotted if in isolated
areas. (Prime to be bare metal.)
CRACKING
Cracking is evidenced by the
paint curling. Frequently, cracking
starts at the edge of the panel. This
is caused by poor mixing of paint
or by temperature changes during
Forel
the Publishing Company,
various painting stages.LLC
Acrylic Enamel.
Woodbridge, Refinish panel.
VA 22192
(Prime if both color and primer
www.ForelPublishing.com
cracking.)
CROW FOOTING
Crow footing may be described
as small lines branching off from
a point in all directions and giving
the appearance of a crow's foot.
Crow footing is usually caused by
spraying a second coat before the
first coat is dry, by spraying an ex-
cessively thick coat, or by thinners
which evaporate too fast.
Acrylic Enamel. Refinish panel.
(Color coat.)
DIRT IN PAINT
Patches where dirt appears are
sometimes confused with blistering.
To vertify the condition, prick the
suspected areas, and note whether
there is foreign material under the
surface.
Acrylic Enamel. Refinish panel.
procedure will be effective in most
cases. (Color coat.)
MILDEW
Mildew growth which occurs
along radial lines is most common-
ly found in a very dark gray or
black color.
Acrylic Enamel. Repair by polish-
ing.
OFF-COLOR
The term off-color is applied to
adjacent areas on which the colors
do not match. It may also appear
when making spot repairs.
Acrylic Enamel. Refinish panel
if polishing does not correct condi-
tion (Color coat.)
ORANGE PEEL
Orange peel is a term used to
describe an uneven, mottled appear-
ance on the paint surface. This is
usually caused by improper thin-
ning of the paint.
Acrylic Enamel. Refinish panel if
polishing does not correct condition.
(Color coat.)
OVERSPRAY
Overspray is evidenced by a
rough, dull finish in the area sur-
rounding the paint repair.
PEELING
Peeling occurs when large areas
of the finish or primer coat separate
from the metal or prime coat. This
is usually caused by wax, grease,
rust or oil under the paint. Do not
confuse with orange peel.
PITS AND POP-UPS
Pits and craters may be identified
by the appearance of small round
depressions in the paint. These may
be caused by not allowing the first
coat ot dry sufficiently before apply-
ing the second coat or from failure
to remove silicone polishes before
repainting.
Acrylic Enamel. First use polish
repair procedure refinish panel if
necessary. (Color coat.)
THIN PAINT
The primer will show through
the finish coat as a result of an ex-
cessively thin color coat, or applica-
tion of the color coat before the
surface is dry.
Acrylic Enamel. Refinish panel.
(Color coat.)
RUNS AND SAGS
The uneven collections of paint
on the finish surface are referred to
as runs and sags. The collections
may appear in the form of tear
drops or sagging lines. Usually these
lines are quite soft and sometimes
they may be wrinkled. This is usually
 PART 17-1- GENERAL BODY SERVICE 17-7

,
.
_,,,·
___ , ..
/ ,
,,,,,,.~

'/,,,,. ..
.,.. .
.......

}
.' ..
'
.. .. ("' '· ·, ... , .. -~,,
,_'._...:-:..~ \ It;:... "':"
.-·- .-
; ' ..':\'' ...'-~-·- ...
,.-.. ;.
I, -

RANDOM BLISTERS CRO WFOOTING PITS AND POP-UPS SCRA TCHE S

• - -
: .. • !

.. .... . ··-
PATTERN BLISTERS DIRT IN PAINT CRAT ERS WATER SPOTTING

.. ·,
1• '.

~
.. .·..
~ ~

. , • r
LIN E CHECKING MILDEW THIN PAINT INDUSTRIAL FALL · OUT

Forel Publishing Company, LLC

.-
Woodbridge, VA 22192
www.ForelPublishing.com

CHI PPING OFF COL OR RU NS AN D SAGS ORGANIC F AL L -OUT

-~

BRUISES ORANGE PEEL PEELING

!::~·· •• · ....... ·, .

CRACKING OVERSPRA Y
N-1471-A

FIG. 4 ....Paint Defects

17-8 GROUP 17 - BODY, DOORS AND WINDOWS
caused by over-application of paint
or hesitation in the stroke of the
gun.
Acrylic Enamel. Use polish re-
pair procedure.
SCRATCHES
Scratches are thin marks or tears
that may partially or completely
penetrate the surface of the finish
coat of paint.
Acrylic Enamel. Use polish re-
pair procedure for shallow penetra-
tion. Refinish panels to correct con-
ditions of deep penetration.
SPOT DISCOLORATION
This is evidenced by brown spots
or stains on the surface. Stains or
spots can be caused by road tar, acid
or alkali-bearing water from the
streets.
Acrylic Enamel. Use polish re-
pair procedure.
WATER SPOTTING
Water spotting is evidenced by a
milky pattern where water drops
have fallen.
Acrylic Enamel. Use polish re-
pair procedure.
INDUSTRIAL FALL-OUT
Industrial fall-out is the result of
Forel
particles being exhausted into the
air by the various processes of heavy
industry, or in areas where there is
a concentration of industry.
Industrial fall-out particles appear
to the eye as tiny rust-colored dots
on the paint film and the surface
will feel rough to the touch. Some
of the particles have excellent ad-
hesion and are difficult to remove.
However, the following procedure
has proven effective in the removal
of this fall-out.
1. Wash the car with car wash
compound (COAA-19B52 l-A) to re-
move loose soil. Rinse well and
examine the painted surfaces for
iron base fall-out particles. If there
EJ CLEANING AND INSPECTION
FLOOR PAN PLUGS
AND GROMMETS
The floor-pan plugs seal the vari-
ous access holes. If any plugs are
missing or improperly installed, a
dust or water leak may result. This
also applies to the grommets used
on the dash panel. When dust or
is a significant quantity of fall-out
not removed by ordinary washing,
the oxalic treatment should then be
used. All cracks, ledges, grooves,
etc., where fall-out has accumulated
should be cleaned by wiping or by
air blow-off.
2. Dissolve six to eight ounces
of oxalic acid (dry) in one gallon
of warm water and add one or two
tablespoonsful of a non-alkaline de-
tergent such as car wash compound
(COAA-19B521-A). This acid deter-
gent solution must be prepared and
kept in a clean NON-METALLIC
container.
Apply this solution liberally to all
affected surfaces of the car with a
large sponge. Use a broad wiping
stroke and keep the work completely
wet for about 15 minutes, or until
the operator can no longer feel any
surface roughness or isolated gritty
particles with bare or gloved finger
tip. If this is not done thoroughly,
rust staining may soon redevelop.
Be sure that the entire acid cleaning
procedure is performed in a shel-
tered area so that the work will be
kept as cool as possible to prevent
rapid evaporation of water and con-
sequent surface drying. Do not work
in the sun.
3. Rinse with clear water. This
mustPublishing
be done Company,
very thoroughly
LLC to
prevent possible corrosion.
Woodbridge,
No traces of VAacid22192
should be left
www.ForelPublishing.com
on any surface. Bright trim parts,
particularly anodized aluminum
and stainless steel, may be stained
by prolonged contact with the
cleaning solution. Painted areas
also can be spotted by prolonged
exposure. It is also important to
keep the oxalic acid cleaner solu-
tion from leaking to the inside of
the car because some fabrics might
be bleached or discolored by the
solution.
If the fall-out is not completely
removed or is deeply imbedded in
the paint film, cleaning with the
acid detergent mixture must be
water leaks are evident, these plugs
and grommets should be checked
for proper installation.
DRAIN HOLES
Drain holes or valves located on
the underside of each rocker panel,
quarter panel, and door should be
repeated. This may be aided by
using a fine scrub brush, possibly
a nylon bristle type. Make sure
that the light scrubbing required
does not scratch the paint. It is
sometimes helpful to briskly rub
the work with a mixture of equal
parts of oxalic acid cleaner and
FoMoCo cleaner wax polish (SA-
19519-A) using a piece of heavy
toweling. Again, a thorough water
rinsing is extremely important.
Sometimes small black spots re-
main after the oxalic cleaning has
removed all iron based fall-out. Such
deposits might be asphaltic or they
might be over-spray. These usually
can be removed by rubbing vigor-
ously with a cloth saturated with a
mixture of kerosene and Actusol
(about five parts of kerosene to one
part of Actusol). Any residue of this
solvent mixture may be readily flush-
ed off with water.
ORGANIC FALL-OUT
Organic fall-out may result from
parking cars under trees or from
the air under certain atmospheric
conditions.
Acrylic Enamel. Refinish dam-
aged panels. (Color coat and
primer.)
INTERIOR PAINT REPAIRS
The proper matching of colors
can be obtained if the following
procedures are carefuly adhered to:
1. Clean the surface to be painted
with wax and silicone remover.
2. Feather-edge the damaged area
with 400 grit wet or dry sandpaper.
(Prime all areas of bare metal with
M-6J-12S Primer.)
3. Mix the paint per instructions
on the can and spray several light
coats.
Allow the paint to become tacky
between coats.
4. Spray the entire area sparingly
with B7 A-645-S Lacquer Leveler
which will blend the repaired area
with existing painted surfaces.
cleared periodically.
BODY MAINTENANCE
Regular body maintenance pre-
serves the car's appearance and re-
duces the cost of maintenance dur-
ing the life of the car. The follow-
ing steps are suggested as a guide
 PART 17 - 1 - GENERAL BODY SERVICE
for regular body maintenance:
1. Vacuum the interior thorough-
ly and wash the car.
2. Check all openings for water
leaks, and seal where necessary.
3. Cement all loose weatherstrips
which are still usable.
4. Replace all door and deck lid
weatherstrips which are unfit for
service.
5. Apply silicone lubricant to the
weatherstripping.
6. Replace all cracked, fogged,
or chipped glass.
7. Align the hood, doors, and
deck lid if necessary.
8. Inspect the windshield wiper
blades and replace them if necessary.
9. Tighten the sill plate and gar-
nish moulding screws.
10. Clean the seats, door trim
panels, and headlining.
11. Touch up or paint chipped
or scratched areas.
12. Drain holes located on the
underside of each rocker panel,
quarter panel, and door, should be
cleared periodically.
RATTLE ELIMINATION
Most rattles are caused by a loose
bolt or screw. Foreign objects such
as nuts, bolts, or small pieces of
body deadener in the door wells,
pillars and quarter panels are often
the source of rattles. Door wells can
be checked by carefully striking the
underside of the door with a rubber
mallet. The impact made by the
mallet will indicate if loose objects
are in the door well.
In the event that tightening the
bolts and screws, located on such
assemblies as the doors, hood, and
deck lid does not eliminate the rat-
tles, the trouble is probably caused
by misalignment. If this is the case,
follow the adjustment and alignment
procedures for these assemblies.
Rattles and squeaks are sometimes
caused by weatherstripping and anti-
squeak material that has slipped out
of position. Apply additional cement
or other adhesive, and install the
material in the proper location to
eliminate this difficulty.
EXTERIOR CLEANING
The outside finish should be fre-
quently washed. Never wipe the
painted surface with a dry cloth.
Dusting the finish when it is dry
tends to rub the dust and dirt into
the baked enamel, and leaves a
sandpaper effect on the surface. To
keep the finish bright and attractive
and eliminate the necessity of using
polish, wash the car whenever it has
accumulated a moderate amount of
dirt and road salt.
The bright metal parts of the car
require no special care. Periodic
cleaning will preserve the beauty and
life of these finishes. Wash with clear
water or if the parts are very dirty
use FoMoCo COAA-19B521-A com-
pound. Using a clean soft cloth or
a sponge and water, rinse and wipe
the parts dry. FoMoCo Chrome
Cleaner may be used sparingly to
remove rust or salt corrosion from
chrome plated parts. Do not scour
aluminum or chrome finished parts
with steel wool or polish them with
products containing abrasives. A
FoMoCo Polish will provide excel-
lent protection for all bright metal
parts.
INTERIOR CLEANING
Use a vacuum cleaner to remove
dust and dirt from the upholstery or
floor covering. Vinyl and woven plas-
tic trim that is dusty can usually be
cleaned with a damp cloth. Do not
use cleaning materials containing
kerosene, naptha, toluol, xylol 10°,
lacquer thinners, cellulose acetate,
butyl cellosolve, carbon tetrachlor-
ide, body polish, battery acid, anti-
freeze, Forel Publishing
gasoline, Company,
motor oils or otherLLC
type lubricants.
Woodbridge, VA 22192
Approved cleaners B8A-19523
www.ForelPublishing.com
-A, or -B, B5A-19525-A, COAZ-
19526-A or -B (soft trim cleaners),
BAF-19521-A Oeather and vinyl up-
holstery cleaner), and CIAZ-19C507
-A (convertible back window cleaner)
are available for service. Instructions
for the use of these cleaners are
indicated with their containers.
CARE OF WOOD GRAIN
PANELING
WASHING
Never wipe the panels or trim
rails with a dry cloth. This method
of cleaning tends to rub dust par-
ticles into the finished surface and
leave fine scratches. Flush off all
loose dirt and other elements, and
wipe the body panels and rails with
a sponge and plenty of cold water.
If desired, a mild soap may be used.
Rinse thoroughly with clear water
and wipe dry.
GLASS FIBER TRIM RAIL
REMOVAL AND
INSTALLATION
The glass fiber trim rails are serv-
iced with the wood-grain already
17-9
applied. To remove the body side
trim rails, remove the cap over each
trim rail screw to gain access to the
screws. Remove the screws and the
trim rail assembly.
When installing the body side
trim rail, apply sealer (AB-19560-A)
around each mounting hole. Install
the cap retainer, screw and cap.
APPLICATION OF WOOD-
GRAIN TRANSFERS
Wood grain transfers are available
for application to the panels. The
materials necessary to apply the
transfers are a bonding coat
(M-4584), 20% transfer solution of
M-5412-A, and clear spar varnish.
If the surface on which the trans-
fer is to be applied is damaged, re-
pair and metal finish first.
1. Mask off the area where the
transfer is to be applied.
2. Prime-coat all bare metal areas,
and wet-sand.
3. Spray the surface with transfer
bonding coat (M-4584). This coat
is the binder for the transfer ad-
hesive.
4. Allow the binding coat to air-
dry for one hour, or heat-dry
(160°F) for 20 minutes.
5. Lightly wet-sand the binding
coat, and wipe it dry.
6. Make a paper template of the
damaged area, and cut the new
transfer to size, using the template
as a guide. Leave about 1h inch of
extra material around the edge of
the transfer to allow for matching
and trimming.
7. Mix a solution of 20% transfer
solution M-5412-A and 80% water.
This solution permits shifting of the
tr an sfer after it has been applied, so
that the graining can be matched.
Try a sample of the transfer and
solution on an old piece of metal or
fender. If the transfer cannot be
pulled off after two minutes, the
solution is too strong and must be
diluted with more water.
8. Soak the transfer in lukewarm
water for one minute to loosen the
paper backing. Do not remove the
backing until the transfer is applied.
9. Using a cheese cloth pad, ap-
ply a 20% M-5412-A transfer solu-
tion to the panel. Any excess solu-
tion that runs down on adjacent
panels must be wiped off immedi-
ately.
10. Place the wet tr an sfer on the
panel, paper side out. Adjust the
transfer to match the graining on
adjoining panels, and carefully re-
move the paper backing.
17-10 GROUP 17 - BODY, DOORS AND WINDOWS

11. Sponge the transfer with clean
water to remove all traces of the
paper backing adhesive.
12. Remove all air bubbles and
wrinkles with a squeegee.
13. Wash the transfer with clear
water and dry wi th a chamois.
14. Pierce any blisters or small
air bubbles as they appear, and press
down the area with a finger to re-
move the air and excess solution.
15. Allow the panel to air-dry for
one hour, or heat dry (I 60°F.) for
20 minutes.
16. When the panel is dry, spray
two coats of clear spar varnish over
the transfer. Do not use clear lac-
quer or sheUac.

E] HOISTING VEHICLE
The unitized body-frame construc-
tion requires special precautions and
procedures when the car is jacked
up or hoisted. In some cases, spe-
cial hoist adapters must be u sed as
recommended by speci fic hoist
manufacturers.
Refer to the Owner's Manuals
when using the jack supplied with
the car.
DRIVE-ON TYPE HOIST
To prevent possible damages to
the underbody, do not drive the
car onto the drive-on type hoist
without first checking for possible
interference between the upright
flanges of the hoist rails and the
underbody. Should there be inter-
ference, the hoist flanges should be
modified as necessary and / or the
approach ramps built up to provide
the needed clearance.
Forel Publishing Company, LLC
RAIL TYPE-FREE WHEELING
HOIST
FRONT
The front adapters or hoist plates
must be carefully positioned in con-
tact with the lower suspension arms
to assure safe, accurate lifting.
post adapters must be positioned
carefully to contact the center of
the lower suspension arms (Figs. 5
and 6).
REAR
To prevent damage to the shock
absorbers, the rear forks must con-
tact the axle at points not farther
ou t board than one inch from the
circumference welds near the differ-
entia l housing. Carefully raise the
rear post and check the position of
the fork (Figs. 5 and 6).
FRAME CONTACT HOIST
Frame contact hoist adapters are
necessary to lift the car. The hoist
adapter pads should each cover at
Woodbridge, VA 22192
www.ForelPublishing.com
least 12 square inches of underbody
area. F igs. 5 and 6 show recom-
mended contact points for the hoist
pads.
FLOOR JACK
When a stationary floor jack or a
roll jack is to be used, there are
several specific recommended points
of contact. Either side of the car
may be raised a t the fron t by jack
contact at the lowi::r arm strut con-
nection. Either side of the front
encl of the car may also be raised
by jack pressure on the front cross-
member, or on the crossmember
to wh ich the stabilizer is connected.
Do not a ttempt to use jack pressure
on either front or rear Mustang
bumpers.

REAR
The hoist adapters must be posi-
tioned carefully under th e rear axle
to prevent damage to the shock ab-
sorbers when the ca r is ra ised. The
hoist rails should be raised slowly
and the position of the adapters
checked.

FORK LIFT-TWIN POST

HOIST
FRONT
.
FRO N T FRAME CO N TAC T AREA M1111 . A
REAR RA I L T YPE, F ORK [ IFTO R
FLOOR J ACK CO NTAC T AR EA M1112-A

To assure safe hoisting, the front FIG. 5-Front Hoist Contact Areas FIG. 6-Rear Hoist Contact Areas
 17-11

PART FRONT SHEET METAL, BUMPERS,

17-2 EXTERIOR MOULDINGS

Section Page Section Page

In-Car Adjustments and Repairs .... . .......... J 7-11
Hood Adjustments ..... . .... . ....... . . .. ... 17-11
Hood Lock Adjustments- Mustang . ......... 17-11
Hood Lock Adjustment-Comet, Falcon,
Fairlane ................................ J 7-11
2 Removal and Insta Ila lion ........ .. ........... 17-1 2
Hood Hinge ......... . .... . ....... . ....... 17-1 2
Radiator Grille-Comet .... . . . ...... . . ..... 17-12
Radiator G rille-Falcon .................... 17-12
Radiator G rille-Fairlane ..... . ....... ...... 17-12
Radiator Grille-Mustang . ................. 17-1 4
Front Bumper-Comet, Falcon, Fairlane ... .. 17-14
Front Bumper-Mustang ........... . . . .. . .. 17- 15
Rear Bumper-Falcon ......... . ..... . ...... 17-16
Rear Bumper-Comet, Fairlane ........ . .... 17-16
Rear Bumper-Mustang .. . ...... . ...... . . . . 17-16
Rear Bumper G uard-Mustang ..... .. .... . .. 17-17
Exterior Mou ldings ..... . . . .. . . .. . .. ... . . . . 17-17

DIN-CAR ADJUSTMENTS AND REPAIRS

HOOD ADJUSTMENTS
The hood is provided with fore
and aft, vertical, and side-to-side
adjustments (Fig. 1). These direc-
tions refer to the position of the
hood when it is fully lowered. The
elongated bolt slots in the hinge at
the hood provide the side-to-side
adjustment. The enlarged holes in
the hinge at the fender apron pro-
vide both vertical and fore and aft
adjustments.
H ood bumpers, located on the top
left and the top right surface of
the radiator support, can be adjust-
ed up and down to provide a level
surface alignment of the hood panel
with the front fe nders
HOOD LOCK ADJUSTMENTS
MUSTANG
Before adjusting the h ood lock
mechanism, make certain that the
hood is properly aligned. The hood
Jock (Fig. 2) can be moved fore
or aft and side to side to align it
with the lock dowel. The safety
catch can be adjusted to engage the
hood lock catch.
1. Loosen the hood lock attach-
ing bolts. Move the Jock assembly
as required to align it with the lock
dowelForel
on the hood. Company, LLC
Publishing
2. Tighten the attaching bolts.
Woodbridge, VA 22192
3. Loosen the lock nut on the
www.ForelPublishing.com
hood lock dowel and turn the dowel
inward to adjust the hood tighter,
or outwa rd to loosen the adjustment.
Do not bend the hood lock dowel.
4. The lock dowel is adjusted
correctly when the top of the hood
is flush with the fenders, when
locked.
5. Tighten the dowel Jock nut
after ad justing the Jock dowel.
6. To adjust the safety catch
striker, loosen the two attaching
screws and position the catch cor-
rectly. Tighten the screws and lower
the hood to make certain the safety
catch striker engages the hood Jock
safety catch.
7. Open and close the hood sev-
eral times to be certain that the lock
mechanism is secure.
COMET, FALCON AND
FAIRLANE
1. With the hood open loosen the
hood lock retaining screws (Figs. 3,
4 and 5) .
2. Move the hood Jock mechan-
ism as required to align it with the
Jock striker.
3. Tighten the Jock retaining
screws. Open and close the hood
several times to be sure that it
latches securely.

LOCK DOWEL SAFETY CATCH STRIKER HOOD LOCK

SAFETY CATCH Nll 84-B

FIG. 1-Hood Hinge Installation
-Typical FIG. 2-Hood Lock Mechanism-Mustang
17-12 GROUP 17 -BODY, DOORS AND WINDOWS
EJ REMOVAL AND INSTALLATION
HOOD HINGE
1. Prop the front of the hood in
the open position and cover the
fender and cowl panel.
2. Remove the hinge-to-hood re-
taining bolts, the retaining bolts at
the fender apron and cowl (Fig. 1),
and remove the hinge.
3. Position the hood hinge on the
body and install the hinge retaining
bolts.
4. Adjust the hood for proper fit.
RADIATOR GRILLE-COMET
REMOVAL
1. Remove one screw and two
bolts retaining the grille assembly
to the center lock support and the
right and left sides at the stone
deflector (Fig. 3) .
2. Remove the four screws re-
taining the grille assembly to the
upper support: remove the grille
assembly from the grille opening
and place it on a bench.
3. Remove the eight screws re-
taining the grille center panel to the
grille assembly and remove the
panel.
4. Remove the nut and washer re-
taining the grille ornament to the
STONE DEFLECTOR 17779
FIG. 3-Comet Grille and Hood Lock Assembly
grille and remove the grille orna-
ment.
INSTALLATION
1. Position the grille ornament
on the left grille and install the re-
taining nuts and washers.
2. Position the grille center panel
to the grille assembly and install
the retaining screws.
3. Position the grille assembly in
the grille opening.
4. Install the grille top retaining
screws, the grille-to-center lock sup-
port retaining screw and the right
and left side grille retaining bolts.
RADIATOR GRILLE-FALCON
REMOVAL
1. Remove the headlight door re-
taining screws and remove the head-
light doors.
2. Remove one retaining screw
from each side of the grille at the
headlight housing (Fig. 4).
3. Remove the lower grille to cen-
ter retaining screw (Fig. 4 ).
4. Remove the upper grille to sup-
port bracket retaining screws (Fig.
4) and remove the grille assembly.
Forel Publishing Company, LLC
Woodbridge, VA 22192
www.ForelPublishing.com
INSTALLATION
1. Position the grille assembly in
the grille opening and loosely install
the upper retaining bolts.
2. Loosely install the lower grille-
to-center support bracket retaining
screw.
3. Install the end grille retammg
screw at each headlight housing and
tighten all bolts and screws.
4. Install the headlight doors.
RADIATOR GRILLE-FAIRLANE
REMOVAL
1. Remove the headlight door re-
taining screws and remove the head-
1ight doors.
2. Remove the screws retaining
the grille assembly to the hood lock
support, the screws retaining the
grille to the upper grille support
brackets, and the three retaining
screws from each end of the grille
(Fig. 5).
3. Remove the grille assembly
from the car.
4. Remove the three nuts retain-
ing the grille ornament and remove
the ornament.
5. Remove the screws retaining
the upper and lower grille mould-
H 1322 • D
 PART 17-2 FRONT SHEET METAL, BUMPERS, EXTERIOR MOULDINGS 17-13

HEADLAMP DOOR. 13064

N 1185-E

FIG. 4-Falcon Grille and Hood Lock Assembly

Forel Publishing Company, LLC

Woodbridge, VA 22192
www.ForelPublishing.com

FIG. 5-Fairlane Grille and Hood lock Assembly

17-14 GROUP 17 - BODY, DOORS AND WINDOWS

ings to the grille assembly and re-

move the grille mouldings and grille
moulding retainers.
INSTALLATION
1. Install the upper and lower
grille moulding retainers on the
grille mouldings, position the grille
mouldings on the grille and install
the grille moulding retaining screws.
2. Position the grille ornament
on the grille and install the orna-
ment retainer and retaining nuts.
3. Position the grille assembly on
the car and grille assembly retain-
ing screws
4. Install the headlight doors.
GRILLE-MUSTANG
REMOVAL
1. Open the hood.
2. Remove the four grille retain-
ing screws from the lower inner
flange of the grille.
3. Remove the four grille retain-
ing screws from the upper flange of
the grille upper center support
bracket to the hood lock hook sup-
port.
N 1365 • C
4. Remove the grille assembly.

INSTALLATION FIG. 6-Comet Front Bumper Installation

1. Transfer the upper center sup-
port bracket, the grille bars and
ornament, and the spring nuts to the Forel Publishing Company, LLC
new grille assembly.
2. Position the grille assembly on Woodbridge, VA 22192
the car and install the grille retain- www.ForelPublishing.com
ing screws.
3. Close the hood.
FRONT BUMPER-COMET,
FALCON, FAIRLANE
REMOVAL
1. Disconnect the parking light
wiring connectors and push the wires
through their routing holes in the
fender aprons.
2. Remove the bumper left and
right inner and outer arm-to-frame
side· rail retaining bolts and remove
the bumper assembly. (Figs. 6, 7,
and 8).
3. Remove the bumper inner and
outer arms from the bumper.
4. Remove the license plate.
5. Remove the parking light as-
sembly retaining nuts and remove
the parking light assemblies. IMPACT BAR-17757

INSTALLATION
l. Install the license plate on the
new bumper.
2. Install the parking light assem-
N 1366 • B
blies in the new bumper.
3. Install the bumper inner and
outer arms on the new bumper using Fl G. 7-Falcon Front Bumper Installation
 PART 17-2 - FRONT SHEET METAL, BUMPERS, EXTERIOR MOULDING
FIG. 8-Fairlane Front Bumper Installation
spacers and washers as shown in
Figs. 6, 7 and 8.
4. Position the bumper assembly
to the car and loosely install the
bumper arm-to-frame side rail re-
taining bolts.
BUMPER GUARD
OUTER ARM ASS'Y.
BUMPER GUARD
FIG. 9-Mustang Front Bumper Installation
17-15
FRONT BUMPER-MUSTANG
REMOVAL
1. Raise the car to provide work-
ing access.
2. Tape the stone deflector to pre-
vent scratching the paint finish.
3. Remove the left and right
bumper-to-fender bracket bolts from
the fenders.
4. Remove the bumper bar-to-in-
ner arm and the bumper bar-to-outer
arm retaining bolts from each side
of the bumper (Fig. 9). Remove the
bumper and bumper-to-fender brack-
et as an assembly.
~.~ INSTALLATION
1. Transfer the bumper-to-fender
bracket to the new bumper.
\
L .H. OUTER ARM
2. Position the bumper on the car.
17754 Install the bumper bar-to-inner arm
and the bumper bar-to-outer arm re-
L.H. INNER ARM
17766
taining bolts.
R 1178. B 3. Install the bumper-to-fender
bracket retaining bolts.
4. Remove the protective tape
from the stone deflector and lower
S. Align the bumper assembly and the car.
tighten the bumper arm-to-frame side
rail retaining bolts. FRONT BUMPER GUARD-
6. Route the parking light wiring MUSTANG
through the fender aprons and con- 1. Remove the screw and washer
nect the wiring connectors. retaining the bumper guard to the
Forel Publishing Company, LLC
Woodbridge, VA 22192
www.ForelPublishing.com
VIEW-BB
Nl386-A
17-16
lower frame side rail (Fig. 9).
2. Remove the screw and washer
retaining the bumper-guard-to-guard
upper bracket and remove the
guard assembly.
3. Transfer the nut and retainer
assembly and the rubber spacer to
the new bumper guard (Fig. 9, View
"BB").
4. Position the bumper guard as-
sembly on the car.
5. Install the two retaining screws
and washers.
REAR BUMPER-FALCON
REMOVAL
1. Remove the screws retaining
the license plate lamp assembly to
the rear bumper.
2. Remove the rear license plate.
3. Remove the four bumper arm-
to-frame retaining bolts (Fig. 10),
and remove the bumper assembly.
INSTALLATION
1. Tran sfer the rear bumper arms
and rubber bumper to the new
bumper.
2. Position the bumper assembly
on the car and install the bumper
arm-to-frame retaining bolts.
3. Position the license plate lamp
assembly to the bumper and install
the retaining bolts.
4. Install the license plate.
BUMPER ARM-17A929
"~·'*••'/• f),\
LOWER EXTENSION-178875
FIG. 10-Falcon Rear Bumper Installation
GROUP 17 - BODY, DOORS AND WINDOWS
REAR BUMPER IMPACT BAR-
COMET, FAIRLANE
REMOVAL
1. Open the luggage compart-
ment. Disconnect the license light
wiring connector and push the lic-
ense light wire out of its routing
grommet.
2. Remove the spare tire and
wheel assembly.
3. From beneath the car, remove
the access covers from the lower
bumper arm-to-lower back panel re-
taining screw and washer assem-
blies.
4. Remove the lower inner arm-
to-lower back panel retaining screw
and washer assemblies (Fig. 1 1 ) .
5. From inside the luggage com-
partment, remove the upper inner
arm-to-lower back panel retaining
screw and washer assemblies (Fig.
11 ) . Remove the bumper assembly
from the car and place it on a
bench.
6. FAIRLANE ONLY: Remove
the screw and washer assemblies re-
taining the license plate support
bracket to the impact bar (Fig. 11),
and remove the license plate support
bracket assembly from the impact
bar.
7. Remove the rubber license sup-
Forel Publishing Company, LLC
Woodbridge, VA 22192
www.ForelPublishing.com
_)<~\!&/ I,
_...... '·.·:••...........
port bracket-to-in:ipact bar bumpers
(Fig. 11).
8. Remove the bumper outer and
inner arm-to-impact bar retaining
bolts and spacers (Fig. 11). Remove
the outer and inner arms from the
impact bar.
INSTALLATION
1. Insert the bumper inner and
outer arm-to-impact bar retaining
bolts in the impact bar. Install the
spacers and the inner and outer
arms on the impact bar. Torque
the retaining nuts to 17 to 23 ft-lbs.
2. Install the license plate support
rubber bumpers on the impact bar.
3. FAIRLANE ONLY: Install
the license plate support on the im-
pact bar.
4. Position the bumper assembly
on the car. Feed the license plate
light wire through its routing grom-
met in the lower back panel and
start one upper arm-to-body retain-
ing screw on each side.
5. Shift the bumper assembly as
necessary for proper alignment and
install the remaining bumper arm-
to-body retaining screws. Torque the
retaining screws to 25 to 38 ft-lbs
specification.
6. Install the lower bumper arm-
to-lower back panel retaining screw
access covers.
7. Install the spare tire and wheel
assembly. Connect the license plate
light wiring connector.
REAR BUMPER-MUSTANG
REMOVAL
1. Open the luggage compart-
ment. Remove the spare wheel and
disconnect the license light wiring
connector.
2. Remove the four bumper
mounting bracket-to-body retaining
bolts and remove the bumper assem-
bly (Fig. 12).
3. Remove the four bumper-to-
mounting bracket retaining bolts and
remove the brackets (Fig. 12).
....... , .... "'
/ 4. Remove the two license plate
light and bracket retaining screws
and remove the light and bracket.
INSTALLATION
1. Position the license plate light
and bracket on the bumper and in-
stall the two retaining screws.
2. Position the bumper mounting
brackets on the bumper and install
the bumper-to-mounting bracket re-
N 1367· B taining bolts.
3. Connect the license light wiring
and install the spare wheel.
 PART 17-2-FRONT SHEET METAL, BUMPERS, EXTERIOR MOULDINGS 17-17

REAR BUMPER GUARD-

MUSTANG
REMOVAL
1. Open the luggage compart-
men t door and remove the spare tire
assembly to provide access to th e
upper guard retaining screw and
,":···
'
washer.
.............. .,'' 2. From inside the luggage com-
_ ··:..."
... partment, remove the upper guard
retaining screw and washer (Fig. I 2).
3. From benea th the car, remove
the lower gua rd retaining screw and
washer ( Fig. 12). Remove the
bumper guard.
INSTALLATION
1. Transfer the two nuts and re-
ta iners to the new bumper gua rd.
T ransfer the ru bber spacers to the
new bu mper guard.
LICENSE PLATE
2. Position the bumper guard on
SUPPORT BRACKET · 13393
the car and insta ll the two retaining
screws and washers.
IMPACT BAR· 17906 3. Insta ll the spa re tire assembly.
EXTERIOR MOULDINGS
Before remov ing the exterior
mou ldings, it should be determined
by the type of retainer used whether
N 1417 - B
a respective door, quarter or lug-
FIG. 11-Comet, Fairlane Rear Bumper Installation gage compartment trim panel must
fi rst be r emoved to prov ide access
(Figs. I 3 through 3 I ).
Forel Publishing Company, LLC
a ..
~ :
J
··~
f ~yPLuG
~
Bu noN Woodbridge, VA 22192
www.ForelPublishing.com
1
~1 ~ GUARD

:~oc:
:~
~ ~ "'::::,""""'
' '·
'
p
EXTEN SION

~----..;:!'-~ ~~- _.·

GUARD

cc
MOUNTIN G
BR ACKE T

N 1387-A

FIG. 1 2-Mustang Rear Bumper Installation

17-18 GROUP 17 - BODY, DOORS AND WINDOWS

MODELS C6GB·63E·63H·76C·76H
FIGURE 2
MODELS ALL C6GB·EXCEPT 63E·63H·76C·76H SHOWN
MODELS C6GB·63E·63H·76C·76H TYPICAL
MODELS ALL C6GB FIGURE 1

N 1473·A

FIG. 13-Exterior Front Mouldings-Comet Models (ALL)

Forel Publishing Company, LLC

Woodbridge, VA 22192
www.ForelPublishing.com

MODEL C6GB·62A SHOWN

MODEL C6GB·54A TYPICAL
FIGURE 1

@
SHOWN TYPICAL

~.·.·.··..
v~~

@ ®
FIG. 14-Exterior Mouldings-Comet Models 54A, 62A, 638
 PART 17-2 -FRONT SHEET METAL, BUMPERS, EXTERIOR MOULDINGS 17-19

MODELS C6GB·54D·63C·63D-76B·76D FIGURE 3

MODELS C6GB·63E·63H·76C·76H FIGURE 4

~··.
®
N 1374·C

FIG. 15-Exterior Front Mouldings-Comet (Except Models 71 ()

Forel Publishing Company, LLC

Woodbridge, VA 22192
www.ForelPublishing.com

N 1375-C

FIG. 16-Exterior Mouldings-Comet Models S4D, 63(, 63D, 768, 76D

17-20 GROUP 17 - BODY, DOORS AND WINDOWS

MODEL C6GB· 71 B
FIGURE 2
MODEL C6GB·71A
FIGURE 1

© ® © ®
SHOWN TYPICAL N 1376-C

FIG. 17-Exterior Mouldings-Comet Model 71

Forel Publishing Company, LLC

Woodbridge, VA 22192
www.ForelPublishing.com

MODELS C6GB-71A·71B FIGURE 1 Model C6GB· 7 lC FIGURE 2

N 1474-A

FIG. 18-Exterior Rear Mouldings-Comet Model 71

 PART 17-2 - FRONT SHEET METAL, BUMPERS, EXTERIOR MOULDINGS 17-21

.~
, 1
I

A.
.
-
FIG. 19-Exterior Rear Moulding-Comet Models (Except 71)
@
,,.

.
--;---
~

Forel Publishing Company, LLC

-~!\~
Woodbridge, VA 22192
www.ForelPublishing.com

0 B

MODELS C6DB- 62A SHOWN

MODEL C6DB- S4A TYPICAL

FIG. 20-Exterior Mouldings-Falcon Models 54A, 548, 62A, 621, 62C

17-22 GROUP 17-BODY, DOORS AND WINDOWS

MODEL C6DB • 71 B

FIG. 21-Exterior Mouldings-Falcon Models 71 A, 71 B

Forel Publishing Company, LLC

Woodbridge, VA 22192
www.ForelPublishing.com

MODELS C6DB-66B-66D SHOWN

MODEL C6DB-66A TYPICAL

FIG. 22-Exterior Mouldings-Falcon Model 66

 PART 17-2 - FRONT SHEET METAL, BUMPERS, EXTERIOR MOULDINGS 17-23

MODE LS C6D B • 54A • 62A

~~
~

~
'- ~~©o--~--~-.-=-:,--~~---,..::::--~~~~~~~-,

~···
FIG. 23-Exterior Rear Mouldings-Falcon Models 54, 62, 71

Forel Publishing Company, LLC

Woodbridge, VA 22192
www.ForelPublishing.com

MODEL S C60B ·54A·62A·66A·66C -71A

MODEL S C6DB • 54B • 62B • 62C · 66B • 66D-71 B

N 1475· A

FIG. 24-Exterior Front Mouldings-Falcon Models (All)

17-24 GROUP 17 - BODY, DOORS AND WINDOWS

MODELS C60B-54A·62A·71D

MODELS C60B • 548 • 62B • 638 • 63C • 71B·76B • 76C

FIG. 25-Exterior Front Mouldings-Fairlane

Forel Publishing Company, LLC

Woodbridge, VA 22192
www.ForelPublishing.com

A 0

MODEL C60B- 62A

MODEL C60B·S4A ©
N 1381-C

FIG. 26-Exterior Mouldings-Fairlane Models 54A, 62A

 PART 17-2 -FRONT SHEET METAL, BUMPERS, EXTERIOR MOULDINGS 17-25

MODEL C60B-62B SHOWN

MODELS C60B-63B- 76B TYPICAL

Forel Publishing Company, LLC

Woodbridge, VA 22192
www.ForelPublishing.com
MODEL C60B- 54B

I
i
® H 1382-C

FIG. 27-Exterior Mouldings-Fairlane Models 548, 628, 638, 768

17-26 GROUP 17 - BODY, DOORS AND WINDOWS

Forel Publishing Company, LLC

Woodbridge, VA 22192
www.ForelPublishing.com

®
FIG. 28-Exterior Mouldings-Fairlane Models 63(, 63D, 76(, 76D
 PART 17-2 - FRONT SHEET METAL, BUMPERS, EXTERIOR MOULDINGS 17-27

Forel Publishing Company, LLC

Woodbridge, VA 22192
www.ForelPublishing.com
MODEL C60B-71B

i
8
N 1383- C

FIG. 29-Exterior Mouldings-Fairlane Models 71

 GROUP 17 - BODY, DOORS AND WINDOWS

MODELS 63D- 76D

Forel Publishing Company, LLC

Woodbridge, VA 22192
www.ForelPublishing.com

MODE LS 548 - 628 - 638-768

 PART 17-2 - FRONT SHEET METAL, BUMPERS, EXTERIOR MOULDINGS 17-29

MODEL C5ZB · 65 SHOWN

MODEL C5ZB. 76 TYPICAL

MODEL CSZB · 63

Forel Publishing Company, LLC

Woodbridge, VA 22192
www.ForelPublishing.com

N 1416 - A

FIG. 31-Exterior Mouldings-Mustang Models CALL)

17-30

PART DOORS, WINDOWS, TAILGATE AND DECK LID

17-3
Section Page
In-Car Adjustments and Repairs ............... 17-30
Door Alignment. .......................... I 7-30
Lock Striker Adjustment. ................... I 7-30
Vent Window Adjustment-Comet, Falcon
Except Models 63, 76 ..................... 17-31
Door Glass Adjustment-Comet, Fairlane
Models 63, 76 ........................... 17-31
Front Door Glass Adjustment-Comet,
Falcon, Fairlane Models 54, 71 ............ I 7-32
Door Glass Adjustment-Comet, Falcon,
Fairlane Models 62 ...................... 17-32
Door Window Adjustment-Mustang ........ 17-32
Rear Door Window Adjustment-Comet,
Falcon, Fairlane ......................... I 7-33
Quarter Window Adjustment-Comet,
Falcon, Fairlane Model 62 ................ I 7-36
Quarter Window Adjustment-Comet,
Fairlane Model 63 ....................... 17-36
Quarter Window Adjustment-Comet,
Fairlane Model 76 ....................... 17-36
Quarter Window Adjustment-Mus tang ...... 17-36
Tailgate Emergency Opening Procedure ....... 17-36
Dual-Action Tailgate Adjustments ........... I 7-37
Standard Tailgate Hinge Adjustment ......... 17-37
Deck Lock Adjustment. .................... I 7-37
Forel Publishing
Deck Lid Alignment ....................... 17-37 Company, LLC Back Window-Mustang Model 63 .......... 17-50
Woodbridge,
2 Removal and Installation ..................... 17-39
VA 22192 Inside Rear View Mirror (Bonded to
www.ForelPublishing.com
Doors .................................... 17-39
Front Door Lock-Except Models 63, 76 ..... 17-39
Front Door Lock-Models 63, 76 ............ 17-39
Rear Door Lock ........................... I 7-39
Door Lock Cylinder ........................ I 7-39
Door Handle or Push Button ................ 17-39
Door Vent Window Frame-Except
Models 63, 76 ........................... 17-39
Vent Window or Weatherstrip-Models
63, 76 .................................. 17-41
Front Door Glass-Except Models 63. 76 ..... I 7-41
Section Page
Front Door Glass-Comet, Fairlane
Model 63, 76 ............................ 17-41
Front Door Window Regulator-Manual-
Comet, Fairlane-Model 63, 76 ............ 17-42
Front Door Window Regulator-Except
· Models 63, 76 ........................... 17-42
Front Door Rear Glass Run-Models 63, 76 .. 17-42
Rear Door Glass-Comet, Falcon-
Model 54 ............................... 17-42
Rear Door Window Regulator .............. 17-42
Quarter Glass-Model 62 ................... 17-43
Quarter Window Regulator-Model 62 ....... 17-43
Quarter Window Regulator-Model 63 ....... 17-43
Quarter Window Front Guide-Model 63 ..... 17-43
Quarter Window Rear Guide-Model 63 ..... 17-43
Rear Quarter Window Glass-Fairlane,
Comet-Model 76 ....................... 17-43
Rear Quarter Window and/or Weatherstrip-
Model 71 ............................... 17-44
Windshield-Comet, Falcon, Fairlane ........ 17-44
Windshield-Mustang Model 63, 65 .......... 17-47
Windshield-Mustang Model 76 ............. 17-48
Back Window and/or Weatherstrip-
Comet, Falcon, Fairlane .................. I 7-49
Back Window-Mustang Model 65 .......... 17-49
Windshield) ............................. 17-51
Tailgate Glass ............................. 17-52
Tailgate Window Regulator ................. 17-53
Tailgate Switch and Lock Cylinder-Power ... 17-54
Tailgate Window Handle and Lock Cylinder-
Manual. ................................ 17-54
Dual-Action Tailgate Hinges ................ 17-55
Dual-Action Tailgate Locks ................. 17-55
Dual-Action Tailgate Torsion Bar ............ 17-55
Deck Lid Hinge or Torsion/Bar. ............. 17-55
Deck Lid Lock ............................ 17-55

D IN-CAR ADJUSTMENTS AND REPAIRS

DOOR ALIGNMENT
The door hinges provide sufficient
adjustment to correct most misalign-
ment conditions. Loosen the door
hinge attaching bolts and adjust the
door so that it is centered in the door
opening when closed. Then, tighten
the hinge attaching bolts.
After adjustment at the hinge
attaching points. check the align-
ment between the door lock and
striker plate for proper door closing.
Do not cover up poor door adjust-
ment with striker plate adjustment.
LOCK STRIKER ADJUSTMENT
The striker pin can be adjusted
laterally and vertically as well as
fore and aft. The lock striker should
not be adjusted to correct door sag.
The lock striker should be shimmed
to get the clearance shown in Fig. 1
between the lock striker and the
lock. To check this clearance, clean
the lock jaws and the striker area,
and then apply a thin layer of dark
grease to the lock striker. As the
door is closed and opened, a measur-
able pattern will result. Move the
striker assembly laterally to provide
a flush fit at the door and the pillar
or quarter panel.
 PART 17-3 - DOORS, WINDOWS, TAILGATE AND DECK LID
LOCK STRIKER
FIG. 1 -Door Lock Striker
Adiustment
VENT WINDOW ADJUST-
MENTS-COMET, FALCON
EXCEPT MODELS 63, 76
The vent glass and/ or the vent
window frame may be adjusted in
various ways. With the vent glass in-
stalled, the lower pivot spring ten-
sion may be adjusted with a socket,
extension, and ratchet used through
the access hole in the door inner
panel. Adjust so that the glass will
stay open at highway speeds. The
door frame mounting holes are
elongated to provide a tight fit for
the vent window frame in the door
frame. The upper pivot mounting
holes are slotted to help provide
a weather-proof fit of the glass frame
within the vent window frame.
EQUALIZER ARM BRACKET -23230
GLASS RUN RETAIN ER AND BRACKET ASS'Y. - 223A24.
FIG. 2-Door Window Mechanism-Comet, Fairlane Models 63, 76
DOOR GLASS ADJUSTMENT-
COMET, FAIRLANE MODELS
63, 76
The door must be properly aligned
in the body opening before glass
adjustments are made.
1. Remove the door trim panel
and peel back the watershield to pro-
vide access.
2. Loosen screw and washer as-
sem b Iies A. J, Z and AB. also nuts
C. E and L (Fig. 2).
3. Cycle the window to its up
position and manually position the
window assembly inboard or out-
board. as required, for proper align-
ment to the outside belt weather-
strip and tighten the screw and
washer assemblies 1.
4. Tilt the window assembly fore
or aft as required. to obtain a par-
allel relationship between the top
of the window and the roof rail
weatherstrip. This will position the
rear guide assembly in correct fore
and aft alignment. Tighten nut L
temporarily. Turn screw G clock-
wise or counter-clockwise, as re-
quired, to maintain position of the
guide assembly and tighten nut and
washer assembly H securely. At
this point, adjust the door window
stop assemblies up or down as re-
quired, for correct engagement.
Forel Publishing Company, LLC
Woodbridge, VA 22192
www.ForelPublishing.com
~i---~-r----
i~BEL T INSIDE WEATHERSTRIP-21436·7
5 N 1283· D
17-31
Tighten the screw and washer as-
semblies, Y and AB securely.
5. Position the vent window as-
sembly and vent window division
bar glass run rearward, into a posi-
tion relative to the door window
glass and tilt fore and aft, as re-
quired, to maintain a parallel rela-
tionship to the front body pillar.
Tighten the screw and washer as-
semblies A securely. The adjusted
position of the vent window assem-
bly should be such as to provide
window travel free of binding.
6. To provide a proper interfer-
ence relationship of the vent window
and the door window assemblies to
the top roof rail weatherstrip, tilt
these assemblies inboard or outboard
as required, by turning the screws.
B, D and K clockwise or counter-
clockwise, to the desired setting and
then tighten the nuts C, E and L
securely. At this point, secure the
vent window regulator assembly
door vent window, by tightening the
screw and the washer assemblies A
securely.
7. When the above steps are com-
pleted, cycle the window down un-
til the top of the window is flush
with the belt and position the down
stop assembly to the bumper door
window stop and secure it with the
17-32 GROUP 17 - BODY, DOORS AND WINDOWS
screw and washer assemblies Z.
8. Install the watershield and the
door trim panel.
FRONT DOOR GLASS AD-
JUSTMENTS-COMET, FALCON
FAIRLANE MODELS 54, 71
The door trim panel must be re-
moved to make any of the following
adjustments.
Fore-and-aft adjustment for snug
glass fit within the runs may be made
by using suitable shim stock between
the front run and the vent window
division bar. The front and/ or the
rear run may also be shimmed at the
lower attaching point(s).
Vertical adjustment is possible by
means of the single stop (Fig. 3).
When the glass is fully lowered, the
upper edge should be even with the
belt line.
Lateral adjustment for smooth
movement of the glass within the
runs can be made by moving the
lower attaching points of the run
(Fig. 3).
DOOR GLASS ADJUSTMENT-
COMET, FALCON, FAIRLANE
MODELS 62
1. Remove the door trim panel
and peel back the watershield to pro-
Forel Publishing Company, LLC
FIG. 3-Front Door Window Mechanism-Models 54, 71-Typical
vide access. Refer to Fig. 4 for the
following adjustments.
2. To obtain proper alignment of
the lockside glass run retainer as-
sembly to the door window frame
and vent window division bar with
the retainer, loosen nut and washer
assembly D and screw and washer
assembly E. Drop the top edge of
the glass and channel assembly to
approximately four inches above the
door outer panel belt line. Turn
screw C clockwise or counterclock-
wise as required. Tighten items D
and E securely.
3. To obtain a flush condition be-
tween the top edge of the glass and
channel assembly and the belt line
when the window is in the down
position, the stop assembly is ad-
justed up or down at screw and
washer assemblies U. After adjust-
ment, tighten the screw and washer
assemblies U securely.
DOOR WINDOW ADJUST-
MENT-MUSTANG
1. Remove the door trim panel
and watershield.
2. With the glass and channel as-
sembly in the up position, the vent
window assembly is adjusted forward
or backward and up or down at
Woodbridge, VA 22192
www.ForelPublishing.com
points A to obtain a parallel clear-
ance between the windshield side
moulding and the forward edge of
the front door vent window frame,
typical of Fig. 5. Adjustment fore
and aft is to be made so that the
glass and channel assembly will op-
erate freely with no binding in the
door glass lockside run and retainer
assembly, but still have adequate en-
gagement of sliding glass with the
vent window division bar run and
bracket assembly. Tighten the screw
and washer assemblies at point A
sufficiently to hold the vent window
in position.
3. To obtain proper alignment
with the windshield outside side
moulding and to obtain the proper
interference between the roof rail
weatherstrip and the top edge of the
vent window frame. the vent window
assembly may be tilted toward the
inside or outside of the body by
rotating the adjusting screw at point
B clockwise or counterclockwise.
Tighten the jam nut at point B.
Then, adjust the set screw at point C
until the shoulder of the screw is
against the door vent window di-
vision bar lower support. Do not
create any bind or distort the glass
run. After adjustment, tighten the
jam nut at point C. Tighten the
VIEW. DD
VIEW. EE
VIEW. FF
N 1080. C
 PART 17-3 - DOORS, WINDOWS, TAILGATE AND DECK LID 17-33

DIVISION BAR GLASS

VIEW A

~
~T
VI EW B
OUTSIDE BEL T
RE AR CH ANN EL
BRACKE T - 23296

VIEW C

MANUAL WINDOW REGULATOR VIEW D

INSIDE BELT
ASSEMBLY - 23200 · 1 WEA TH ERST RIP - 21436- 7

22Al 00 · 1
N1478 - A

FIG . 4-Door Window Mechanism-Falcon, Comet, Fairlane-Model 62

screw and washer assemblies at
point A.
4. To obtain the proper interfer-
ence of the glass assembly agai nst
the outside belt rail weatherstrip
and the roof rail weatherstrip, the
glass assembly may be adjusted to tween the top edge of the glass and
Forel Publishing
tilt toward Company,
the inside or outside LLC
of channel asse mbly and the top edge
the body at points D and
Woodbridge, E. After
VA 22192 of the vent window frame, the front
adjustment, tighten the screw and stop assembly is adjusted up o r
www.ForelPublishing.com
washer assemblies at points D and E. down at point F; after adjustment,
5. To obtain a flush condition be- tighten the screw and washer assem-
bly at point F sec urely. (See View
AA, F ig. 5).
6. To make the top edge of the
glass assembly para llel to the roof
rail weatherstrip, the equa li zer arm
bracket and the rear stop assembly
may be adj usted up or down as re-
quired at points G and H . After ad-
justme nt, tighten th e nuts at poi nts
G and the screw and washer assem-
bly, point H securely.

REAR DOOR WINDOW

ADJUSTMENT-COMETI
FALCON, FAIRLANE
1. Remove the door trim panel
and watershield.
2. To obtain proper alignment of
retainer and division bar assembly-
to door- window frame, loosen nut
LOCK SIDE RUN and washer assemb ly C. Drop the
ANO RETAINER
ASSEMl3L Y · 21508 glass and channel assembly to its
EQUALI ZER ARM BRAC KET
down position and turn screw B
ASSEMBLY . 2323G
R 1290 - A
clockwise or counterclockwise as re-
qu ired. Tighten nut and washer as-
FIG. 5-Door Window Mechanism- Mustang sembly C securely (Fig. 6) .
17-34 GROUP 17 - BODY, DOORS AND WINDOWS

GLASS RUN - 25766 OUTSIDE BELT WEATHERSTRIP-25596·7

REGULATOR MOTOR BRACKET-270A02· 3

GLASS RUN RETAINER AND DIVISION BAR-263A58·9 \ D O W REGULATOR

••••• S~L~;:!.}_OOl0·1
_)~.)
__ :·__ _,, ~

STOP BUMPER-21762 ~~ R 1042-C

FIG. 6-Rear Door Window Mechanism-Comet, Falcon, Fairlane

Forel Publishing Company, LLC

Woodbridge, VA 22192
www.ForelPublishing.com

....:::::>,_. .
. ·'
--·

:~:}:::;~
~~~~~;;....~~-STOPBUMPER-

·:;~r
21762

/ BRACKET - 303A08
LOWER STOP-
UPPER REAR GLASS
/ 21758 GLASS AND CHANNEL
I f ASSEMBLY - 29704 • 5 RUN -30104

I
'

I 1,1 L. ,,;~. . . . .
I~~~~:;:::::~-
~~-
::·f·~r-- ~
---~-. ·r··~
('l

7
CHANNEL BRACKET - .;,;._'·/..., ·
30550 1lr ' " -•••••

FIG. 7-Quarter Window Mechanism-Falcon, Comet, Fairlane-Model 62

 PART 17-3-DOORS, WINDOWS, TAILGATE AND DECK LID 17-35

UPPER STOP -222A24

REAR GUIDE LOWER BRACKET EXTENSION-298A52

MANUAL
REGULATOR-
30306. 7 :.
LOCK PILLAR·TO·WINDOW FRAME SEAL -28182· 3

N 1326· B

FIG. 8-Quarter Window Mechanism-Comet, Fairlane-Model. 63

Forel Publishing Company, LLC /j I

STOP UPPER BRACKET - 29998
Woodbridge, VA 22192 '" I,
,'/:

www.ForelPublishing.com

FIG. 9-Quarter Window Mechanism-Comet, Fairlane-Model 76

17-36 GROUP 17 - BODY, DOORS AND WINDOWS
3. Install the watershield and door
trim panel.
QUARTER WINDOW ADJUST-
MENT-COMET, FALCON,
FAIRLANE-MODEL 62
1. Remove the quarter trim panel
and watershield.
2. To obtain proper clearance be-
tween the quarter window assembly
and the quarter window glass run
retainer assembly, operate the win-
dow to its full down position, loosen
screw and washer assembly D, and
adjust the retainer assembly for-
ward. After adjustment, tighten the
screw and washer assembly finger
tight (Fig. 7).
3. To obtain proper clearance be-
tween the quarter window assembly
and the quarter window glass run
retainer assembly. operate the win-
dow to its full up position. Loosen
screw and washer assemblies D and
adjust the retainer assembly for-
ward. After adjustment, tighten
screw and washer assemblies D
securely.
4. Install the watershield and
quarter trim panel.
QUARTER WINDOW ADJUST-
MENT-COMET, FAIRLANE
MODEL 63
1. Remove the quarter trim panel
and watershield to provide access.
Refer to Fig. 8 for the following
procedure.
2. Temporarily loosen screw and
washer assemblies A, B, C, E, F. G,
H. K, and L (Fig. 8).
3. It is necessary to obtain a
0.26 to 0.30 inch pa.rallel dimension
between the front edge of the quar-
ter window frame and the rear
edge of the door window frame as
shown in view B, the 0.26 inch
parallel dimension as shown in view
C, and maintain height relationship
of the quarter window to the door
window frame and roof rail weath-
erstrip. To do this, set the quarter
window assembly into position and
temporarily secure the front guide
assembly and the rear guide assem-
bly, by tightening screw and washer
assemblies G and B finger tight.
Also secure the upper stop assem-
blies and the door window stop
bracket, by tightening the screw and
washer assemblies K, L and M
securely. The extension assembly,
quarter window front guide lower
bracket, is secured by tightening
screw and washer assemblies E.
4. To obtain proper alignment of
the quarter window assembly with
the door window glass and channel
assembly and proper interference
with the roof rail weatherstrip, tilt
the front guide assembly inboard or
outboard at the bottom as required.
When adjustment is complete, tighten
screw and washer assemblies H se-
curely.
5. Cycle the quarter window as-
sembly to its down position, flush
with the top of the quarter panel.
This will locate the rear guide as-
sembly and quarter window rear
guide lower extension assembly in
its proper position.
6. Tighten screw and washer as-
semblies A and C securely. Position
the quarter window lower stop as-
sembly firmly against the bottom
edge of the quarter window assembly
and tighten screw and washer as-
semblies F securely.
7. Cycle the quarter window as-
sembly to its down position and
secure the front and rear guide
assemblies by tightening screw and
washer assemblies B and G securely.
8. Install the watershield and
quarter trim panel.
QUARTER WINDOW ADJUST-
MENT-COMET, FAIRLANE
MODEL 76
Forel 1. Remove Company,
Publishing the quarter LLC
trim panel
and watershield.
Woodbridge, VA screw
2. Loosen the 22192and washer
www.ForelPublishing.com
assemblies A, B, E, G, K, L and
M (Fig. 9).
3. Position the window fore and
aft and tilt it fore and aft as re-
quired for alignment to the front
door window and roof rail. This will
properly position the quarter win-
dow guide panel assembly. Tighten
screw and wao;her assemblies E se-
curely.
4. Position the upper stop assem-
blies (Fig. 9) and the quarter upper
stop brackets and tighten the retain-
ing screw and washer assemblies L
and M.
5. Secure the window guide lower
bracket to the guide assembly by
tightening screw and washer assem-
bly G.
6. To provide alignment with the
front door window and an interfer-
ence fit with the roof rail weather-
strip, tilt the guide assembly inboard
or outboard as required. Tighten
screw and washer assemblies A and
B.
7. Cycle the window to its down
position so that the top of the
window is flush with the belt line.
Position the lower stop assembly
against the window channel and
tighten the lower stop assembly re-
taining screw K (Fig. 9).
8. Cycle the window up and
down to recheck alignment. Then,
install the watershield and quarter
trim panel.
QUARTER WINDOW ADJUST-
MENT-MUSTANG
1. Remove the rear seat cushion
and seat back.
2. Remove the quarter trim panel
and watershield.
3. To obtain the 0.28-inch parallel
dimension between the front edge of
the quarter window frame and the
rear edge of the door window frame
as shown in sectional view AA (Fig.
10) and to maintain a parallel align-
ment and interference between the
top edge of the quarter window as-
sembly and the roof rail weather-
strip, the quarter window guide as-
sembly is adjusted forward or back-
ward and up or down at the screw
and washer assembly items A. See
sectional views BB and CC (Fig. IO).
Tighten the screw and washer as-
sembly at items A, finger tight.
4. To obtain the proper align-
ment and interference between the
top edges of the quarter window as-
sembly and the roof rail weather-
strip, the guide assembly may be
tilted toward the inside or outside of
body at the screw and washer as-
sembly at items A and B. After ad-
justment, tighten the screw and
washer assemblies, items A and B
securely.
5. To obtain the proper level be-
tween the quarter panel at the belt
line and top edge of the glass and
channel assembly, the quarter win-
dow stop may be adjusted up or
down as required at the screw and
washer assembly, item C. This ad-
justment is made with the window
in the down position. After adjust-
ment, tighten the screw and washer
assembly, item C securely.
TAILGATE EMERGENCY
OPENING PROCEDURE
Should failure occur on the power
operated tailgate window in the up
position, entry can be accomplished
by disconnecting the window regu-
lator arms from the glass assembly.
Use the following procedure:
Carefully insert a hooked tool or
wire between the outer weatherstrip
and the tailgate window. Locate the
window regulator arm rollers. Insert
the hooked tool into the roller re-
taining spring clip and remove the
 PART 17-3 - DOORS, WINDOWS, TAILGATE AND DECK LID 17-37

QUARTER WINDOW
GUIDE ASSEMBLY

R 1287 - A

FIG. 10-Quarter Window Mechanism-Mustang Model 65, 76

clip from the roller. Hold the tail- STANDARD TAILGATE HINGE
gate window firmly and pry the ADJUSTMENT
regulator arms off of the two rollers, The tailgate can be adjusted fore to body mounting bolts.
carefully lower the window into the
tailgate, then open the tailgate. or aft and up or down at the hinge To adjust the tailgate from side
Forel Publishing Company, LLC
DUAL-ACTION Woodbridge, VA 22192
TAILGATE ADJUSTMENTS www.ForelPublishing.com
While full adjustments are pro-
vided for the dual action tailgate, no
unique methods are employed. The
following information will assist in
locating and performing the adjust- FLOATING TAPPING PLATES
IN PILLAR PROVIDE
ments. FORE & AFT AND UP
The fore and aft and up and down &DOWN ADJUSTMENT
adjustment of the tailgate is accom- {LOOSEN SCREWS)
plished at the hinge side by means
of square holes in the body pillar,
backed by floating tapping plates, at
the upper and lower hinge attach-
ments· (Fig. 11 and 12).
Lateral adjustment of the tailgate
is accomplished at the upper hinge
by adding or removing spacer shims
between the hinge on the body and
the pillar. Lateral adjustment at the
lower hinge is accomplished by
means of oversize holes in the tail- i
I
gate at the hinge on the gate attach- I
I
ment (Figs. 11 and 12).
Fore and aft and up and down
adjustment of the strikers is accom-
plished by means of square holes in
the pillar backed by floating tapping
plates. Lateral adjustment is accom- VERTICAL PIVOT
plished by adding or removing
shims (Fig. 13). FIG. 11-lower left Hinge Assembly
17-38 GROUP 17 - BODY, DOORS AND WINDOWS

to side in the tailgate opening, re·

move the trim panel, loosen the
hinge to tailgate bolts and shift the
tailgate as required.

/ '- / " , ADJUSTM ATERAL DECK LOCK ADJUSTMENT

,,, " / '-/'. Jr~~~-.~~-ENT The striker plate can be adjusted

laterally and vertically and the lock
can be adjusted laterally. Before ad-
justing the deck lid lock, make sure
'' ~
'~~
11
/' /f FLOATI NG TAPPING that the deck lid is properly aligned.
i. PRO~IEDSEINF PILLAR
'
f"l\ \I\''.
,,,
PLA
\ \. '-:) '\ Ii'- i'
~\ ",\ ,,, l
\'\ ,, !i:. ". / I#I/ / ' AFT ANO UP
ORE A
ND
To adjust the lock, loosen the
attaching screws, move the lock as
·~'\"<
(li
~--~
\ \:\ \(,
\•\,\, :<i:'
';/ j,f / DOWN AD AND required to make good contact and

l\'\tfll/T
I// / (LOOS JUSTMENT
' \ U/ // EN SCREWS)
tighten the attaching screws. Move
~, /~ \;'i 'J'.f /- 1
:,__,
, t_J,
,--:••\•I "- i/ · //LO WE R HINGE ASSEMBL the striker plate up or down as
"'-:!>*5;, 1/ I y necessary to increase or decrease
,.-.-·····~· the clearance between the deck lid
\(i ·~ \\J v./ ,' and the lower back panel.

DECK LID ALIGNMENT

The deck lid can be shifted fore
and aft, up and down, and from
side to side. Slotted holes in the lid
provide fore and aft movement.
Slotted hinge bolt holes in the mount-
ing bracket provide up and down
movement. Enlarged hinge mounting
bolt holes in the lid inner panel pro-
N 1480-A
vide limited lateral movement.
FIG. 1 2-Upper left Hinge Assembly

Forel Publishing Company, LLC

Woodbridge,
UPPER VA 22192
LOCK STRIKER

~::=:::::::::~---_·:::::::::::--·-------------,.
J./,/~ ~ ~"oCER
www.ForelPublishing.com
UPPER LOCK ............ __ -----....
!i
-,, '· SHIMS

~---~'1\
(INCORPORA ----.... VIDE LATERAL
ASSISD ..__ TES "POP OPEN" ------ ji i!! \\ \ !. , ' ....
I STRIKERS
ADJUSTMENT OF

"-.· f' \ \J/\' ·,/ "\\ \

__ , i "' ' ' " \'
.l'
!
I I
l
'\
''
:
i \''·
'\ ' \
: '. I
\. ,, if
\\ ,,
\\ \l i
"
/!:
\'
\:
;r·,c
. . l.c' •';•

/;-:\~~~: j,,; \ . \~(/J

l> \\ ·, \i : :I ___:::.
I<. :::.\: :"i II

,J,c
i:
~ ---------· ..
:1
.)'~, :~ ~· !i
!!- --~:::.:,::;:J
·---------~--::::::::::: /~~:- -_,.- -;- _j~"'\
\ ,~ - - - - - - - - - · - - . - ./ ·- - - - . - - ;
\ •I -----------
\\ If! _____ SHIM
PACER \
TO OPEN: ROTATE IN
CLOCKWISE DIRECTION

--- ---\@-~------
, LOWE I

.,
.~
LOWER LOCK
---------------------------
R LOCK STRIKER //

,,.,.........,, ....
................ ...........-~
,
'\
\ ............................
........"'"......... ..
' -....-;..--:,.-.. ~ N 1481-A

FIG. 13-Tailgate lock Striker Adiustment

 PART 17-3 - DOORS, WINDOWS, TAILGATE AND DECK LID
EJ REMOVAL AND INSTALLATION
DOORS
REMOVAL
1. Remove the door hinge-to-door
attaching bolts, and remove the door.
2. If a hinge is damaged, remove
the pillar attaching bolts and remove
the hinge.
3. If the door is damaged, a re-
placement door is furnished as a
sheet metal shell in prime paint.
It has no hinges, trim, glass, runs, or
hardware. When a door is replaced,
make any needed minor repairs to
the new shell, drill holes necessary
for mouldings, paint the door, and
transfer all usable parts. Cement the
weatherstrip properly.
If only a door outer panel is seri-
ously damaged, the whole door need
not be replaced. A replacement outer
panel is available.
INSTALLATION
1. If the hinge was removed, in-
stall it to the pillar.
2. Position the door to the hinges.
Partially tighten the bolts, align the
door, and tighten the bolts securely.
3. Align the door glass, glass runs,
stops, regulator, and remote control.
4. Install the door water shield
and the door trim.
FRONT DOOR LOCK-
EXCEPT MODELS 63, 76
REMOVAL
1. Remove the trim panel and
position the water shield away from
the access holes.
2. Disconnect the door lock re-
mote control link, the lock actuat-
ing rod and the lock control to
cylinder at the lock (Fig. 14). Re-
move the knob from the push but-
ton rod.
3. Remove the glass rear run
lower retaining bolt and position
the run away from the door lock.
4. Remove the lock assembly
from the door. Remove the push
button rod from the lock.
INSTALLATION
1. Connect the push button rod to
the lock.
2. Position the lock in the door
and install the retaining screws. Con~
nect the lock control to cylinder
rod, the lock actuating rod, and the
remote control link at the lock. In-
stall the push button.
3. Position the glass rear run in
th~ door. Install the retaining bolt,
adjust the rear run, and tighten the
retaining bolt.
4. Check the operation of the
lock. If necessary, adjust the lock
striker.
5. Carefully position the water
shield to the inner panel; and install
the trim panel.
FRONT DOOR LOCK-
MODELS, 63, 76
REMOVAL
1. Remove the door trim panel
and watershield.
2. Remove the door window glass
channel bracket retaining screws.
Prop the window in its up position
and cycle the regulator arms to the
down position.
3. Disconnect the control rods
from the lock assembly (Fig. 14).
4. Remove the three screws re-
taining the lock assembly and remove
the lock assembly from the door.
INSTALLATION
1. Position the lock assembly in
the door and install the three lock
assembly-to-door retaining screws.
2. Connect the control rods to
the Jock assembly.
3. Raise the window regulator
arms Forel Publishing
and bracket andCompany, LLC
install the
regulator Woodbridge, - to-window
arm bracket VA
22192
channel retaining screws. Remove
the propwww.ForelPublishing.com
used to temporarily hold
the window in its up position.
4. Install the door trim water-
shield and the door trim panel.
REAR DOOR LOCK
REMOVAL
1. Remove the trim panel and
position the water shield away from
the access holes.
2. Disconnect the door lock re-
mote control rod and door lock
control rod at the door lock assem-
bly.
3. Remove the three screws re-
taining the lock assembly to the
door and remove the lock assembly
from the door (Fig. 14).
INSTALLATION
1. Position the lock assembly in
the door, and install the retaining
screws.
2. Connect the door lock remote
control rod and the door lock con-
trol rod at the door lock assembly.
3. Check the operation of the
lock. If necessary, adjust the lock
striker.
4. Carefully position the water
17-39
shield to the inner panel, and install
the trim panel.
DOOR LOCK CYLINDER
The key code is stamped on the
lock cylinder to assist in replacing
lost keys.
When a lock cylinder is replaced,
both door lock cylinders and the
ignition lock cylinder should be re-
placed in a set. This will avoid
carrying an extra key which will fit
only one lock.
1. Remove the trim panel and
position the water shield away from
the access holes.
2. Disconnect the lock control to
door lock cylinder rod at the lock
cylinder.
3. Pull the door lock cylinder re-
tainer rearward to release the cylin-
der, and remove the lock cylinder
from the door.
4. Transfer the lock cylinder arm
to the new lock cylinder.
5. Position the lock cylinder in
the door, and install the lock cylin-
der retainer (Fig. 14).
6. Connect the lock control to
door lock cylinder rod at the lock
cylinder.
7. Carefully position the water
shield to the inner panel and install
the trim panel.
DOOR HANDLE AND/OR
PUSH BUTTON
1. Remove the door trim panel,
and position the water shield away
from the access holes.
2. Remove the handle retaining
screw and nut, and remove the
handle (Fig. 14). To remove the
front door handle, it will be nec-
essary to disconnect the lock actuat-
ing link.
3. To replace the push button
remove the retaining plate screw,
retaining plate, spring, push button,
and rubber seal from the handle.
4. Install the push button assem-
bly if it was removed, and install
the handle assembly. Connect the
lock actuating link to the door
handle.
5. Carefully pos1t1on the water
shield to the inner panel, and install
the trim panel.
DOOR VENT WINDOW FRAME
-EXCEPT MODELS 63, 76
1. Remove the door trim panel,
trim panel lower retainer and the
watershield.
17-40 GROUP 17 - BODY, DOORS AND WINDOWS

...

~
-,-
LOCK CONTROL KNOB-21850
PAD~-22448-9 ~~:~~.._.a······-.~.~c.-.. ~/LOCK ASSEMBLY -21812-3
~

~
·-~ ~}i
I ~ ~ I ,..
GROMMET-21999 '
,,~.... -~1 LOCK STRIKER
1 ,-...~/ ::' c\'.}
f I :~:i _!
....
. . .1,!f.•J'
.. -~ ....·~; . . . . -

~
21982
·---·--- -- --1.n
OUTSIDE HANDLE-22
~~,.,.-
\ \j
.J//// I:~ ,r:\~;!I
I I

f' i
.'"!:
t
/
I • ~ "1~1
•t,.J
r·.-~.
•,

,~.. 1 1;':\I
•'11t/' PAD-22428·9 ~ f: •::.-:..-.-:..·-o.t::1 ·, ,. I 1¥~q
_.-..·
~
l i 0::
I
/~i
11
'l:t~
r I I
I
-
,·:~;:1
\\•,ti
,!OUTSIDE HANDLE-224001
~ '1:::
: :
/l SHIM-265A06
1{ 1: ~-· ?'· ~: ::
LOCK ACTUATING ROD -218A86· 7 ; (~-.--~-- -·~: ! 11 LOCK CYLINDER - 21990· 1

-c
f
!
s LOCK CYLINDER RETAINER-22023
1
,•!
11
·. ' ,!• PUSH BUTTON ROD - 21852

~:~---
r-··
f"" ··~
' i, .•,;
flV/\i!
LOCK ASSEMBLY· 21812 • 3
··~··
n:,.;;_~-::::::~~::::::::::···- f_/j;r·I: ~;'···...
I

.. r.'i ('-r•r • •._ •••••••••·-... LOCK CONTROL· TO-CYLINDER ROD-22134-5 :::II

irw;-~ :". r··7..-;~::;;<:::::::::.::.:;.::::···... ~ ,',
REMOTE CONTROL- 21818· 9 f1 "1'
ftM'LOCK CONTROL KNOB ::1 I ' •--··
i!r<J : cJ:t··.:::::=::::::::::::::====--··--
i-...,.1 (,;;:·\.J 21850 r . : ::: , .., ~ ;:
i!ft; il : ::~~ (.~:: :~ 17'[-.:~f::.:::.:.==:::::::::::::~~ GROMMET. 21999 :~:~:! :I / 1 L:
!;i.: ii i l!1 1j '•,'•,,: !: "•...•-;, ••r•••••.:::::;·;~:or/7'<',;1; :J/'~I I I : ~ :~
:: : .~,~\. ·:~ t/J}. ~a ~ ~r::~is%·n,.1:r;\\~ :~. : : / ·~---· :~~~ i :
i~:·. :~-~ \ t;r~...... ~r::-=~~~~!!::::.,..J.A ~ : :\. . ... '>i :H11 i! \\\\i p: ~ \\
: f""---·.. :I~"
Wi } ~.... ~ :rt-~~ V"-·...........;:--:~/,.l ~ r~·.,,. .~-4· :· :,./-' o\\ol .-.-· --~.·1 ~
it: .(~~~ l ~- ... ~~~~~.. " . . . . . . . . .:{H ·t';,~~ ?: :! !:! ! ~ 1W! {c-1f' : • · o Cl \ ~ \\
"~....; ~4"4~_-,, .....1(· ~ ~..,.:,...~
7
!/, 't'to•~ ': 11 ~ 1 ···~ 1 ·i~ . . . . .-.--:.h·.~ .
\ . . . . .,. .~~:~;~:J _· H) +?.~,, '·;t!~ ff/ n:!;! ":~ LOCK ASSEMBLY ··;·:~---:::, ··----~~·:
'

tT
,, f • 11,11

/// ·1t._·,i
11/ -...___••..___ . . . . . .~~·~; r; r.;- ·~ ""'"t~;.; ..·J ~ i! !!!I i : r~· · 21812 • 3
., ~- •• ~ ".,, ., ·~ ...... ~
,., ·~:\• ~·::'; j)·t.r"~
I~
• \ ·. !~. -·· · --- :, ,. \:
--
""'7....................,
. . . . .).: :. . . ., ' •"'' ' -
.,.
11(
--- '··.,....:::;"'<"'~•• ': ('., ~- !!! ~ ~ ~:
-._.....__ ,,.,.,-14' _,,.,~,•,.:..f' ;,/ :•;"',J; ·~1
----... .-.. . . . . . . . . . . . . . "'4;.r;
1.f
l!~··:--.7?~/
I
., \' /
'~
~'
•::,
I
I
/
~--
. ': ,.
', ',
\
\ '.
I
:
I:

11
:~
·------ .............~.fl: ~~~1 ·:~~,~ LOCK STRIKER-21982 '
~~···-•• I/~ REMOTE CONTROL LINK-21940
SHIM· 265A06

RE~TE CONTROL LINK-21940

OUTSIDE HANDLE - 26600- 1 PAD- 22448- 9

:·. ~ •, :\
~ Forel Publishing :::"•I: ~ LLC
Company,
~--.······-,,...i.,···... ::•:; •111jtiH

: -. . . ~-- .ii{....,.~··,
. . . .-........ ~
Woodbridge, ···-..:,·····~·.J...,
·· .................VA •1i1 22192
··...::-....··. - ........\

~
.. " _
'
JC..
www.ForelPublishing.com
~........
..... !;,,, /

~.-.. ~y. ""-1:1 .

~l)
. ......
. . . . . ~ .>-..
P
AD-22428-9 t'i!J-
f
I • I ,.,,,
-:~\
...........

t I .f". I 1!1;

LOCK CONTROL ROD LINK - 26408

REMOTE CONTROL LINK- 26414-~.to---

~~
~

\
\
'\

SHIM· 265A06

H 1281· D

FIG. 14-Door Handle and Lock Installation

 PART 17-3-DOORS, WINDOWS, TAILGATE AND DECK LID
2. Remove the inner and outer
door belt line weatherstrips (view
D, Fig. 4) by prying them loose
from the door.
3. Remove the window lower
stop and completely lower the door
window.
4. Remove the front glass run
adjusting bolt, lock nut and washer.
5. Remove the front glass run
from the division bar retainer at
the vent frame by sliding the run
down and removing it from the
door through the inner panel access
hole.
6. Remove the three screws re-
taining the vent frame to the door
frame. Remove the vent window
assembly and place it on a bench.
7. Remove the screws retaining
the upper vent pivot to the vent
frame assembly. Remove the nut
retaining the lower pivot bolt and
remove the spring nylon bushings,
washer and stop washer.
8. Remove two screws from the
top of the assembly and remove the
four rivets retaining the vent frame
and division bar weatherstrip. Sepa-
rate the frame and division bar.
9. Using a tool such as shown in
Fig. 15, remove the glass. Remove
the weatherseal.
INSTALLATION
1. Position new weatherseal to
the vent glass.
2. Lubricate the weatherseal with
Ru-Glyde and seat the glass assem-
bly in its channel.
3. Position the division bar to
the vent frame. Position the vent
frame and division bar weatherstrip
and install the four rivets and two
screws at the top of the frame.
4. Assemble the vent tension
spring to the lower pivot and adjust
the pivot spring tension so that the
window will stay open at highway
speeds.
GLASS AND CHANNEL REMOVAL TOOL (NO. 2900)
AVAILABLE FROM SOMMER AND MALA GLASS
MACHINE COMPANY, 5501 W. OGDEN AVENUE,
CHICAGO 50, ILLINOIS
FIG. 15-Glass Channel
Replacement
5. Position the frame assembly on
the door and install the three retain-
ing screws.
6. Position the glass front run in
the door and slide it into the vent
frame retainer.
7. Loosely install the front run
adjusting bolt and nut.
8. Raise the window halfway and
loosely install the lower glass stop.
9. Adjust the front run and
tighten the retaining nut.
10. Lower the window so that
the top of the glass is level with the
window opening belt line.
11. Install the belt line weather-
strips.
12. Install the door watershield
and trim panel.
VENT WINDOW OR WEATHER-
STRIP-MODELS 63, 76
REMOVAL
The vent window glass may be
removed and/ or installed by using
the tool shown in Fig. 15. When
installing new glass, use new glass
tape, and apply sealer to the frame
horizontal channel and to the other
channel in the area of the upper
pivot.
1. Remove the door trim panel
and position the water shield away
from the access holes.
Forel Publishing
2. Remove the front Company,
run bracketLLC
retaining bolt, and position
Woodbridge, the run
VA 22192
out of thewww.ForelPublishing.com
vent window division bar
(Fig. 2).
3. Remove the door vent window
assembly retaining bolts and retain-
ing nut, and remove the vent win-
dow assembly.
4. Remove the upper pivot from
the frame and remove the lower
pivot spring assembly, then remove
the vent window and frame.
5. Remove the weatherstrip.
INSTALLATION
1. Install the weatherstrip.
2. Position the vent window and
frame into the vent assembly.
3. Install the pivot and the pivot
spring assembly. Adjust the spring
tension so that the vent glass will
stay open when the car is driven
at highway speeds.
4. Position the vent window as-
sembly in the door and install the
retaining bolts and retaining nut
snugly.
5. Position the front run in the
vent window division bar and install
the retaining bolt snugly.
6. Align the vent window and
front run and tighten the retaining
bolts and retaining nut.
17-41
7. Carefully pos1t1on the water
shield to the inner panel and install
the trim panel.
FRONT DOOR GLASS-
EXCEPT MODELS 63, 76
REMOVAL
1. Remove the trim panel and
position the water shield away from
the access holes.
2. After removing the stop (Fig.
4), lower the glass until the reg-
ulator arm roller is out of the glass
channel.
3. Unsnap and remove the belt
weatherstrips, loosen the front run
attaching bolt at the mounting
bracket, and remove the bracket
attaching bolt from the inner panel.
4. Remove the front run from
the division bar by pulling rearward
on the edges of the run.
5. Remove the glass.
INSTALLATION
1. Using the tool shown in Fig.
15, remove the channel from the
glass.
2. Install the channel. using new
glass tape.
3. Simultaneously, position the
glass and run in the door, and install
the belt weatherstrips.
4. Position the regulator arm rol-
ler in the channel, and finally posi-
tion the run in the division bar.
5. Connect the run and bracket,
making necessary lateral adjustment.
6. Install the stop, making neces-
sary adjustment.
7. Carefully position the water
shield, the inner panel, and install
the trim panel.
FRONT DOOR GLASS-COMET,
FAIRLANE-MODEL 63, 76
REMOVAL
1. Remove the door trim panel
and watershield.
2. Remove the door trim panel
upper retainer from the door. This
provides access to the window upper
stop retaining screws.
3. Remove the window upper
stops (Fig. 2) .
4. Remove the vent window and
division bar retaining screws and
nuts (Fig. l).
5. Remove the rear guide retain-
ing screws and nuts. Remove the
rear guide from the door.
6. Remove the glass channel roller
brackets from the lower window
channel.
7. Lower the window assembly
into the door.
8. Remove the door belt inner
17-42 GROUP 17 - BODY, DOORS AND WINDOWS
weatherstrip by unsnapping the
weatherstrip retainer clips from the
door inner panel.
9. Remove the run assembly from
the vent division bar.
10. Remove the vent window as-
sembly from the door.
11. Lift the door glalis assembly
up and out of the door.
12. Remove the frame from the
glass.
INSTALLATION
1. Position the frame on new
glass.
2. Position the door glass assem-
bly in the door.
3. Position the vent window as-
sembly in the door.
4. Install the front run assembly
in the Vent division bar.
5. Snap the door belt inner weath-
erstrip and retaining clips into place
on the door inner panel.
6. Raise the door glass and install
the regulator channel brackets on
the lower window frame.
7. Position the rear guide assem-
bly in the door and install, but do
not tighten, the retaining nuts and
screws snug.
8. Position the window upper
stops and install, but do not tighten,
the stop retaining screws.
9. Adjust the vent window assem-
Forel
bly to the front pillar and tighten
the division bar retaining screws and
nuts.
10. Adjust the rear guide and
tighten the retaining nuts and screws.
11. Adjust the window upper
stops and tighten the stop retaining
screws.
12. Install the door trim panel
upper retainer.
13. Install the door trim panel
watershield and the door trim panel.
FRONT DOOR WINDOW
REGULATOR-MANUAL-
COMET, FAIRLANE-MODEL
63, _76
REMOVAL
1. Remove the front door trim
panel and watershield.
2. Remove the four regulator as-
sembly retaining screws.
3. Prop the window in its up posi-
tion and remove the front channel
bracket from the window frame.
4. Loosen the front run retaining
nut and remove the regulator from
the door. The regulator arm rollers
will slide out of the rear channel
bracket and the equalizer arm
bracket to permit removal of the
regulator assembly from the door.
INSTALLATION
1. Position the regulator assembly
in the door and install the regulator
arm rollers in the channel brackets.
2. Align the regulator retaining
screw holes with the retaining screw
holes in the door panel and install
the four regulator assembly retain-
ing screws.
3. Install the front run lower
retaining nut.
4. Install the front channel
bracket on the window frame.
5. Install the watershield and door
trim panel.
FRONT DOOR WINDOW
REGULATOR-EXCEPT
MODELS 63, 76
REMOVAL
1. Remove the trim panel and po-
sition the water shield away from the
access holes.
2. Disconnect the regulator from
the glass channel roller.
3. Raise the glass by hand and
secure it in the raised position.
4. Remove the regulator retaining
bolts (Fig. 3) and remove the regu-
lator through the door access hole.
INSTALLATION
1. Position the regulator inside
the door and install the retaining
boltsPublishing
snugly. Company, LLC
Woodbridge,
2. Lower theVAglass
22192
and connect
the regulator.
www.ForelPublishing.com
3. Check the operation of the
glass, adjust it if necessary, and
tighten the retaining bolts.
4. Carefully position the water
shield to the inner panel and install
the trim panel.
FRONT DOOR REAR GLASS
RUN-MODELS 63, 76
REMOVAL
1. Remove the trim panel and
position the water shield away from
the access holes.
2. Remove both window upper
stop brackets from the glass lower
channel.
3. Disconnect both regulator arms
from the glass lower channel, and
remove the rollers. Remove the glass
assembly.
4. Remove the glass rear run
lower retaining bolt. Remove the run
upper adjusting screw lock nut. Do
not disturb the position of the ad-
justing screw. Remove the run from
the door.
INSTALLATION
1. Position the rear run in the
door and install the lower retaining
bolt and upper adjusting screw lock
nut snugly.
2. Position the glass assembly in
the door. Install the rollers in the
glass lower channel, and connect
both regulator arms.
3. Attach the window upper stop
brackets to the lower channel.
4. Adjust the rear run and tight-
en the retaining bolt and nut.
5. Carefully position the water
shield to the inner panel and install
the trim panel.
REAR DOOR GLASS-COMET,
FALCON-MODEL 54
REMOVAL
1. Remove the door trim panel
and watershield.
2. Remove the two screws retain-
ing the regulator roller channel
bracket to the lower window channel
(Fig. 3).
3. Remove the lower stop as-
sembly.
4. Remove the screw and nut re-
taining the rear run retainer and
stationary glass. Move the run re-
tainer and glass back and down in
the door.
5. Remove the door belt, outside
weatherstrip.
6. Tilt the door window down
and then lift it out of the door.
7. Using a tool such as shown in
Fig. 15, remove the glass from the
lower channel.
INSTALLATION
1. Position new glass tape on the
glass and, using a tool such as
shown in Fig. 15, install the lower
channel on the glass.
2. Position the glass and channel
assembly in the door.
3. Position the rear run retainer
and stationary glass assembly and
install the retainer screw and nut.
4. Install the regulator roller chan-
nel bracket on the window channel.
5. Install the lower window stop.
6. Install the door trim water-
shield and the door trim panel.
7. Install the window outside belt
weatherstrip.
REAR DOOR WINDOW
REGULATOR
REMOVAL
1. Remove the trim panel and
position the water shield away from
the access holes.
2. Disconnect the regulator from
the glass channel roller.
3. Raise the glass by hand and
secure it in the raised position.
 PART 17-3 - DOORS, WINDOWS, TAILGATE AND DECK LID
4. Remove the regulator retaining
screws and remove the regulator
through the door access hole.
INSTALLATION
1. Position the regulator inside
the door and install the retaining
screws snugly.
2. Lower the glass and connect
the regulator.
3. Check the operation of the
glass, adjust it if necessary, and
tighten the retaining bolts.
4. Carefully position the water
shield to the inner panel and install
the trim panel.
QUARTER GLASS-MODEL 62
REMOVAL
1. Remove the rear seat cushion
and back.
2. Remove the trim panel and
position the water shield away from
the access hole.
3. Remove the lower and front
garnish moldings.
4. Remove the rear run.
S. Lower the window until the
regulator rollers are accessible, and
disconnect the front rollers from the
channel.
6. Lower and tilt the glass to re-
move it.
INSTALLATION
1. Transfer the channel, using the
tool shown in Fig. 15.
2. Position the glass in the quar-
ter panel, and connect the front
rollers.
3. Install the rear run, adjusting
it as necessary.
4. Install the garnish mouldings,
position the water shield, and install
the trim panel.
S. Install the seat cushion and
back
QUARTER WINDOW
REGULATOR-MODEL 62
REMOVAL
1. Remove the rear seat cushion
and back.
2. Remove the trim panel and
position the water shield away from
the access hole.
3. Disconnect the regulator from
the glass channel rollers.
4. Raise the glass by hand and
secure it in the raised position.
S. Remove the regulator retain-
ing bolts, slide the regulator arm
out of the equalizer and remove the
regulator.
INSTALLATION
1. Position the regulator inside
the quarter panel, engage the arm in
the equalizer, and install the regula-
tor retaining bolts snugly.
2. Position the rollers in the glass
channel, lower the glass and connect
the regulator.
3. Check the operation of the
glass, adjust it if necessary. and
tighten the retaining bolts.
4. Position the water shield, and
install the trim panel.
5. Install the seat cushion and
back.
QUARTER WINDOW
REGULATOR-MODEL 63
REMOVAL
1. Remove the rear seat cushion
and seat back.
2. Remove the quarter trim panel
and watershield.
3. Remove the screws retaining
the glass channel bracket to the low-
er glass channel and remove the
glass channel bracket. Prop the win-
dow assembly in its up position.
4. Remove the four screws retain-
ing the regulator assembly to the
quarter panel and remove the regu-
lator assembly.
INSTALLATION
1. Position the regulator assembly
in the quarter panel and install the
four Forel Publishing
regulator Company,
retaining screws. LLC
Woodbridge, VA
2. Remove the prop used 22192
to hold
the window up and install
www.ForelPublishing.comthe glass
channel bracket on the glass channel.
3. Install the quarter trim panel
watershield and trim panel.
4. Install the rear seat back and
cushion.
QUARTER WINDOW FRONT
GUIDE-MODEL 63
REMOVAL
1. Remove the rear seat cushion
and seat back.
2. Remove the quarter window
handle, arm rest, the quarter trim
panel, trim panel retainer. garnish
moulding, and position the water
shield away from the access hole.
3. Remove the quarter window
front guide lower retaining bolts
and the adjuster screw lock nut.
4. Turn the adjuster screw to its
full in position.
S. With the quarter glass in the
lowered position remove the quarter
window front guide from the glass
channel rollers.
6. Remove the quarter window
front guide through the access hole
with the window glass in the up
position.
17-43
INSTALLATION
1. With the quarter glass in the
up position, install the quarter win-
dow front guide into the glass chan-
nel rollers.
2. Install the quarter window
front guide retaining bolts aod ad-
juster screw lock nut snugly.
3. Check the operation of the
glass, adjust it if necessary, and
tighten the retaining bolts and ad-
juster screw lock nut.
4. Position the water shield and
install the garnish moulding, trim
panel retainer, quarter trim panel,
regulator handle. and arm rest.
5. Install the rear seat back and
seat cushion.
QUARTER WINDOW REAR
GUIDE-MODEL 63
REMOVAL
1. Remove the rear seat cushion
and seat back.
2. Remove the quarter window
handle, arm rest, quarter trim panel,
trim panel retainer and garnish
moulding, and position the water
shield away from the access hole.
3. Position the rear seat back
panel cardboard away from the seat
back panel.
4. Remove the quarter window
rear guide retaining bolt and adjust-
er screw lock nut, and remove the
rear guide.
INSTALLATION
1. Position the rear guide in the
quarter and install the retaining bolt
and adjuster screw lock nut snugly.
2. Check the operation of the
glass, adjust it if necessary, and
tighten the retaining bolt and adjust-
er screw lock nut.
3. Install the rear seat back panel
card board.
4. Position the water shield, and
install the garnish moulding, trim
panel retainer, trim panel. regulator
handle, and arm rest.
S. Install the rear seat back and
seat cushion.
REAR QUARTER WINDOW
GLASS-FAIRLANE, COMET-
MODEL 76
REMOVAL
1. Remove the rear seat cushion,
seat back and quarter trim panel.
2. Remove the quarter window
upper stops.
3. Remove the lower glass chan-
nel bracket (Fig. 9) from the lower
glass channel.
4. Remove the three quarter win-
dow guide panel retaining screws.
17-44 GROUP 17 - BODY, DOORS AND WINDOWS
5. Raise the top assembly off the
windshield header far enough to per-
mit clearance between the window
and roof side rails.
6. Remove the window from the
quarter panel.
7. Remove the retaining screw
from the weatherstrip and remove
the weatherstrip fro m the window.
8. Remove the screws retaining
the window top frame and remove
the frame from the glass.
9. Using a too l such as shown
in F ig. 15, remove the glass from
the lower and side channel.
INSTALLATION
1. Using a tool such as shown in
F ig. 15, install the lower and side
channels on the glass.
2. Position the top frame on the
glass assembly and install the frame
retaining screws.
3. Position the quarter window
weatherstrip on the window assem-
bly and install the weatherstrip re-
taining screw.
4. Position the quarter window in
the guide assembly and install the
guide retaining screws snugly.
5. Install the lower glass channel
bracket on the glass channel.
6. Install the window upper stops
snugly.
Forel Publishing Company, LLC
/====~""':!i~ii~~i.;~;,~-'~ '~r.·,-.~"i.. ~~~~~~~~~~~~~O~U~T~Sl~OE~F R~~
FIG. 16-Stationary Rear Quarter Window-Models 71
7. Raise the top assembly and
fasten the top hold-down clamps.
8. Align the window assembly to
the door glass and top s ide rails. Ad-
just the upper and lower window
stops and tighten all retaining
screws.
9. Cycle the window assembly up
and down to insure proper adjust-
ment. Then, install the quarter trim
panel, rear seat back and seat cush-
ion.
REAR QUARTER WINDOW
AND / OR WEATHERSTRIP
MODEL 71
REMOVAL
1. Remove the spare tire cover
and spare tire.
2. Remove the inside lower gar-
nish moulding from the wheel well
area.
3. Remove the quarter window
ins ide front garnish moulding.
4. Remove the quarter window
outside fron t moulding (Fig. 16).
5. Working from inside the car,
loosen the weatherstrip from the
window opening flange, and push
the window, weatherstrip and mo uld-
ing assembly out of the opening.
6. Remove the moulding and
weatherstrip from the glass.
7. U sing solvent, remove all old
Woodbridge, VA 22192
www.ForelPublishing.com
i.
WEATH ERST RIP - 2990d · 5
sealer from the window opening
flange, the window and the weather-
strip.
INSTALLATION
I. Appl y a bead of sealer around
the window opening flange.
2. Position the weatherstrip on
the glass and install the outer mould-
ing in the weatherstrip.
3. l nstall a draw cord in the
weatherstri p, and app ly Ru-G lyde to
the weatherstrip su rfaces that wi ll
contact the window open ing flange.
4. Position the window assembly
to th e window opening a nd use the
draw cord to pull the weatherstrip
over the window opening flange.
5. Using a caulking gun, apply
sea ler between the outside of the
glass a nd the weatherstrip.
6. l nstall the outside front mou ld-
ing retaining screws (Fig. 16).
7. Install the inside qua rter win-
dow fro nt garnish mouldings.
8. Insta ll the inside lower garnish
moulding.
9. Check for water leaks, then
c lean the glass and mouldings.
10. Install the spare tire and cover.
WINDSHIELD-COMETI
FALCON, FAIRLANE
Following is a general ized pro-
MOULOING- 290A66· 7
\ A SEAL ER
B SEALER
 -a
J>
...
~

/""
/--
..
"I
(,.)
I
c
0
0
~
~

::e
z
c
0
::e
~
.....
l>
Forel Publishing Company, LLC ;::::
Woodbridge, VA 22192 C")
www.ForelPublishing.com .....
l>
""
l>
:z
c
c
""
"""
::::-:::
,....
6

VIEW-B N 1489-A

FIG. 17-Windshield Installation-Comet, Falcon, Fairlane Except Model 76

 ...
.......
~
°""

LOWER
VIEW· E SPACER- Q
OJOA 12 ~
0
.,,c
...
.......
I
m
0
c
...-<
Forel Publishing Company, LLC
c
Woodbridge, VA 22192 0
www.ForelPublishing.com 0
::::IC
V'\

:J::iio
:z
c
:e
zc
0
:e
V'\

·.

VIEW-B

FIG. 1 8-Windshield Installation-Comet, Falcon, Fairlane-Model 76

 PART 17-3-DOORS, WINDOWS, TAILGATE AND DECK LID
cedure for windshield glass replace-
ment. Refer to F igs. 17 and 18 for
Comet, Falcon or Fairlane models.
On convertible models, lower the
top assembly.
REMOVAL
1. Model 76: Remove the pillar
weatherstrips, weatherstrip retainer
retaining screws and the weather-
strip retainers.
2. Remove the wiper arm and
blade assemblies.
3. Remove the cowl top ventilator
grille panel retaining screws and re-
move the cowl top ventilator gri lle
panel.
4. Remove the outside top mould-
ing retaining screws (Model 76) or
unsnap the upper moulding retainers,
(a ll other models), using tool T 64P-
42430 R or L and remove the out-
side top moulding.
5. Remove the outside side
moulding retaining screws and re-
move the outside side mouldings.
6. Remove the outside lower
moulding retainer retai ning screws.
Remove the outside lower moulding
and reta iners.
7. Remove the sun visor and
bracket assemblies.
8. Remove the interior rear view
FIG. 19-Windshield Installation-Mustang Body Types 63, 65
mirror. On models with the rear view
mi rror attached to the glass do not
remove the mirror bracket from the
glass.
9. Remove the interior garnish
mouldings.
10. With the aid of an assistant,
and using a length of piano wire in-
serted between the seal and the flange
of the window opening, cut the seal
around the perimeter of the glass.
ll. Remove the windshield glass.
12. Remove the remaining butyl
tape seal from th.e pinchweld flange
of the window operiing and remove
the moulding retai ners and spacers
fro m the pinchweld flange.
INSTALLATION
1. C lean the pinchweld flange and
prime the flange.
2. fnstall the spacers and mould-
ing retainers on the pinchweld flange.
3. Temporarily position the glass
in the opening. Mark the center of
the glass and the cowl. Position suc-
tion cups on the outside of the glass
to facilitate handling.
4. Remove the glass from the
open ing. C lean a one inch surface
around the inside outer perimeter
of the glass and prime this surface
with the primer supplied in Kit
Forel Publishing Company, LLC
Woodbridge, VA 22192
www.ForelPublishing.com
SECTIONAL VIEW - DD ASSEMBLED
17-47
C4AZ- 19562-A.
5. Mix two tubes of sealer as
directed in Kit C4AZ- 19562-A.
6. Position the sealer in a caulk-
ing gun and apply approximately a
%6 -inch bead of sealer to the inside
edge of the glass.
7. Apply approximately a o/i. 6 -
inch bead of sealer to the pinchweld
flange.
8. Position the glass in the center
of the opening, using the locating
marks as a guide.
9. Remove the suction cups.
10. Install the outside mouldings.
Be sure that the cowl top panel seal
is installed under the lower outside
moulding.
11. Install the cowl top ventilator
grille panel.
12. Install the windshield wiper
arm and blade assemblies.
13. Install the interior garnish
mouldings, rear view mirror and sun
visors.
WINDSHIELD-MUSTANG
MODEL 63, 65
REMOVAL
1. Using Tool T64P42430 R or
L, remove the top left and right out-
side windshield mouldings (Fig. 19).
2. Using Tool T64P42430 R or
L, remove the left and right wind-
N1389-A
17-48 GROUP 17 - BODY, DOORS AND WINDOWS
shield outside side mouldings.
3. Remove the windshield wiper
arm and blade assembl ies.
4. Using Tool T64P42430 R or L ,
remove the windshield outside belt
mouldings (Fig. 19).
5. R emove the winds hield and
weatherstrip assemb ly by push ing
o utward a long the inner edges of the
windshield .
INSTALLATION
l. Remove the weatherstrip from
the glass.
2. Clean all old sea ler from the
weatherstrip and th e body open ing
flange.
3. Using a caulk ing gun, apply
sea ler in the weatherstrip glass open-
ing.
4. Position the weatherstrip on the
glass and insta ll a draw cord in the
body open ing groove of the weather-
strip.
5. Using a caulking gun, apply a
bead of sealer au the way around the
body opening outer flange.
6. Apply rubber lubricant to the
weatherstrip surface that contacts the
body opening fl ange.
7. Position the windshield and
weatherstr ip assem bly in the wind-
shield opening and, with a helper
applying pressure from the o utside,
V Forel Publishing Company, LLC
OUTSIDE TOP MOULDINGS
FIG. 20-Windshield Installation-Mustang Body Type 76
use the draw cord to pu ll the lip of
the weatherstrip over the window
opening lower flange, each sid e
flange and then over the upper
flange.
8. Install the outside belt mould-
ing (Fig. 19) by positioning it and
snappi ng it over its clip r eta in ers.
9 . Install the outside s ide mould-
ings by snapping them over their clip
retainers.
10. Install the top right and left
outside side m ould in gs by snappin g
them over their clip reta iners.
11. C lean the windshield and
moulcliogs.
12. Install the windsh ield wiper
arm and blade assemblies.
WINDSHIELD-MUSTANG
MODEL 76
REMOVAL
1. Lower the convertib le top.
2. R emove the rear view mirror.
3. Remove the four upper garnish
m oulding retaining screws and re-
move the upper garnish mo uld in g.
4. Remove the sun visor bracket
and pivot retaining screws and re-
move the sun visor assemblies.
5. Remove the front upper body
pillar weatherstrips (Fig. 20). Note
that these weatherstrips are pressed
into their r etainers.
Woodbridge, VA 22192
www.ForelPublishing.com
6. Remove the front upper body
pillar weatherstrip retainer retaining
screws (four) and remove the re-
tainers.
7. Remove the retaining screw and
two retain ing nuts from each left and
right windshield outside top mould-
ing and remove the mouldi ngs (Fig.
20, View AA).
8. Remove the two retammg
screws from eac h windsh ie ld outside
side moulding and, using Tool
T 64P42430 R or L, remove the out-
side side mou ldings.
9 . Remove th e windshield wiper
arm and blade assembli es.
10. Using Tool T64P42430 R or
L , rem ove the windshield outside belt
m ould ing.
11. Remove the windshield and
weatherstrip assembly by pushing
o utward along the inner edges of the
windshield.
LNSTALLATION
1. Remove the weatherstr ip from
the glass .
2. Clean all old sea ler from the
weatherstrip and the body opening
flange.
3. U sing a caulking gun, apply
sea ler in the weatherstri p glass opcn-
mg.
4. Position the weatherstrip on the
 PART 17-3 - DOORS, WINDOWS, TAILGATE AND DECK LID
glass and install a draw cord in the
body opening groove of the weather-
strip.
5. Using a caulking gun, apply a
bead of sealer all the way around the
body opening outer flange.
6. Apply rubber lubricant to the
weatherstrip surfaces that contact the
body opening flange.
7. Position the windshield and
weatherstrip assembly in the wind-
shield opening. With a helper apply-
ing pressure from the outside, use the
draw cord to pull the lip of the
weatherstrip over the window open-
ing lower flange. each side flange
and then over the upper flange.
8. Install the outside belt mould-
ing (Fig. 20) by snapping the mould-
ing over the retaining clips.
9. Install the outside side mould-
ings by snapping them over their
retaining clips and install the retain-
ing screws.
to. Position the left and right out-
side top mouldings and install the
retaining screws and nuts.
11. Position the left and right
front upper body pillar weatherstrip
retainers (Fig. 20) and install the
retaining screws.
12. Install the front upper body
pillar weatherstrips by pressing them
securely into their retainers.
13. Install the sun visor bracket
FIG. 21-Back Window Installation-Comet, Falcon, Fairlane
and pivot assemblies.
14. Position the upper garnish
moulding and install the garnish
moulding retaining screws.
15. Install the rear view mirror.
16. Clean the windshield and
mouldings.
17. Install the wiper arm :md
blade assemblies.
BACK WINDOW AND/OR
WEATHERSTRIP-COMET,
FALCON, FAIRLANE
REMOVAL
1. Using Tool T64-P42430-R or
L, release the outside upper mould-
ings (Fig. 21 ), from their moulding
retainers and remove the outside up-
per mouldings.
2. Using Tool T64-P42430-R or
L, release the outside lower mould-
ings from their moulding retainers
and remove the outside lower
mouldings.
3. From inside the car, loosen the
weatherstrip edges and then push
out the back window and weather-
strip as an assembly.
4. Place the window asembly on
a bench and remove the weatherstrip
from the glass.
INSTALLATION
1. Clean the glass, weatherstrip
and the body opening flange.
Forel Publishing Company, LLC
Woodbridge, VA 22192
www.ForelPublishing.com
OUTSIDE LOWER LEFT
MOULDING- 42405
!CD MOULOING RETAIN'ER LOCATIONS
\
® OUTSIDE LOWER RIGHT
MOULDING - 42404
\ ~
17-49
2. Using a sealer gun, apply sealer
in the weatherstrip glass opening.
3. Position the weatherstrip on the
glass, and then insta II the mould-
ings in the weatherstrip.
4. Insert the draw cord in the
weatherstrip, and apply rubber lubri-
cant to the weatherstrip surfaces that
will contact the back window open-
ing flange.
5. Using a sealer gun, apply a
bead of sealer completely around the
back window opening.
6. Position the window assembly
in the body opening. With a helper
applying hand pressure from the
outside. use the draw cord to pull
the lips of the weatherstrip over the
window opening flanges.
7. Install the outside lower left
and right mouldings.
8. Install the outside upper left
and right mouldings.
9. Clean the window and mould-
ings.
BACK WINDOW-MUSTANG
MODEL 65
REMOVAL
1. Using Tool T64P42430 R or L,
remove the outside side mouldings
and the outside upper corner mould-
ings.
2. Using Tool T64P42430 R or L,
~ OUTSIDE UPPER RIGHT
~ MOULDING-42430
R 1245- C
17-50 GROUP 17 - BODY, DOORS AND WINDOWS
remove the outside upper moulding
and the outside lower moulding.
3. Remove the back window and
weatherstrip assembly by pushing
outward along the inner edges of
the glass.
4. Remove the weatherstrip from
the glass.
INSTALLATION
1. Clean all old sealer from the
weatherstrip and the body opening
flange.
2. Using a caulking gun, apply
sealer in the weatherstrip glass open-
ing groove.
3. Position the weatherstrip on
the glass and install a draw cord in
the weatherstrip body opening
groove.
4. Using a caulking gun, apply a
bead of sealer all the way around
the body opening flange.
5. Apply rubber lubricant to the
weatherstrip surface that contacts the
body opening flange.
6. Position the window and
weatherstrip assembly in the body
opening and, with a helper applying
pressure from the outside, use the
draw cord to pull the lip of the
weatherstrip over the body opening
flange.
7. Snap the outside lower mould-
FIG. 22-Back Window Installation-Mustang Body Type 65
ing into position over its retaining
clips (Fig. 22).
8. Snap the outside upper mould-
ing into position over its retaining
clips (Fig. 22).
9. Snap the outside side mould-
ings into position over the retaining
clips (Fig. 22).
10. Install the outside upper cor-
ner mouldings.
11. Clean the glass and mould-
ings.
BACK WINDOW-MUSTANG
MODEL 63
REMOVAL
1. Remove the quarter trim upper
front moulding retaining screws and
remove the quarter trim upper front
mouldings.
2. Remove the quarter trim upper
rear moulding cap retaining screw
and remove the cap. Remove the
quarter trim upper left and right
rear moulding retaining screws and
remove the mouldings. (Fig. 23).
3. Remove the back window gar-
nish moulding upper joint cover. Re-
move the back window upper left
and right garnish moulding retaining
screws and remove the mouldings
(Fig. 23).
4. Remove the left and right vent
Forel Publishing Company, LLC
Woodbridge, VA 22192
www.ForelPublishing.com
OUTSIDE TOP
air extractor grille assembly (quarter
trim upper front panels) retaining
screws and remove the panels (Fig.
23).
5. Remove the back window
lower front left and right trim panel
retaining bolts and screws and re-
move the panels (Fig. 23).
6. Remove the quarter trim upper
rear left and right panel retaining
screws and remove the panels.
7. Using moulding removal Tool
T64P-42006-A or B, remove the
back window exterior mouldings in
the following order: right upper
moulding, right lower moulding, left
upper moulding and left lower
moulding (Fig. 24).
8. With an assistant applying pres-
sure from the inside, remove the
back window and weatherstrip
assembly.
9. Remove the weatherstrip from
the glass.
INSTALLATION
1. Clean excess old sealer from
the body window opening.
2. Clean old sealer from the
weatherstrip if the weatherstrip is to
be re-used.
3. Position the weatherstrip on the
glass and install a pull cord (1/s inch
sash cord) around the weatherstrip
MOULDING RETAINER
M1390-A
 PART 17-3 - DOORS, WINDOWS, TAILGATE AND DECK LID
UPPER FRONT
QUARTER TRIM
PANEL· 6331002.
FIG. 23-lnterior Moulding and Quarter Trim Panel Installation-
Mustang Body Type 63
body opening groove.
4. With the aid of an assistant,
position the glass and weatherstrip
assembly in the body window open-
FIG. 24-Back Window Installation-Mustang Body Type 63
VIEW - AA ASSEMBLED R 1289 ·A
ing. Use the pull cord to pull the lip
of the weatherstrip over the pinch-
weld while applying pressure to the
glass from the outside.
Forel Publishing Company, LLC
Woodbridge, VA 22192
www.ForelPublishing.com
17-51
5. Apply sealer between the
weatherstrip and the outside pinch
weld flange.
6. Apply sealer between the outer
glass surface and the weatherstrip.
7. Snap the window exterior
mouldings into place in the follow-
ing order; left lower moulding, left
upper moulding, right lower mould-
ing and right upper moulding.
8. Install the upper rear left and
right quarter trim panels.
9. Install the upper front left and
right quarter trim panels.
1O. Install the back window lower
front trim panel.
11. Install the upper rear left and
right quarter trim mouldings and
moulding cap.
12. Install the upper front left and
right quarter trim mouldings.
13. Install the back window upper
left and right garnish mouldings and
garnish moulding joint cover.
14. Cle~;n the back window and
mouldings.
INSIDE REAR VIEW MIRROR
-BONDED TO WINDSHIELD
REMOVAL
1. Clean both the inside and out-
side surfaces of the windshield in the
area of the mirror mounting bracket.
17-52
Inspect the windshield for stone
chips and scratches.
2. Using welding putty or wet
rags, insulate all chips or scratches
within 12 inches of the mirror
mounting bracket.
3. Apply heat to the bracket
mounting area from outside the
windshield with a standard 250 watt
infrared bulb (heat lamp). Hold the
lamp approximately 4 inches from
the windshield, and rotate it in a
small circle.
4. The mirror mounting bracket
can be pulled off the windshield
glass in approximately 8-10 minutes
using the mirror as a handle.
5. Slowly remove the heat lamp.
Do not remove the insulating mate-
rials until the windshield has cooled
to room temperature.
6. Remove the mirror and arm
from the bracket.
INSTALLATION
1. Locate and mark with a wax
pencil the bracket location on the
·:·:-···,:··.'·,'.',"'·,'
'•,,'• .',•,
~;..:::-=::.:-:::::_:~:__
FOR 2112 MINUTES
EPOXY CATALYST
FIG. 25-Bonded Rear View Mirror Installation-Comet, Falcon, Fairlane
GROUP 17 - BODY, DOORS AND WINDOWS
outside surface of the windshield
(Fig. 25).
2. Use a good grade of Ethyl Al-
cohol to thoroughly clean the inside
glass surface bracket mounting area
and mounting bracket face. It is im-
portant that the mounting surfaces
are properly cleaned before the resin
is applied.
3. To mix the resin pour the en-
tire contents of the small catalyst
bottle ino the large epoxy bottle
(Fig. 25).
4. Stir the contents for 3 to 5
minutes.
To guarantee the correct mixing
ratio and resulting bond strength it
is mandatory that the entire contents
of both bottles are used and prop-
erly mixed. Under no circumstances
should only portions of the epoxy or
catalyst be used.
5. Apply the mixed resin to the
bracket mounting surface. Level off
the resin film as smoothly as pos-
sible.
6. Place the mounting bracket
A not be mounted to the bracket for
Forel Publishing Company, LLC
.
Woodbridge, VA 22192
www.ForelPublishing.com
---------
v
'
WINDSHIELD
~
==--i
___..._.._~....___.] ~
BRACKET
SECTIONAL VIEW AA
MIRROR ASSEMBLY
Rl 175-A
surface upward in a vise or in a
small mound of permagum or any
suitable holding material that will
support the mounting bracket (Fig.
25). Hold a standard 250 watt infra-
red lamp about 5 to 6 inches from
the mounting surface of the bracket
for 2V2 minutes.
7. Allow the bracket to cool for
one minute. With light hand pres-
sure apply the mounting surface ol'
the bracket to the desired inside area
of the windshield.
8. Secure the bracket to the wind-
shield using a piece of tape about 5
inches long located just under the
knob of the bracket. Apply another
piece of tape in the vertical direction
to firmly hold the mounting bracket
in place on the windshield.
9. When the temperatures are
above 67°F., the mirror and arm
should not be mounted to the brack-
et for 8 hours, to allow the resin to
properly adhere the bracket to the
glass. However, the car may be used
with the bracket taped in place one
hour after installation.
When the temperatures are below
67°F., the mirror and arm should
16 hours. However, the car can be
used 2 hours after the bracket has
been taped in place.
10. After the bracket has had
time to adhere to the glass, remove
the tape and install the mirror and
arm to the bracket.
TAI LG A TE GLASS
REMOVAL
1. Open and temporarily support
the tailgate.
2. Remove the tailgate cover
panel retaining screws and remove
the panel.
3. Remove the window regulator
arm roller retaining pins, disconnect
the arms from the rollers, and re-
move the rollers from the glass
channel.
4. Remove the window from the
tailgate.
INSTALLATION
1. With a glass remover tool, re-
move the glass lower retainer and
channel, and weatherstrip.
2. Remove the weatherstrip from
the glass lower retainer and channel
assembly, and then clean the glass
groove.
3. Position the weatherstrip into
the glass lower channel. Install the
weatherstrip and channel to the
glass.
 PART 17-3 - DOORS, WINDOWS, TAILGATE AND DECK LID 17-53

4. Slide the wiodow assembly
ioto the glass ruos a od conoect the
regulator arms aod rollers to the
glass lower chanoel.
5. Apply Lubriplate to the glass
rollers.
6. Clean the old sealer fro m the
tailgate cover panel and apply new
sealer.
7. Iostall the ta ilgate cover paoel
to the tailgate.
8. Connect the tailgate hinge sup-
ports a nd remove the temporary
support.
TAILGATE WINDOW
REGULATOR-COMET, FAIRLANE
REMOVAL
If the tailgate window regulator
mechanism should fail with the win-
dow in a partially closed or closed
position, the tailgate can be opened
by removing the window side and
upper runs (Fig. 26).
1. Opeo aod temporarily support
the tailgate.
2. Discoonect the ta ilgate hinge
supports at the tail gate.
3. Remove the tai lgate cover pao-
el retaining screws aod remove the
panel.
4. Remove the wiodow regulator
arm roller retaining pins, disconnect
the arms from the rollers, and re-
move the rollers from the glass
channel.
5. Remove the tailgate window
from the tailgate and scribe the reg-
ulator mounting location.
6. Remove the regulator retaining
bolts and remove the regulator.
INSTALLATION
1. Place the regulator manua l
drive spline into the h andle, a lign
the regu lator, and install the regu-
lator retaining bolts.
Insta ll the window assembly in
the ta ilgate.
2. Clean the old sealer from the
ta ilga te cover panel and apply new
sealer.
3. Install the tailgate cover panel
to the tailgate.
TAILGATE WINDOW
REGULATOR-POWER
REMOVAL
If the tailgate window regulator
mecha nism should fail with the
window in a partially closed or
closed position, the tailgate can be

SEALER
MOULDING AND RUN RETAINER

Forel Publishing Company, LLC MOULDING AND

Woodbridge, VA 22192 RUN RETAINER

www.ForelPublishing.com
SIDE UPPER RUN

SEALER

BUMPER

ANTl·RA TILER

Rl 132-B

FIG. 26-Tailgate and Weatherstrip Installation-Typical

17-54 GROUP 17 - BODY, DOORS AND WINDOWS
opened by removing the wi ndow
side and upper runs (Fig. 26).
1. Open and temporarily support
the tailgate.
2. Disconnect the tailgate hinge
supports at the tailga te.
3. Remove the tailgate cover pan-
el retai ning screws and remove the
panel.
4. Remove the window regu lator
arm roller retainin g pins, disconnect
the arms from the rollers, and re-
move the rollers from the glass
channel.
5. Remove the window from the
tailgate.
6. Disconn ect the motor leads
from the wiri ng harness in the tail-
pre. . assembly to reveal the mountmg
7. Scribe the regulator mountmg
location, remove the regulator re-
taining bolts, and remove the regu-
lator with the motor a ttached.
INSTALLATION
1. Do not remove the electric
regulator drive assembly for transfer
to the new regulator until the regu-
lator counterbalance spring is un-
loaded. T o unload the regu lator
cou nterbalance spring, place the
spring in a vise so that the spring
cannot unwind, disconnect the
spring from the outer retaining tab,
and then slowly loosen the vise jaws.
2. Remove the sc rews retaining
the regula tor drive assem bly and the
motor to the regulator and remove
the drive assembly and mo tor.
3. Position the drive assembly
and motor to the new regula tor and
install the retai nin g screws.
4. Drill out the rivets retaining
the manual clutch and housing as-
sembly to the regulato r. Remove and
discard the manual drive assembly.
The manual clutch and gear assem-
bly should not be removed until the
electric drive assembly is instaJled.
S. Instal l the regulator assembly
on the tail gate and align th e regu-
lator as requ ired.
6. Connect the wiri ng harness to
the motor and secure the harness in
place with the reta iner.
7. Install the window assembly
into the ta ilgate.
8. Apply Lu briplate to the glass
rollers.
9. Clean the old sealer from the
tailgate cover panel and apply new
sealer.
I 0. Install the tailgate cover pan-
el to the tai lgate.
11. Connect the tailga te hinge
supports and remove the temporary
s upport.
TAILGATE SWITCH AND 6. Apply Lubr iplate to the glass
LOCK CYLINDER-POWER rollers.
REMOVAL 7. Clean the old sealer from the
1. Open and temporarily support ta ilgate cover panel and apply new
the tailgate. sealer.
2. D isconnect the tailgate hinge 8. Install the tailgate cover panel
supports at the tailgate. to the ta il gate.
9. Connect the tailgate hinge sup-
3. Remove the tailgate cover pan-
el retaining screws and remove the ports and remove the temporary
panel. support.
4. Remove the window regulator
TAILGATE WINDOW HANDLE
arm ro ller retaining pins, disconnect AND LOCK CYLINDER-
th e arms from the rol l.ers, and re-
MANUAL
move the rollers fr om the glass REMOVAL
channel.
5. Remove the window from the 1. With the tailgate window !n
the closed position, unlock the ta il-
tail gate.
gate ha nd le, and rotate the han?le
6. Remove the regulator.
7. Remove the nuts retaining the
Jock and switch, and then remove screws (Fig. 28). .
2. Remove the handle mountmg
the Jock and lock cylinder from the
screws, and then remove the handle
tailgate (Fig. 27).
8. If the switch requires rep lace- assem bly and pad.
3. T o remove the lock cylinder
ment d isconnect the switch w ires
turn the key in the cylinder to align
from ' the tailgate wiring harness and
the cylinder locking pin with the ac-
remove the switch and wires.
cess hole in the handle assembly.
9. To remove the lock cylinder,
Depress the locking pin and remove
depress the lock cylinder retaining
the lock cy li nder.
pi n, insert th e key and rotate the
cyli nder until the retaining pin d rops, INSTALLATION
and then remove the lock cylinder.
1. To replace the lock cy lin d~ r ,
INSTAL LATION transfer the 0-rings, and then with
the key in the cyli nder, install the
1. To install the lock cylinder, in-
Forel lock cylinder in the handle assembly.
serL Publishing Company,
th e key in the LLC and
lock cylinder
2. lf the window regulator has
slidWoodbridge,
e the cylinderVAinto 22192 r etainer.
the
been replaced, it may be necessary
2. To insta ll the switch assembly,
www.ForelPublishing.com
route the wiring harness through the
to reposition the handle. assemb.ly so
that it hangs in a vertical pos1tion,
ta ilga te to the ta ilgate harness swi tch
with the tailgate window in a close?
connector.
position. To adjust the han?le posi-
3. Place the lock assembly and
tion, remove the snap rmg and
gasket to the tailgate and position
socket from the window regulator
the switch to the lock assem bly. It
stem , and then install the socket
may be necessary to rotate the lock
with the notch at the top.
cylind er to align the switch and the
3. Install the pad and handle as-
lock. Install the retaining nuts.
sembly.
4. Install the window regulator.
5. Install the tailgate window as-
sembly into the tailgate.
TAILGATE UPPER EDGE
0-RING
LOCK
CYLINDER
PAD
R1081 - B
SWITCH
R1082-A
FIG. 28-Tailgate Window
FIG. 27-Tailgate Switch and Regulator Handle Installation
Lock Installation-Typical -Typical
 PART 1 7 -3 - DOORS, WINDOWS, TAILGATE AND DECK LID
DUAL-ACTION TAILGATE
HINGES
REMOVAL AND
INSTALLATION
Upper Left Hinge
1. Open the tailgate (horizontally,
as a dropgate) and scribe a location
mark around that part of hinge to
be replaced.
2. Remove the hinge retainer
screws.
3. Position the hinge to the scribe
marks and install the retainer screws.
Lower Left Hinge
1. Open the tailgate (horizontally,
as a dropgate) and position a sup-
port under the hinge side of the gate.
2. Remove the tailgate door
check. Raise the tailgate partially
and remove the torsion bar retainer
link from the body.
3. Scribe the hinge location on
the body and the tailgate. Remove
the hinge retainer screws and re-
move the hinge.
4. Position the hinge to the body
and tailgate scribe marks and in-
stall the hinge retainer screws.
5. Close the tailgate and check
for proper lower hinge alignment.
Adjust the hinge if necessary.
6. Open the tailgate partially and
install the torsion bar retainer link
to the body.
7. Install the tailgate door check.
DUAL-ACTION TAILGATE
LOCKS
REMOVAL AND
INSTALLATION
Right Lower Lock
1. Open the tailgate (side open-
ing). Remove the tailgate trim panel,
watershield and access panel.
2. Disconnect the linkage from
the lock. Remove the three retaining
screws and remove the lock.
3. Transfer the linkage retainer
clips to the new lock. Position the
lock in the gate and install the re-
tainer screws.
4. Install the linkage to the lock.
Install the access cover, watershield
and trim panel.
Right Upper Lock
1. Open the tailgate (side open-
ing). Remove the tailgate trim panel,
watershield and access panel.
2. Engage the upper lock pawl to
the closed position and raise the win-
dow partially out of the gate. Re-
move the regulator arms from the
window regulator channel and re-
move the window assembly.
3. Disconnect the linkage at the
upper lock. Remove the wire con-
nector from the upper lock safety
switch.
4. Remove the right guide upper
retainer bolt. Remove the three
screws retaining the lock and remove
the lock assembly.
5. Tran sfer the linkage retainer
clips and the safety switch to the
new lock assembly.
6. Position the lock in the gate
and install the lock retainer screws.
Install the window guide upper re-
tainer bolt.
7. Connect the wire connector to
the switch and connect the linkage
to the lock.
8. Position the window assembly
in the gate and install the regulator
arms to the regulator channel. Close
the lock pawl to engage the switch
and lower the window into the tail-
gate.
9. Install the tailgate access panel,
watershield, and trim panel. Open
the upper lock and close the tail-
gate. Check the lock alignment to
the striker. Adjust the lock striker
if necessary.
DUAL-ACTION TAILGATE
TORSION BAR
REMOVAL
1. Forel
Remove Publishing Company,
the tailgate LLC
trim panel,
watershield and access cover.
Woodbridge, VA 22192
2. Move the tailgate glass out
www.ForelPublishing.com
partially by closing the right upper
lock pawl and turning the key in
the tailgate cylinder.
3. Remove the lock control bell-
crank assembly and window lower
stop.
4. Loosen the window regulator
motor harness to gain slack at the
tailgate-to-body location.
5. Raise the tailgate partially and
remove the torsion rod retainer link
from the body (2 screws).
6. With an assistant. remove the
left lower hinge pivot bolt. Unlock
the right lower lock, remove one
check cable retainer screw from
each side and move the tailgate as-
sembly away from the body opening.
Place the tailgate on an appropriate
stand approximately bumper high.
7. Remove the torsion bar re-
tainer bracket and remove the tor-
sion bar from the left side of the
gate. (Fig. 29).
INSTALLATION
1. Place the torsion bar in its
respective mounting position and in-
stall the torsion bar right retainer
bracket.
17-55
2. With an assistant, position the
tailgate assembly to the body open-
ing. Engage the right lower lock to
the striker plate. Install the left
hinge pivot bolt and install the
check cable retainer screws.
3. Install the torsion bar retainer
link to the body.
4. Position the motor wiring har-
ness in its original position.
5. Install the window lower stop
and lock the bellcrank assembly.
6. Lower the window in the tail-
gate to where the top edge of the
glass is even with the weatherstrip
and adjust the lower stop if neces-
sary.
7. Install the tailgate access cover,
watershield and trim panel.
DECK LID HINGE OR
TORSION BAR
REMOVAL
1. Prop the deck lid open.
2. Mark the hinge position on the
lid and on the mounting bracket for
reference when a new hinge is in-
stalled.
3. Using a tool T64K-44890-B
pry the anchor end of the torsion
bar out of its adjustment notch (Fig.
30). Lower the deck lid and from
inside the luggage compartment re-
move the bar.
4. Position a cover under the
hinge edge of the deck lid to pre-
vent paint damage. Remove the
hinge attaching bolt from the deck
lid and from the mounting bracket,
and remove the hinge.
INSTALLATION
1. Position the hinge, and par-
tially tighten the mounting bolts.
2. Remove the protective cover
and install the torsion bar, reversing
the procedure in step 3 above. The
farther rearward the anchor end is
twisted, the greater the tension.
3. Remove the prop and check
the lid position. After any necessary
adjustment, tighten the hinge attach-
ing bolts.
DECK LID LOCK
1. Unlock and open the deck lid.
2. Remove the bolts retaining the
lock assembly and remove the lock.
3. Position the lock assembly to
the deck lid and loosely install the
retaining bolts.
4. Adjust the lock assembly and
tighten the bolts.
DECK LID LOCK CYLINDER
REMOVAL
1. Open the deck lid and remove
17-56 GROUP 17 - BODY, DOORS AND WINDOWS

OUTSIDE LOCK RELEASE

HANDLE 430A70

HANDLE PAD
430A74

OUTSIDE HANDLE
BRACKET 430A66

";;-'~ CONTROL~
~~~:-=--~-
LOCK RELEASE LOCK RELEASE

~~~::~~.'=:~~'""''~-~--
43170 HANDLE 31062

K ASSEMBLY\':.\~ -..., ~··· ' ·,

LOWER HINGE
STOP 430A48

')~._,,:.C .<0\\
·~---------~~~\~fr()j~J
ACCESS HOLE TORSION BA ; ij!
COVER 40790
Forel Publishing Company, LLC
43012 R
UPPER LOCK
ro.".'~~~:¢~,~~30
Woodbridge, VA 22192 NTE ~; \"...,
p:
-·-....__ o ·:
www.ForelPublishing.com
' 'LOWER HINGE
·.

UPPER LOCK
RELEASE LINK 431054

LOCK RELEASE
HANDLE 31062
!ll
i Ii
~~
~l

t
UPPER HINGE
TORSION BAR RELEASE LINK
43012 --=:=::::-- 431E60
R 1114-C

FIG. 29-Tailgate lock Mechanism

 PART 1 7 -3 - DOORS, WINDOWS, TAILGATE AND DECK LID 17-57

turn the key in the cylinder Vs turn
clockwise from the locked position
and insert the cylinder into the
sleeve assembl y.
2. Position the sleeve assembly
spacer, and washer to the deck lid
door and install the retaining nut.
3. Position the door lock exten-
sion, install the lock assembly and
adjust it.

TORSION BAR
ACTUATING END

Nll 89- A

FIG. 30-Deck Lid Torsion Bar

-Typical

the lock assembly and the door lock

extension.
2. Remove the sleeve assembly re-
taining out, lock washer, spacer, and
sleeve and cylinder (Fig. 3 I).
3. To remove the lock cylinder
from the sleeve assem bly, turn the

"""~
key in the cylinder Vs turn clockwise
from the locked position, depress the
cylinder retaining pin, and remove COC<

f~,./~
the key and cylinder.
INSTALLATION R1247-A

1. T o install the lock cylinder FIG. 31 - Deck Lid Lock Installation-Typical

Forel Publishing Company, LLC

Woodbridge, VA 22192
www.ForelPublishing.com

TRIM~ SEATS, AND
CONVERTIBLE TOP
PART 18-1
INTERIOR TRIM AND LANDAU
TOP COVER ..... .... ... . .
PART 18-2
SEATS .. .. ................... 18-11
PART INTERIOR TRIM AND LANDAU TOP COVER
18-1
Section
l Door and Quarter T rim Panels ................ 18- I
2 Headlining . . ................... . ... ... ... ... 18- 3
3 Instrument Panel Safety Cover .... .. ... . .... . .. 18- 7
D DOOR AND QUARTER TRIM PANELS
REMOVAL AND INSTALLATION
Basically, all door and quarter
trim panels are retained in the same
manner. In view of this, one removal
and installation procedure will cover
all models.
1. Remove the window regulator
handle and the four inside handle
retaining screws and remove the
handles from their shafts.
2. Remove any screws retaining
the trim panel to the inner panel,
such as the arm rest retaining screws
(Fig. I).
PAGE PART 18-3
CONVERTIBLE TOP
. 18- 1
Forel Publishing Company, LLC
Woodbridge, VA 22192
www.ForelPublishing.com
Page Section
4 Conso le .......... ..... . . ... .. ... . . .. . ...... 18- 9
5 Roof Outside Cover .. . . . . . ......... . .. . .. . . . . 18- 9
3. With a putty knife, pry the trim
panel retaining clips out of the inner
panel at each side.
4. Bow the trim panel out of the
r etainers, and carefu lly loosen the
water shield , if necessary.
5. Place a daub of sea ler ov_er each
trim retaining clip hol e to seal the
retaining clips when they are pushed
into the door. Also, apply thi s sea ler
around the window regulator shaft
and other existing holes.
6. Fasten the water shield to the
inner panel (Figs. 2 and 3).
18-l
GROUP
18
PAGE
. 18-19
Page
7. Make sure that all the retaining
clips are installed in the trim panel.
Place the upper edge of the trim
panel in the retainer, bow the trim
panel , and then insert the lower edge
-
into the retainer. Push the retaining
clips into th e holes in the door inner
panel.
8. Install the arm r est retaining
screws.
9. Place the friction plate against
the trim panel and push the handle
onto the shaft. Install the handle re-
taining screws.
18-2 GROUP 18 -TRIM, SEATS, AND CONVERTIBLE TOP

DOOR TRIM MOUL DING

(MODEL 54D) - 25626 - 7
LO WER TRIM PANE L
RETAINER - 23760

R 1035 - B

FIG. 1-Typical Door Trim Panel Installation

Forel Publishing Company, LLC

Woodbridge, VA 22192
www.ForelPublishing.com

SECTIONAL VIEW DD
SECTI ONAL SECTIONAL SECTIONAL SECTIONAL
VIEW - J J VIEW - CC

,;;;;.;~:V:l:EWJ-UFF~~=~V~IE~W~-~G~G:;;=;;;:;;;,,_,_ VIEW _ HH

WATERSHIELD - 237A04 · 5

A SEALER
B SEALER
C TAPER
D TAPE
E TAPE
F SEALER WAT ERSHIELD-27458 - 9
G TAP E N 1102 - D

FIG. 2-Typical Door Trim Water Shields

 PART 18-1 - INTERIOR TRIM AND LANDAU TOP COVER
FIG. 3-Typical Quarter Trim Water Shields
EJ HEADLINING
COMET-FALCON-FAIRLANE
REMOVAL
1. Remove the sun visors and rear
view mirror.
2. Remove the windshield side
and upper garnish mouldings.
3. Pull the door opening weather-
strips down far enough to provide
access to the headlining perimeter.
4. Remove the rear seat cushion
and seat back.
5. Remove the quarter trim
panels.
6. Remove the rear package tray
trim panel.
7. Remove the coat hooks and the
dome light lens assemblies.
8. Unhook the headlining from
the rear quarter retaining strips.
9. Cut the headlining loose around
the back window.
1O. Peel the headlining from
around the windshield and door
openings (Figs. 4 and 5).
11. Unhook the headlining sup-
port rods and remove the headlining
assembly from the car.
INSTALLATION
1. Unpack and lay out the new
headlining.
2. Transfer the support rods from
the old headlining to the new one.
3. Position the headlining in the
car and insert the support rod ends
into their respective retaining holes
in the roof side rails.
4. Measure and trim excess mate-
rial from the headlining around the
back window.
5. Apply trim cement around the
back window flange and around the
mating headlining edge. Tuck the
headlining under the back window
weatherstrip and pull out any wrin-
kles. Forel Publishing Company, LLC
Woodbridge,
6. Apply VAaround
trim cement 22192 the
www.ForelPublishing.com
rear quarter area and to the mating
surface of the headlining. Hook the
headlining material over the retain-
ing strips and bend the retainer tabs
down.
7. Apply trim cement to the roof
header and to the mating surface
around the front of the headlining.
8. Position the headlining to the
roof header and pull out any wrin-
kles.
9. Apply trim cement around the
door openings and mating surface of
the headlining. Steam between the
headlining panels as required to help
remove any wrinkles and secure the
headlining perimeter.
10. Trim the excess headlining
material.
11. Install the package tray and
quarter trim panels.
12. Install the coat hooks and
dome light lens.
13. Install the windshield upper
and side interior mouldings.
14. Install the windlace around
the door openings.
15. Install the rear view mirror
and sun visors.
16. Install the rear seat back and
18-3
WATER SHIELD
R1258-A
rear seat cushion.
17. Clean· the interior and head-
lining.
MUSTANG (MODEL 63)
1. Remove the sun visors and the
inside rear view mirror.
2. Remove the roof headlining
side front retainer from each A pil-
lar (Fig. 6-View BB).
3. Remove 5 screws and remove
the back window upper garnish
moulding.
4. Remove 4 screws and remove
the quarter trim upper front mould-
ings and caps (Fig. 7).
5. Remove 5 screws and remove
the quarter trim upper front panel.
6. Remove the windlace from the
door openings (Fig. 6).
7. Cut the headlining at the wind-
shield weatherstrip and loosen the
headlining.
8. Cut the headlining at the back
window weatherstrip and loosen the
headlining.
9. Pull the headlining from the
door opening pinch weld, disconnect
the bows. and remove the headlining.
1 O. Place the old and new head-
1inings on a clean surface and trans-
fer the bows to the new headlining.
The bows are color coded on one
end for identification (Fig. 6).
11. Position the headlining in the
car and install the roof bows in the
side rails.
12. Apply trim cement (C2AZ-
19C525-A) to the back side of the
18-4 GROUP 18 -TRIM, SEATS, AND CONVERTIBLE TOP
LOWER SIDE RETAINER
(MODEL 54)-52194 - 5

HEADLIN ING ASSEMBLY -

5 1916

NO. l SUPPORT
(PURPLE · YELLOW )- 52 10 l

SIDE REAR LOWER TACKI NG

STRI P - 50992 R 11 67 - B

FIG. 4-Headlining Installation-Typical Comet, Falcon, Fairlane

Forel Publishing Company, LLC

Woodbridge, VA 22192
www.ForelPublishing.com FRONT SOUND
ABSORBER- 54310
V I EW - E E

NO. 2 SUPPORT
(BRON ZE· BRONZE) 52102

TRIM MOULOING-
SEC T I ON AL 03542
VIE W - AA
HEADLINING RETAINER
STRIP- 50966

A · B·C· D · E· F ADHESIVE (C2AZ-19C525·A)

R 1259-B

FIG. 5-Headlining Installation-Typical Station Wagon

 PART 18-1 - INTERIOR TRIM AND LANDAU TOP COVER 18-5

SECTIONAL RETAIN ER
VI EW- AA 63521 80

CEM ENT
19C525
NO. 3 BOW
ONE ENO P INK ~ ~°J:.Jtl)ff;f.'.:;;.'
6352102 ~~

.·~~·
r~~ ·
f/Y
WlNDLAC E
RETAIN ER
65026 1d
Forel Publishing Company, LLC
Woodbridge, VA 22192 R 1294· A

FIG. 6-Headlining Installation-Mustang Model www.ForelPublishing.com

63

headlining at the back window open-

ing.
13. Tuck the headlining under the
back window weatherstrip. Smooth
out any wri nkles or gather ing and
trim off any excess material.
14. Apply trim cement (C2AZ-
19C525-A) to the back side of the
head lining at the windshield opening.
15. Tuck the h eadlin ing under the
windshield weatherstrip. Smooth out
any wrinkles or gatheri ng and trim
off any excess material.
16. Apply trim cement (C2AZ-
19C525-A) to the r oof side rails at
the door openings. Positio n the head-
lin ing to the side rails and trim off
any excess material (Fig. 6).
17. Install the windlace in the
REAR QUARTER L OWER door openings.
'I TRIM PANEL . 6331 070 18. Iastall the roof headlining side
----
-
UPPER FRONT OUAR TE R
TRIM MOULDING . 6331282

L OWER FRCNT QUARTER

T RIM PANEL · 6331486

UPPER FRONT QUARTER TRI M MOULDING CA P. 63290C86 VI EW - AA ASSEM BLED R 1289· A

front retainer at each A pillar.
19. Install the inside rear view
mirror and sun visors.
20. Install the right and left quar-
ter trim upper front panels (Fig. 7).
21. Install the quarter trim upper
FIG. 7-lnterior Mouldings and Quarter Trim Panel Installation fro nt mou ldings and front caps.
18-6 GROUP 18 - TRIM, SEATS, AND CONVERTIBLE TOP

22. Install the back window upper
garnish moulding.
23. Clean all mouldings and re-
move any headlining scraps from the
car.
MUSTANG (MODEL 65)
1. Remove the rear seat cushion
and seat back and remove the quar-
ter trim panels.
2. Remove 2 clips and r etainers
and remove the package tray.
3. Bend back the headlining low-
er rear side retaining strip tabs
(Fig. 8).
4. Remove the coat hanger hooks.
5. Remove the sun visors.
6. Remove the headlining retain-
er from each A pillar (Fig. 8).
7. Remove 3 screws and remove
the rear view mirror.
8. Remove the door opening wind-
lace from each side of the body.
9. Cut the headlining along the
edge of the windshield and back
window weatherstrips.
10. Remove the headlining from
the right and left sides in the package
tray area. Then, r emove the head-
lining from the roof side rails and
remove it from the car.
11. Place the new and old head-
lining on a clean surface and trans-
fer the headlining support wires in
sequence to the new headlining. The
roof bows are color coded on one
end. When ordering new roof bows,
be sure to note the color code.
12. Position the headlining in the
car and install the rear support wire
and 2 rear support retainers. Then,
install the remaining support wires,
working towards the front of the car.
13. Trim the headlining at the
windshield header, leaving approxi-
mately 1h inch of material for tuck-
ing under the windshield header
weatherstrip.
14. Apply trim cement to the
windshield header and, starting from
the center, cement the headlining to
the header. Insert the remaining head-
li ning material under the windshield
header weatherstrip.
15. Trim the headlining at the
rear window, leaving approximately
l/2 inch of material for tucking under
the weatherstrip. Apply trim cement
to the rear window upper rail and,
starting from the center, cement the
headlining to the upper r ail. Insert
the remaining material under the rear
windoy; weatherstrip.
16. Pull the headlining down at
the sides to remove wrinkles. Cut the
listings at each end to eliminate gath-
ering of the material.
17. Apply trim cement to the left
roof side rail over the door and quar-
ter window. Pull the headlining down
to remove wrinkles and cement it in
p lace. Then, trim the headlini ng as
necessary. Cement and trim the r ight
side the same way.
18. Straighten the metal prongs
(View AA- Fig. 8) at the package
tray area; attach the headlining to the
prongs and bend the prongs down as

HEADLIN ING SUPPORT

RETAINER TRIM CEMENT
6452180 19CS25

Forel Publishing Company, LLC

Woodbridge, VA 22192 VIEW-BB
www.ForelPublishing.com

Rl 274-A

FIG. 8-Headlining Installation-Mustang Model 65

 PART 18-1 - INTERIOR TRIM AND LANDAU TOP COVER
shown.
19. Roll the lower rear side re-
taining strips into the headlining and
retain them by bending the tabs
(View AA).
20. Install the right and left roof
EJ INSTRUMENT PANEL SAFETY COVER
REMOVAL AND INSTALLATION
COMET,FALCON,FAIRLANE
1. Open the glove box door. Re-
move the glove box liner retaining
screws and remove the glove box
liner.
2. Fairlane: Remove the radio
control knobs and the control shaft
retaining nuts.
3. Comet: Remove the radio
speaker grill by prying upward to
release the two retaining clips.
4. Remove the instrument cluster
retaining screws.
S. Pull the instrument cluster out
far enough to disconnect the speed-
ometer cable, light sockets and wir-
ing connectors from the instrument
cluster. Remove the instrument
cluster.
6. Remove the nuts retaining the
safety cover to the instrument panel.
MODELS ALL C6DB
FIG. 9-lnstrument Panel Safety Cover Installation-Falcon, Fairlane
side windlace at the door and win-
dow openings.
21. Install the headlining retainer
at the A pillar (View DD).
22. Install the rear view mirror.
sun visors, and coat hooks.
7. Pry up and remove the safety
cover.
8. Position the new safety cover
to the instrument panel (Figs. 9 and
10).
9. Install the safety cover retain-
ing nuts.
10. Position the instrument clus-
ter to the iitstrument panel. Connect
the wiring connectors and the speed-
ometer cable. Install the light sockets.
11. Install the instrument cluster
retaining screws.
12. Comet: Position the radio
speaker grille and snap the retainers
in place.
13. Fairlane: Install the radio
control shaft retaining nuts and the
radio control knobs.
14. Position the glove box liner
in place and install the glove box
liner retaining screws.
Forel Publishing Company, LLC
Woodbridge, VA 22192
www.ForelPublishing.com
18-7
23. Slide the package tray into po-
sition and install the retainers and
clips. Then. install the quarter trim
panels and rear seat back and cush-
ion.
MUSTANG
1. Remove the right and left side
lower mouldings (Fig. 11) and the
upper retaining mouldings.
2. Remove the radio speaker
grille.
3. Remove 2 nuts retaining the
cover above the radio (View DD),
and pull the cover from the instru-
ment panel.
4. Using solvent, clean the old
cement from the instrument panel
mounting surfaces.
S. Apply cement to the instru-
ment panel mounting surface and
cover. Position the cover on the in-
strument panel and install the 2 re-
taining nuts in the area over the
radio.
6. Install the radio speaker grille,
upper retaining mouldings, and low-
er mouldings.
~ PAD AND RETAINER
ASSEMBLY -04282
18-8 GROUP 18-TRIM, SEATS, AND CONVERTIBLE TOP

FIG. 10-lnstrument Panel Safety Cover Installation-Comet

Forel Publishing Company, LLC

Woodbridge, VA 22192
www.ForelPublishing.com
 PART 18-1 - INTERIOR TRIM AND LANDAU TOP COVER
FIG. 11-lnstrument Panel Safety Cover Installation-Mustang
EJ CONSOLE
REMOVAL AND INSTALLATION
MUSTANG
The Mustang has 2 optional con-
soles; one is used when air condition-
ing is installed and one is used with-
out air conditioning. Models that are
not equipped with air conditioning
IJ ROOF OUTSIDE COVER
COMET, FALCON, FAIRLANE
REMOVAL
1. Remove the rear seat cushion
back and quarter trim panels.
2. Remove the quarter trim panel
retainer mouldings and quarter win-
dow garnish mouldings.
3. Remove the package tray pan-
el and loosen the headlining in the
quarter area sufficiently to permit
Forel Publishing Company, LLC
Woodbridge, VA 22192
www.ForelPublishing.com
have a glove box at the front end of
the console. Models equipped with
air conditioning do not have the
glove box.
1. Remove the knob or handle
from the gear shift selector lever.
2. Remove 3 screws from each
side of the console in the seat area.
access to the side belt moulding re-
tainer nuts (Fig. 12).
4. Remove the side and rear belt
mouldings.
5. Remove the back window out-
side mouldings. Remove the back
window and weatherstrip.
6. Remove the windshield wiper
arm assemblies and remove the top
cowl panel.
18-9
3. Remove 2 screws from inside
the glove box (if equipped).
4. Lift the console rear end up
and remove the console from the car.
5. Position the console to the ftoor
pan and install the attaching screws.
6. Install the gear shift lever knob
or handle.
7. Remove the side, top and bot-
tom windshield outside mouldings.
8. From within the vehicle re-
move the rear view mirror assembly,
the windshield pillar cap mouldings
and the plastic windshield header
moulding.
9. Cut the windshield sealer as
described in Part 17-3 and remove
the windshield.
18-10 GROUP 18-TRIM, SEATS, AND CONVERTIBLE TOP
10. Remove the sealer from the
windshield pinch weld flange and
remove the moulding retainer clips.
11. Remove the drip rail mould-
ing and then using a 0.128 to 0.132
inch diameter drill, remove the riv-
ets from the drip rail cover retainers
and discard the retainers.
12. Remove the staples from the
front and back window opening that
are retaining the cover and remove
the cover from the roof.
13. Remove the old adhesive from
the roof area with a scraper or use
an appropriate cleaning solvent. It
is extremely important that the en-
tire roof and drip rails are thorough-
ly cleaned.
INSTALLATION
It is recommended that drive nails
be substituted for the staples shown
in Fig. 12.
Wherever possible, use the exist-
ing drive nail or screw holes. There-
fore, each location should be identi-
fied on the pinch weld flange with
a wax crayon.
Seal all unused holes with either
ClAZ-19627-A Pressure Sensitized
Tape or AB-19560-A caulking cord.
1. Carefully position the outside
Forel Publishing Company, LLC
SIDE FRONT SIDE REAR
SECTIONAL
VIEW -CC
FIG. 12-Roof Outside Cover Installation-Comet, Falcon, Fairlane
cover on the roof panel. (Fore and
Aft center punch marks have been
provided in the cover for centering
purposes.)
2. With the cover properly posi-
tioned and temporarily secured, ap-
ply an even coating of C2AZ-19C-
525-A adhesive to the roof panel and
a like amount to the corresponding
area of the roof outside cover as-
sembly. For best results, secure lim-
ited sections at a time. Make certain
that the adhesive is not lumpy as it
will be objectionable from an appear-
ance standpoint.
3. Using a 0.128 to 0.132 inch
diameter drill, pierce the vinyl mate-
rial at the existing staple or screw
hole locations. Install drive nails in
each of the holes.
4. Position both drip rail retainers
and, using the same drill referred to
above, pierce the vinyl at each of
the holes. Install the Pop rivets from
the underside of the drip rail except
at the extreme rear hole in which
case the rivet should be inserted
from the retainer side.
5. Trim the excess cover material
from around the entire perimeter.
6. Apply sealer C3AZ-19562-A
Woodbridge, VA 22192
www.ForelPublishing.com
VIEW-AA
(for white tops) or sealer C3AZ-
19562-B (for black tops) over the
entire surface of the drip rail re-
tainers. With the drip rail properly
sealed, a minimum depth of Vs inch
should be retained for adequate water
drainage. Place masking tape on the
cover assembly for the entire length
of the drip rail before applying seal-
er. After sealer has been applied,
remove the tape.
7. Install the drip rail mouldings.
8. Install the back belt center and
side mouldings.
9. Reposition and secure the head-
lining.
10. Install the back window and
outside window mouldings.
11. Install the quarter trim panel
retainer mouldings and quarter win-
dow garnish mouldings.
12. Install the package tray panel,
quarter panels, rear seat back and
seat cushion.
13. Install the windshield.
14. Install the windshield interior
garnish mouldings and sun visor as-
semblies.
15. Install the windshield exterior
mouldings, retainers, and windshield
wiper blade assemblies.
BACK BELT
MOULDING - 423A20
N 1300- D
, > ,·

PART SEATS
18-2
Section
Standard Seats-Removal and Installation ...... 18-11
Seat and Seat Track ........................ 18-11
Front Seat Cushion and Back ............... 18-11
Rear Seat Cushion and Back ................ 18-11
Front Seat Cushion Cover .................. 18-11
Rear Seat Cushion Cover ................... 18-13
D STANDARD SEATS
REMOVAL AND INSTALLATION
SEAT AND SEAT TRACK
Work, other than that of minor
nature, is more easily performed
when the front seat assembly is re-
moved from the car.
1. Remove the nuts retaining the
seat tracks to the floor pan. If
equipped with power seats, discon-
nect the seat wiring loom connector.
Lift the seat assembly from the car
(Fig. 1).
2. Disconnect and remove the re-
lease cable from the seat frame.
Remove the seat tracks from the seat
frame.
3. Transfer the seat adjusting lev-
er knob and the retracting springs,
if necessary, to the new track as-
sembly.
4. Position the seat tracks on the
seat frame and install the retaining
bolts and release cable.
5. Position the seat assembly in
the car and install the retaining bolts
and nuts.
Release Cable Adjustment. Re-
lease cable maladjustment will affect
only the right side of the seat. In
case the latch retaining the track
fails to release, turn the release cable
turnbuckle or eye bolt enough turns
to shorten the release cable travel
sufficiently to release the track latch.
If the latch fails to secure the seat
travel, turn the release cable turn-
buckle or eye bolt to lengthen the
release cable enough to allow the
latch to snap in the locking position.
FRONT SEAT CUSHION
AND/OR BACK
1. Remove the front seat and seat
track from the car if the cushion is to
he replaced.
2. To replace the seat cushion, re-
Page Section
Front Seat Back Cover ..................... 18-13
Rear Seat Back Cover ...................... 18-13
2 Bucket Seats-Removal and Installation ........ 18-16
Seat and Seat Track ........................ 18-16
Front s~at Cushion Cover .................. 18-16
Front Seat Back Cover ..................... 18-16
move the seat assembly from the seat
track.
3. On cars with a solid seat back,
remove the bolts and washers at-
taching the seat back to the seat
cushion frame. Before being able to
remove the attaching bo!ts it is nec-
essary to remove the seat back and
seat cushion trim from the bolts.
4. On cars with a split front seat
back. remove the hairpin clip from
the center seat back stud and the
seat cushion stud. Before being able
to remove the hair pin clips it is
necessary to Publishing
remove the pivot covers.
Forel Company, LLC
5. Position the seat back assem-
Woodbridge, VA 22192
bly on the seat. On cars with the
split seatwww.ForelPublishing.com
back, install the hairpin
clip at the seat center bracket and
the seat cushion stud and install
the pivot covers.
6. On a car with a solid scat back,
install the bolts and washers attach-
ing the seat back to the seat and fas-
ten the seat back and seat cushion
cover trim with hog rings.
7. Position the seat cushion on the
seat track and install the retaining
bolts if removed.
8. Install the front seat and seat
track in the car.
REAR SEAT CUSHION
AND/OR BACK
1. Lift the rear seat cushion and
pull it forward to remove it from the
car.
2. Remove one rear seat arm rest
(two-door sedans).
3. Remove 2 rear seat back attach-
ing screws located at the bottom of
the seat back.
4. Lift up on the seat back to dis-
engage the seat from the upper hooks
and remove the seat back from the
car.
18-11
Page
5. Position the seat back in the car
and engage the seat with the upper
hooks.
6. Install the seat back lower re-
taining screws and the removed arm
rest. Then install the rear seat cush-
ion.
FRONT SEAT CUSHION COVER
Fig. 2 shows a front seat cushion
buildup. Seat cushions for all models
arc built up in basically the same
manner. Therefore,. when installing
new seat cushion covers or pads, re-
fer to Fig. 2 for the location of listing
wires, hog rings, anti-squeak pads,
and seat pad stack-up.
1. Remove the seat and seat track
assembly.
2. On models with a solid seat
back. remove the bolts and washers
attaching the seat back to the seat
cushion frame.
3. On models with a split seat
back, remove the seat back outer
support arm covers and remove the
hairpin clips from the pivot pins.
4. On models with a split seat
back, remove the retaining screw
from the seat back center support
trim cover and remove the seat back
center pivot hair pin clips.
5. Remove the seat back assem-
bly.
6. Remove the seat back stop
plates from the seat cushion.
7. Remove the hog rings retaining
the seat cushion cover and remove
the cover (Fig. 2). Inspect the pad
and replace it if necessary.
8. Transfer the listing wires to the
new cover.
9. With the seat cushion assembly
right side up, make sure that the pads
are stacked properly and centered;
then place the cover over the pads to
hold them in position.
18-12 GROUP 18 - TRIM, SEATS, AND CONVERTIBLE TOP

MANUAL TRACK Forel Publishing Company, LLC

ASS EMBLY
Woodbridge, VA 22192
www.ForelPublishing.com
SEAT CUSHION
ASSEMBLY

Ii//~ . TIE ROD

~J--
MANUAL TRACK
·.
~
ASSEMBLY

R 1036 • 0

FIG. 1-Typical Front Seat Track Installation


LOWER PAO
FILLER -63456
ASSEMBLY -63245
FIG. 2-Typical Front Seal Cushion Cover Installation
10. Carefully turn the seat assem-
bly over so that the pads do not shift
out of position.
11. After centering the cover and
straightening the seams along the
front edge of the cushion, fasten the
cover to the front of the seat frame
with hog rings. Make sure that the
hog rings encircle the listing wire. In-
stall 1 hog ring in each hole provided
in the seat cushion frame.
12. At the rear of the seat assem-
bly, pull the cover taut over the
pads, and install hog rings at the
seat frame.
13. F asten the side of the cover
to the seat frame side with hog rings
through the holes provided (Fig. 2).
14. Install the seat back stop
plates and the seat back.
15. lnstall the seat tracks to the
cushion and the seat assembly in the
car.
REAR SEAT CUSHION COVER
1. Remove the rear scat cushion
from the car by lifting on the front of
the seat and pulling it forward.
2. Remove the cushion cover hog
rings and remove the c ushion cover
from the seat frame.
3. Inspect the p ad and replace it
if necessary.
4. Transfer the listing wire, if
PART 18-2 - SEATS
62900
equipped, to the new cush ion cover.
5. Position the new cushion cover
on the Forel Publishing
seat frame Company,
and springs LLC
and at-
Woodbridge,
tach it in place VA 22192
with hog rings (Fig. 3).
6. Install
www.ForelPublishing.com
the seat cushi on in the
car.
FRONT SEAT BACK COVER
Repairs to sea t backs are per-
formed out of the ca r a nd are
usuall y limited to rep lacement of
torn or burned seat covers. In a few
instances, the pads may be damaged
and require replacement.
Figs. 4 and 5 show a front seat
back build-up. Seat backs for all
other models are built up in basically
the same manner. Therefore, when
installing new seat back covers m
pads, refer to Figs. 4 and 5 for the
location of listing wires, hog rings,
ant i-squeak pads, and seat pad stack-
up.
1. Remove the scat back.
2. Remove the ash receptacle and
ash receptacle retainer, if equipped.
3. Remove the hog rings retain-
ing the seat back cover to the frame.
Unhook the listing wires from the
seat spring assembly tabs, and re-
move the cover (Figs. 4 and 5).
4. Transfer the list ing wire to the
new seat back cover.
5. Inspect the seat pad and spring
18-1 3
A HOG RING (3 REQ' D)
B HOG RING (17 REQ'D)
C HOG RING ( 11 REQ'D)
D HOG RING (7 REO' D)
R1164 · B
assembl ies, and r epair or replace as
necessary.
6. Carefully place the cover over
the seat fra m e a nd pad assembl y.
Pu ll the cover taut over the pads,
hook the lis ting wires on the seat
spring assembly tabs and install the
hog rings (Figs. 4 and 5).
7. Cut a ho le in the cover for the
ash receptac le retainer, if equ ipped,
and insta ll the receptacle assembly.
8. Install the seat back to the seat
cushion.
REAR SEAT BACK COVER
1. Remove the rear seat back
from the car.
2. Remove the hog rings retaining
the seat back cover to the frame and
remove the rear seat back cover.
3. T ransfer the listing wires to the
new cover.
4. Posi tion the new cover on the
pad and seat frame and secure it m
place with hog rings (Fig. 6).
5. Install the rear sea t back in
the ca r.
18-14 GROUP 18-TRIM, SEATS, AND CONVERTIBLE TOP

COVER ASSEMBLY -

PAD ASSEMBLY -
63840

A HOG RING (4 REQ'D)

B HOG RING (4 REQ'D)
C HOG RING (18 REQ'D)
D HOG RING (16 REQ'D)
E HOG RING (7 REQ'D)

R 1277 • B

FIG. 3-Typical Rear Seat Cushion Cover Installation

PAD ASSEMBLY - Forel Publishing Company, LLC

Woodbridge, VA 22192
www.ForelPublishing.com

COVER ASSEMBLY -
64416

MODELS 54B· 71 B

R 1278· B

FIG. 4-Typical Front Seat Back Cover lnstallation-4-Door

 PART 18-2 - SEATS 18-15

A HOG RING (I REQ'D EACH LOWER CORNER)

B ADHESIVE -C2AZ· 19C525· A
C TABS (ON SPRING ASSEMBLY)
D HOG RING (3 REQ'D AT OUTER SIDE)
E HOG RING (3 REQ'D AT INNER SIDE)

R 1165- B

FIG. 5-Typical Front Seat Back Cover lnstallation-2-Door

Forel Publishing Company, LLC

A
PAD ASSEMBLY - Woodbridge, VA 22192
66800
www.ForelPublishing.com

C A HOG RING (5 REQ'D)

B HOGRING(llREQ'D)
C HOG RING (8 REQ'D)
D HOG RING (II REQ'D)

D
R 1262-C

FIG. 6-Tynkal Rear Seat Back Cover Installation

18-16 GROUP 18 -TRIM, SEATS, AND CONVERTIBLE TOP
EJ BUCKET SEATS-MANUAL
The seat is mounted in the con-
ventional manner on two seat tracks.
The seat release is located at the
lower front center of the seat, and is
operated by pulling the lever side
ways to release the seat tracks.
REMOVAL AND INSTALLATION
SEAT AND SEAT TRACK
The seat track assembly is easily
replaced if the seat assembly is re-
moved from the car.
1. Remove 4 floor pan plug but-
tons to gain access to the seat track
retaining nuts (Mustang only).
2. From under the car, remove
the seat track retaining stud nuts and
washers. Remove the seat assembly
from the car and place it on a clean
work area.
3. Remove the screws which re-
tain the seat track assembly to the
seat cushion and remove the seat
track assembly.
4. Disconnect the seat track brace
and latch release rod from the track
being replaced, and connect these
parts to the new seat track.
5. Loosely install the track-to-floor
retaining studs in the seat track.
6. Place the seat track assembly
on the seat cushion, and install the
retaining screws.
7. Place the seat assembly in the
car and install the washers and nuts
on the retaining studs.
8. Install the floor pan plug but-
tons (Mustang only).
FRONT SEAT CUSHION COVER
Repairs to seat cushions or seat
backs are performed out of the car
and are usually limited to replace-
ment of torn or burned seat covers.
In a few instances, the pads may be
damaged and require replacement.
When installing a new seat cover
or pad, refer to Figs. 7 and 8 for
the location of listing wires, hog
rings, anti-squeak pads, and seat pad
stack-up.
Comet, Falcon (Model 76 Only)
1. Remove the seat and seat track
assembly from the car and place it
on a clean work area.
2. Remove the seat cushion from
the seat track. From each side of the
seat, remove the seat back retainer,
and remove the seat back.
3. Remove the seat back scuff
plates and remove the hog rings re-
taining the seat cushion cover to the
spring assembly. Separate the bottom
cover from the seat cushion pad and
remove the cushion cover.
4. Inspect the pad and spring as-
semblies, and repair or replace as
necessary.
5. Tran sfer the listing wires to the
new cover.
6. Place the new cover assembly
over the pad and seat spring assem-
bly and secure it to the front bolster
wire with hog rings. Apply trim
cement (C2AZ-19C525-A) to the
bottom of the cushion cover and
position the cover correctly to the
seat cushion pad.
7. Secure each side bolster wire
to the seat spring assembly with hog
rings.
8. The front and side edges of the
cover assembly can now be secured
to the bottom of the spring assembly
with hog rings as shown in Fig. 7.
9. Secure the rear edge of the
cover assembly to the bottom of the
spring assembly with hog rings.
10. Install the two scuff plates on
the cushion.
11. Install the seat back side
shield and seat tracks. Install the
Forel
seatPublishing
assembly. Company, LLC
Woodbridge, VA 22192
Mustang
www.ForelPublishing.com
1. Remove the front seat and track
from the car and remove the seat
tracks from the seat.
2. Remove the front seat back
shield and the seat back pivot side
cover.
3. Remove the seat back pivot pin
and remove the seat back from the
seat cushion.
4. Remove the seat cushion scuff
plate.
5. Remove the seat cushion cover
and pad.
6. Position the seat cushion pad on
the frame and install the hog rings
(Fig. 8).
7. Position the cushion cover on
the pad. Cement with trim cement
(C2AZ-19C525-A) and retain with
hog rings (Fig. 8).
8. Install the seat cushion scuff
plate.
9. Position the seat back on the
pivot and install the pivot pin,
10. Install the front seat back
shield and the seat back pivot side
cover.
11. Install the seat on the seat
tracks and install the seat and seat
track in the car.
FRONT SEAT BACK COVER
1. Remove the seat and seat
tracks from the car, if required, for
acces~ibility to the seat side shield
retaining screws.
2. Remove the right and left seat
back side shields and remove the seat
back retaining bolts or retainer pins
and remove the seat back from the
cushion.
3. Unsnap and remove the seat
back rear cover (Figs. 7 and 8).
4. Remove the seat back upper
moulding retaining screws and re-
move the mouldings.
5. Remove the seat back stop ad-
justing bolts and remove the hog
rings retaining the cover to the
frame.
6. Bend up the side retaining tabs
(Fig. 7) and lift the cover off the
tabs.
7. Remove any additional hog
rings retaining the cover to the seat
frame.
8. Position the trim cover off the
side padding to gain access to the
hog rings in the center of the seat
back and remove the hog rings.
9. Position the new cover over the
front center of the seat back and at-
tach it with hog rings. Position the
cover around the sides and top of
the sponge padding, pulling the ma-
terial tight. Then, turn the seat back
face down.
10. Pull the trim cover tight and
install hog rings at the top. Pull the
cover tight and install hog rings at
the bottom.
11. Pull the trim cover tight at the
sides and position it over the side
retaining tabs (Fig. 7). Bend the tabs
down.
12. Position the rear cover on the
seat back and snap it into place. In-
stall the seat back stop adjusting bolts
and nuts.
13. Install the seat back upper
moulding.
14. Install the seat back on the
cushion and install the seat back pivot
covers.
15. Install the seat and seat track
in the car.
 PART 18-2-SEATS 18-17

~
'~ 1-~_J
~ '\
~-

65d47
\
~
STOP - 61064

A HOG RING (16 REQ'O)

B HOG RING 13 REQ'O EACH BOL STER)
C HOG RING 16 RE Q'O EACH BOLSTER)
0 HOG RING 15 RE Q'O)
E HOG RING (7 REO' O) Forel Publishing Company, LLC

~~
F HOG RING 15 REQ' O ALONG READ)
G AOH ESIVE -C1AZ · 19C515 · A Woodbridge, VA 22192
www.ForelPublishing.com

COVER ASSEMBLY -
SCUFF PLATE-
61900
61643

SCUFF PLATE -
60060 '

~=-
AN TI- RATTL ER-
63115
,l. "

R 1098 - C

FIG. 7-Typical Bucket Seat Back and Cushion Cover Installation-Comet, Falcon, Fairlane
 -
18-18 GROUP 18-TRIM, SEATS, AND CONVERTIBLE TOP

REAR TRIM PANEL

PAD - 64625

COVER ASSEMBLY -
64416

A HOG RING ( 19 REQ'D) SPRING ASSEMBLY -

64700 · I
B HOG RING ( 3 REQ 'D)
C HOG RING (5 RE Q'D)
D HOG RING (17 REQ' D)
E HOG RING (5 REQ ' D)
F HOG RING ( 12 REQ' D)
G HOG RING (5 REQ'D)
K ADHESIVE C2AZ· 19C525· A
Forel Publishing Company, LLC
Woodbridge, VA 22192
A HOG www.ForelPublishing.com
RING ( 15 REQ'D)
C HOG RING ( 12 REQ'D)
B HOG RING (4 REQ' D)
E HOG RING (5 REQ' D)
SIDE WIRE
F HOG RING ( 12 REQ'D)
631 A34
G HOG RING (4 REQ' D)
H ADHESIVE -C2AZ· 19C525· A

F
00
G

.
.

REAR WIRE -
63602

BOLSTER WIR E -
631 AOB
SPRING ASSEMBLY -
63 100· I
R 1306 · A

FIG. 8-Typical Bucket Seat Back and Cushion Cover Installation-Mustang

 18-19

PART CONVERTIBLE TOP

18-3
Section Page
1 Care of Top Fabric .......................... 18-19
2 Diagnosis and Testing-Power Top ............ 18-19
Mechanical Checks ......................... 18-19
Electrical Tests ............................ 18-19
Hydraulic Tests ............................ 18-20
3 Adjustments and Light Repairs ................ 18-21
Comet, Fairlane Top Adjustments ........... 18-21
Mustang Top Adjustments .................. 18-21
Side Rail Weatherstrips Adjustment. ....... 18-21
Lateral Adjustment. ..................... 18-21
Intermediate Side Rail Adjustment. ........ 18-21
Balance Link Adjustment. ................ 18-21
Toggle Clamp Adjustment ................ 18-21
Dowel Pin Adjustment ................... 18-23
No. 2 Bow Adjustment ................... 18-24
Hold-Down Side Clamps-Manual Top .... 18-24
4 Removal and Installation ..................... 18-24
Section Page
Motor and Pump-Power Top .............. 18-24
Lift Cylinder-Power Top .................. 18-25
Counterbalance Cylinder-Mus tang
Manual Top ............................ 18-25
Back Curtain .............................. 18-25
Comet, Fairlane ......................... 18-25
Mustang ................................ 18-26
Back Curtain Zipper ....................... 18-26
Comet, Fairlane ......................... 18-26
Mustang ................................ 18-27
Convertible Top Fabric ..................... 18-27
Comet, Fair lane ......................... 18-27
Mustang ................................ 18-29
Roof Front Header Weatherstrip ............ 18-33
Comet. Fairlane ......................... 18-33
Mustang ................................ 18-33

D CARE OF TOP FABRIC

Proper care of the top material
will reduce the possibility of water
stains, mildew, or shrinkage. Do not
stack the top if it is damp. Always
use the convertible top vinyl boot to
keep the top material clean, dry, and
positioned when the top is stacked.
The rear window slide fastener
should be lubricated at least once a
year with stainless stick lubricant.
Use the top compartment behind to rinse the top thoroughly with
the rear seat back only for storage clean water during and after washing.
of the top. The storage of other Do not use a cleaning material
items not only interferes with the that is not recommended for vinyl
Forel
proper Publishing
operation of theCompany, LLC
top, but may material because damage to the top
Woodbridge,
also damage or stain theVA
top22192
material. may result.
The vinyl top may be washed each
www.ForelPublishing.com The vinyl coating becomes tacky
time the car is washed. Clean the at approximately 180°F. Therefore,
material with FoMoCo Interior Trim when making paint repairs. be sure
Cleaner and a scrub brush. Be sure to protect the top material from heat.

EJ DIAGNOSIS AND TESTING-POWER TOP

Refer to Wiring Diagram Manual
Form 7795P-66 for locations of wir-
ing harnesses. Schematics are shown
in Group 22 of this manual.
If the top cannot be lowered or
raised satisfactorily, or if it fails to
operate at all, and the trouble is not
readily apparent, make the following
mechanical, electrical, and hydraulic
tests to find the cause of the trouble.
Always check the battery before
making any of the following checks.
Table 1 shows symptoms and pos-
sible causes of trouble.
MECHANICAL CHECKS
1. If the action of the top is slow,
raise and lower it and look for bent
or misaligned linkage.
2. If binding is noted when clamp-
ing the top at the header, check the
alignment of the door and the
quarter windows with the side rail
weatherstrips. Also check the top
sag adjustment and toggle clamp ad-
justment.
ELECTRICAL TESTS
BATTERY CHARGE
The battery charge should be
determined before making any elec-
trical checks because a partially dis-
charged battery will cause slow motor
and pump operation.
CURRENT DRAW
To check the current draw in the
top operating circuit, disconnect the
black wire at the circuit breaker (lo-
cated on the starter relay), and con-
nect an ammeter in series in the
circuit. Operate the top control
switch and note the ammeter read-
ings. The current draw should be
28 amperes maximum operating.
Ct:rrent in excess of 7 5 amperes in-
dicates a frozen pump or cylinder or
a mechanical obstruction. Low am-
perage with the motor running and
no top movement indicates a defec-
tive pump or low fluid level in the
reservoir.
TOP CONTROL SWITCH
1. Disconnect the wiring harness
at the switch multiple connector lo-
cated behind the instrument panel.
2. Connect one terminal of a test
lamp to the black (feed) wire of the
top control switch, and ground the
18-20 GROUP 18-TRIM, SEATS, AND CONVERTIBLE TOP

TABLE 1-Trouble Symptoms and Possible Causes

Trouble Symptoms

t)
....~ ..c: ~ ..c:
u
VJ u il.l
Q) ·50 il.l VJ

~ 00
:;j
.....
~
....
~
.....
Cl) ~ j
il.l ..... .....
0 Ci5 c. 0 o~ 0
Possible Causes of Trouble Symptoms z c: 0 >.
c
z ..-U: z~ z
VJ
il.l .g VJ
il.l il.l
VJ
il.l g-0 [G~ ~
VJ
~
0
Cl
c.
<
u

c.
:'E
Cl)

g.;:)
:>
il.l
c:
0
Cl
c.
~z
~o
oe
Cl 0
0
Cl
c.
3c.
0 0 0 ~Q c.U::
0 0 0
(-. (-. (-. (-. Ci5 (-. (-. (-.

Top Control Switch x x

Inadequate Battery Charge
Motor and Pump
Circuit Breaker
Faulty Wiring
Hydraulic Cylinder(s)
Air in Hydraulic System
Insufficient Hydraulic Fluid
Top Lowered when Wet Causing Fabric to Shrink
Toggle Clamp Adjustment(!)
Door Window Adjustment(!)
Quarter Window Adjustment(!)
Weatherstripping
Balance Link Bracket Adjustment
Forel Publishing Company, LLC
Center Side Rail Adjustment (Mustang only)
©The top should not be raised with the windows up.
other lead. If the test lamp does not
light, there is an open or short cir-
cuit between the battery and the
switch or a bad circuit breaker.
3. If there is voltage to the switch.
connect a jumper wire between the
black (feed) wire and the red wire,
and then between the black wire
and the yellow wire. If the top motor
operates, the switch is faulty and
must be replaced.
CIRCUIT BREAKER
If there is no voltage at the top
control switch, connect a jumper wire
across the terminals of the circuit
breaker (located on the starter relay)
and operate the switch. If the top
motor operates, the circuit breaker
is faulty and must be replaced. If
there is no voltage at the circuit
breaker, check the black wire from
the circuit breaker to the starter
relay.
SWITCH-TO-MOTOR WIRES
Disconnect the yellow and the red
x x x
x x x
x x
x x x
x x x x
x x x
x x x
x
x x
x x
x x
x
x x
x
Woodbridge, VA 22192
www.ForelPublishing.com
switch-to-motor leads at the junction HYDRAULIC TESTS
block near the motor. Connect a 12- Faulty hydraulic system operation
volt test lamp between the yellow can be caused by lack of fluid, leaks,
wire and a ground and check by air in the system, obstructions or
operating the top control switch to kinks in the hoses, or faulty oper-
raise the top. Connect the test lamp ation of the cylinder or the pump.
between the red wire and a ground,
and check by operating the switch to FLUID LEVEL
lower the top. If the test lamp does
1. Remove the rear seat and raise
not light in either case, the wire
from the junction block to the switch the top.
2. Place absorbent cloths below
is open or shorted.
the filler plug.
MOTOR 3. Remove the filler plug, and
Check the operation of the motor check the fluid level. It should be
by connecting first one motor lead, level with the bottom edge of the
hole.
and then the other, directly to the
4. If the level is low, check the
battery positive terminal. If the system for leaks, adding automatic
motor operates in either case, but transmission fluid Type A, Suffix A
will not operate when hooked into as necessary.
the wiring harness, check the wiring
harness again for short or open cir- LIFf CYLINDER
cuits. If the motor will not ·work Remove the rear seat and the
when hooked directly to the battery, quarter trim panels, operate the top
check the black (ground) wire from control switch, and check the op-
the motor. If the motor still does not eration of the lift cylinders for the
work, it must be replaced. following:

If the movement of the piston
rods are sluggish or uneven, check
the hoses from the pump to the cyl-
inders for kinks.
EJ ADJUSTMENTS AND LIGHT REPAIRS
Before aligning the top, visually
determine if the trouble results from
top misalignment and/ or window
misalignment. It may be necessary to
align both the top and the windows
because of the relationship between
the two. Adjustments of the door
and quarter windows must be
checked and any necessary changes
made before making top adjustments.
These windows must be fully closed
to insure proper top adjustment.
Door window and quarter window
adjustments are outlined in Part 17-3.
COMET, FAIRLANE TOP
ADJUSTMENTS
Refer to Fig. 1 for the following
Comet and Fairlane top adjustments:
1. Loosen screw and washer as-
semblies item A and adjust the
bracket item B (part of top Assem-
bly), inboard or outboard to obtain
the 0.30-inch clearance dimension
between the rear side rail and belt
side moulding. The bracket must be
adjusted and secured in the vertical
position. Tighten the screw and
washer assemblies (views H and J).
2. Loosen nut item C and rotate
cam pin item D to obtain the 0.50-
inch parallel dimension between the
rails and door glass and between
the rear rail and quarter glass. The
cam pin must not be rotated more
than 90° either side of the mean ad-
justment mark on the rail. Hold the
cam pin item D and tighten the nut
item C (views C and K).
If the dowel item E does not line
up with the sun visor bracket dowel
hole on a fore and aft line, the top
cloth is to be removed from the No.
1 bow. Loosen two screws, item F
and adjust the No. 1 bow fore or
aft to position the dowel. Tighten
the screws, item F. The top cloth is
then retacked and cemented (views
Band D).
3. Loosen the nut item G and
adjust the dowel item E inboard or
outboard to center the dowel into
the sun visor bracket dowel hole.
Tighten nut item G (view E).
4. Maintain a proper design rela-
tionship between the No. 1 bow and
the header, loosen set screw item H
PART 18-3 - CONVERTIBLE TOP
If one piston rod moves slower
than the other, the cylinder with the
slower rod is defective and should
be replaced.
and rotate hook item J in or out.
Tighten the set screw item H (view
E).
5. If interference is encountered
between the top cloth and top of the
door glass frame when the door is
opened, the No. 2 bow and/ or No.
3 bow can be adjusted by loosening
the nuts items K and L and raising
the bows. After the adjustment,
tighten the nuts items K and L
(views F and G).
6. To maintain the correct design
relationship between rails and glass,
the set screw item W must be backed
out (view A).
7. Operate the folding top assem-
bly one complete cycle and recheck
the alignment as indicated in steps
I through 7.
8. With the top assembly in the
down position, locate the strikers
item M on the rail-folding top center
side, opposite the clamp assembly
item N. Secure the striker to the
Forel Publishing
rail. Loosen two screwsCompany, LLC
item P and
Woodbridge, VA 22192
adjust the clamp assembly up or
down towww.ForelPublishing.com
insure proper hold-down
effort on the striker. After adjust-
ment, tighten screws item P (view
L).
MUSTANG TOP ADJUSTMENTS
SIDE RAIL WEATHERSTRIPS
ADJUSTMENT
The rear and center side rail
weatherstrips are adjustable fore and
aft to provide a good seal at the break
joints. The front weatherstrip is not
adjustable.
1. Lock the top assembly to the
windshield header.
2. Trim the rear edge of the front
top side rail weatherstrip flush with
the rear end of the front side rail to
obtain a water tight seal at point X
(Fig. 2).
3. Adjust the rear side rail weath-
erstrip to provide a water tight seal
at the joint (Fig. 2), and tighten the
weatherstrip retaining nuts.
LATERAL ADJUSTMENT
This adjustment shifts the top as-
sembly sidewise to obtain a good fit
between the rear side rail and the
quarter outside rear side belt mould-
ing.
18-21
If both rods move slowly, or do
not move at all, disassemble and re-
pair the pump.
1. Loosen the screws which retain
the main pivot bracket to its support
(Fig. 3).
2. Shift the main pivot bracket
toward either side as necessary to
obtain the proper clearance (%2
inch) between the rear side rail and
the quarter outside rear side belt
mouldings and tighten the retaining
screws.
INTERMEDIATE SIDE RAIL
ADJUSTMENT
This adjustment moves the top as·
sembly to obtain a good fit between
the top assembly and the side window
glass line.
1. With the door glass properly
adjusted, loosen the eccentric nut
(View B, Fig. 4 ), and rotate the
eccentric pin to obtain a %-inch
parallel dimension between the front
door glass and the front and center
side rails.
2. Hold the eccentric pin to pre-
vent it from turning, and tighten the
eccentric nut. The main balance link
marking and washer pointer is an
average dimension of adjustment.
Rotation of the eccentric will raise or
lower the side rails to obtain the cor-
rect design-height dimension between
the side rails and the glass.
BALANCE LINK ADJUSTMENT
The balance link is retained to the
intermediate side rail assembly with
an eccentric pin (Fig. 4, View B).
Rotation of the eccentric pin raises
or lowers the side rail over the door
glass area. Clearance between the
glass frame and side rail is ¥s inch
constant.
TOGGLE CLAMP ADJUSTMENT
The toggle clamps that hold the
No. 1 how against the header can be
adjusted to provide a good seal.
1. To determine which side is not
sealing, check the weatherstrip be-
tween the No. 1 bow and the header
with a 3 x 5-inch card. A reasonable
pull must be felt as the card is pulled
out. Both toggle clamps need not be
adjusted unless necessary.
2. Release the toggle clamps (Fig.
5), loosen the Allen screw, and
thread the toggle hook in or out until
18-22 GROUP 18-TRIM, SEATS, AND CONVERTIBLE TOP

,,-, ~

:~~
~~!!:!
>

u..
Jt
w
>

w
Forel Publishing Company, LLC ...,
31:
Woodbridge, VA 22192 w
Jt
w >
www.ForelPublishing.com ;:

co u
Jt Jt
w
>
w
> ...
a.
0
GI
c
a
"'i:
...
·a
..:
GI
E

.."""
0

I
 PART 18-3-CONVERTIBLE TOP 18-23

INTERMEDIATE ~
i
SIDE RAIL ~

~REAR SIDE
I

CLAMP ASS EM BL. Y

BELT MOULDING

FOLDING TOP MAIN

PIVOT BRACKET ASSEMBLY
N1395-A

FIG. 2-Side Rail Weatherstrip

Adiustment-Mustang
adequate sealing pressure is applied
at the header weatherstrip. Excessive
tightening of the toggle hooks will
distort the No. 1 bow and cause poor
weatherstrip sealing. Tighten the Al- _4~:i"'l=~~~;;""'=l~_Jl._ MAIN PIVOT BRACKET TO
len screw after adjusting the clamp. QUARTER PANEL SUPPORT Nl 394-A

DOWEL PIN ADJUSTMENT FIG. 3-Main Pivot Bracket Adjustment-Mustang

To obtain proper alignment of the

Forel Publishing Company, LLC

Woodbridge, VA 22192
www.ForelPublishing.com

VIEW B VIEW A N1393-A

FIG. 4-Top Side Rail Adiustments-Mustang

18-24 GROUP 18 - TRIM, SEATS, AND CONVERTIBLE TOP

LOCKING
SCREW
dowel pins with the dowel pin holes
in the windshield header, loosen the
dowel pin retaining nut (Fig. 5) and
move the dowel pins inboard or out-
board. Then, tighten the dowel re-
taining nut.

NO. 2 BOW ADJUSTMENT

Raise the top and lock it to the
windshield header. Loosen the lock
nut (View A-Fig. 4), and rotate the
eccentric pin to raise or lower the top
material along the door glass line.
The specified clearance for the top
material to door glass frame is Vs
inch. Hold the eccentric and tighten
the lock nut.

HOLD DOWN SIDE CLAMPS-

MANUAL TOP
The hold down side clamp assem-
blies located on each quarter panel
support mounting (Fig. 3), are ad-
justable up and down to retain the
top assembly when in its fully
FIG. 5-Toggle Clamp Hook and Dowel Adiustment-Mustang stacked position.

D REMOVAL AND INSTALLATION

MOTOR AND PUMP-POWER into a clean container. body so that the check balls are not
TOP 2. Scribe lines on the reservoir lost.
A pump repair kit and a reservoir and Publishing
Forel pump body Company,
so that these
LLC parts 7. Remove the inner and outer
repair kit are available for service. can be positioned properly upon as- rotors and the drive ball.
Woodbridge, VA 22192
sembly.
REMOVAL www.ForelPublishing.com
3. Remove the center bolt from ASSEMBLY
1. Operate the top to the fully the reservoir cover (Fig. 6). Use all the parts contained in the
raised position. 4. Remove the reservoir cover and pump repair kit when assembling the
2. Open the deck lid and cover the 0-ring seal from the pump. pump or reservoir.
the luggage compartment floor. 5. Remove the mounting bolts that 1. Install the inner rotor on the
3. Remove the two screws retain- hold the valve body to the pump armature shaft and position the drive
ing the rear folding top compartment body. ball.
support wire retaining clips and re- 6. Place a cloth under the assem- 2. Install the outer rotor over the
move the clips. bly, and carefully remove the valve inner rotor.
4. Disconnect the motor leads
and the ground wire.
5. Remove the attaching nuts,
and remove the motor and pump OUTER ROTOR·CHAMFER
TOWARD MOTOR
assembly from the floor pan. Do not
lose the rubber grommets.
6. Vent the reservoir by removing
the filler plug, and then install the
filler plug. The reservoir must be
vented in order to equalize the pres-
sure. This lessens the possibility of
fluid spraying on the trim and paint
when the hoses are disconnected.
7. Place absorbent cloths beneath
the hose connections, disconnect the
hoses, and then plug the open fittings
and lines.
DISASSEMBLY
Nl 190-B
1. Remove the filler plug, and
drain the fluid from the reservoir FIG. 6-Motor and Pump Disassembled

3. Place the check balls in the mo-
tor body channels.
4. Install the valve body on the
motor body.
5. Install the five valve body
mounting bolts.
6. Install the 0-ring seal on the
valve body.
7. Install a new seal on the center
bolt, and install the reservoir cover
on the valve body, using the line pre-
viously scribed as a guide.
8. Place the assembly in a hori-
zontal position. fill the reservoir with
automatic transmission fluid Type A,
Suffix A to the level of the bottom of
the filler plug hole. Install the filler
plug and a new seal.
INSTALLATION
1. Remove the plugs from the lines
and fittings, and connect the lines to
the pump. Use cloths to absorb any
fluid that leaks out of the lines or
the pump.
FIG. 7-Counterbalance Cylinder Installation-Mustang
PART 18-3-CONVERTIBLE TOP
2. Install the assembly on the floor
pan. making sure that the rubber
grommets are in proper position un-
der the mounting brackets.
3. Connect the motor lead wires
at the connector, and connect the
ground wire.
4. Operate the top assembly two
or three times to bleed any air from
the system, and check the fluid level
in the reservoir. The fluid level should
not be less than \4 inch below the
filler plug opening. The top must be
up when the fluid level is checked.
5. Position the retaining clips on
the rear folding top compartment
support wire and install the retaining
screws.
6. Remove the covers from the
luggage compartment floor and close
the deck lid.
LIFT CYLINDER-POWER TOP
1. Remove the rear seats and
quarter trim panel.
A-LOWER NYLON BUSHINGS
B-COUNTER·BALANCE ROD
C-UPPER NYLON BUSHINGS
0-WAVE WASHER - 3'8"
E-FLAT WASHER - 38"
F- SELF LOCKING PIN
G-CLEVIS PIN
H-REAR SIDE RAIL
J- MAIN PIVOT BRACKET
K-MAIN PIVOT EXTENSION PLATE
Forel Publishing Company,
L- SCREW & WASHER LLC
ASSEMBLY
Woodbridge,
5 16 - 18 xVA
51822192
www.ForelPublishing.com
N 1396-A
18-25
2. Remove the hairpin clip, wash-
er, and clevis pin from the upper end
of the cylinder.
3. Remove the mounting bolts,
bracket, and bushings from the cyl-
inder.
4. Pull the cylinder down; place
absorbent cloths below the hose con-
nections; disconnect the hydraulic
lines, and remove the cylinder.
5. Install the hydraulic lines on
the new cylinder and install the cyl-
inder bushings, mounting bracket,
and bolts.
6. Install the clevis pin, washer,
and hairpin at the upper end of the
cylinder.
7. Operate the top assembly two
or three times to bleed any air from
the system, and check the fluid level
in the reservoir. The fluid level
should not be less than 1/.i inch below
the filler plug opening. The top must
be up when the fluid level is checked.
8. Install the quarter trim panel
and rear seats.
COUNTERBALANCE CYLINDER-
MUSTANG MANUAL TOP
REMOVAL
1. Raise the top. Do not attempt
to remove the counterbalance cylin-
der with the top in the lowered
(stacked) position.
2. Remove the rear seat cushion
and seat back.
3. Remove the quarter trim panels.
4. Remove the self locking pin F,
Flat washer E, wave washers, and
clevis pin G (Fig. 7). Disengage the
counterbalance rod B from the rear
side rail H (Fig. 7).
5. Remove the two bolts L and
the main pivot extension plate K
from the main pivot bracket J (Fig.
7), and remove the counterbalance
spring assembly. Keep the upper and
lower nylon bushings A and C for re-
use if serviceable.
INSTALLATION
1. Position the counterbalance
spring in place and install the main
pivot bracket.
2. Install the counterbalance rod
retaining pin and washers.
3. Install the quarter trim panel.
4. Install the rear scat back and
seat cushion.
BACK CURTAIN
COMET, FAIRLANE
1. Unfasten the clamps that hold
the top to the windshield header.
2. Remove the retainer pins re-
taining the folding top rear compart-
ment trim to the tacking strips and
18-26 GROUP 18 - TRIM, SEATS, AND CONVERTIBLE TOP
SIDE TACKING STRIP---~
FIG. 8-Back Curtain-Comet, Fairlane
position the trim away from the tack-
ing strips.
3. Remove the bolts and lock
washers that retain the curtain tack-
ing strip to the body panel.
4. Open the back curtain window
slide fastener and remove the curtain
assembly.
5. Pull the tacking strips from the
curtain and remove the staples from
the tacking str ip (Fig. 8).
6. Remove the tacking strip lock
screws from the tacking strips.
7. Properly position the curtain
and staple it securely to the tacking
stri p.
8. Staple the side tacking strips to
SIDE TACKI NG STRIP
7641 742·3
~
SECTIONAL V IEW- AA V IEW-BB
FIG. 9-Back Curtain Installation-Mustang
MUSTANG
1. Unhook the top from the win<l-
shield header and prop the top up to
relieve tensio n.
2. Unzip th e back curtain.
3. Remove 3 screws retai ning each
side of the top compartment trim at
the quarter panel.
4. Remove 5 screws attaching the
top compartmen t trim to the rear
sea t and remove the compartment
trim tension springs (Fig. 9).
5. To assure the proper location
of the back curtain assembly during
insta ll ation, the following location
marks should be made with tai lor's
crayon or equivalent:
Locate the center punch mark on
Nl 299-A
the belt center tacking strip reta iner
(Fig. 13, View A-A). Transpose this
center mark to the adjacent rear cur-
tain and compartment trim mate-
the curtain. rials.
9. Position the curtain assembly Mark the rear curtai n along the
to the body panel, and loosely install lower edge of the belt center tacking
the belt tacking strip retaining bolts strip (Fig. 13 , View BB and CC).
and lock washers. Mark the belt center tacking strip
10. Close the curtain window slide to indicate th e rear window opening
fastener. at both sides (Fig. 13, View BB).
11. To adjust the curtain window 6. Pull the top compartment trim
tension and remove wrinkles, tighten back and remove 8 bolts retaining
or loosen the tacking strip retaining the back curta in and the center tack-
bo lts as required. A fter adj usting the ing strip.
curtai n, install and tighten the tack- 7. Remove the staples from the
ing strip lock screws until they bot- webbing and the top quarter from
Forel
tomPublishing
against theCompany, LLC
body panel. the tacking strip. Remove the back
Woodbridge,
12. RepositionVA 22192
the fo lding top window, top compartment trim , and
rear compartment trim and install
www.ForelPublishing.com the tacking strip, as an assembly,
the retainer pins. from the car.
8. Remove the back curtain from
the tacking strip and position the new
back curtain to the tacking strip. Cut
out the bolt hole locations o n the
back curtain.
9. Pos ition the back curtain as-
OUST HOOD FRON T
RE T AINER 765,1476 sembly into the car and tack the web-
bi ng and quarter assemb ly to the
tacking strip. Then , zip the back cur-
tain shut.
10. Remove the prop fr om the top
and secure the top to the windshield
header.
11. Install and tighten the tacking
strip attaching bolts.
12. Install th e top compartment
trim quarter and seat back retaining
screws. C lean the top in the rear roof
CENTER TACK ING STRIP ~
bow area with a suitable clea ner.
7641745 / ~----
BACK CURTAIN ZIPPER
COMET, FAIRLANE
1. Unhook the top from th e wind-
shield header and prop the top up to
relieve tension.
Nl409-A
2 . Unzip the back curtain.
SECTIONAL VIEW-CC
3. Remove the retainer pins re-
taining the folding top rear compart-

ment trim to the tacking strips and
position the trim away from the tack-
ing strips.
4. Remove the holts and flat
washers that retain the curtain tack-
ing strip to the hody panel. and re-
move the back curtain.
5. Mark the zipper location on
the back curtain, then, remove the
zipper from the hack curtain and
sew on a new zipper.
6. Remove the bolts and flat
washers that retain the side belt
tacking strips to the body.
7. Remove the rear how binding
end cap: slide out the binding insert
and remove the staples and retainer.
8. Remove the staples retaining
the top deck and quarter assembly
to the rear bow.
9. Remove the staples retaining
the top right and left back stay pad
case assemblies to the rear roof bow.
10. Remove the staples retaining
the zipper to the rear how tacking
strip and remove the zipper.
11. Position the upper half of the
back curtain zipper to the center of
the rear roof bow tacking strip.
Staple or tack it securely to the tack-
ing strip.
12. Staple the top left and right
back stay pad case assemblies to the
rear bow tacking strip. Seal the un-
used holes in the top material.
13. Staple the top deck and quar-
ter assembly to the rear bow tacking
strip.
14. Staple the binding in position,
and install the binding end caps.
15. Position the side belt tacking
strips to the body and install the re-
taining bolts.
16. Position the back curtain in
the car and install the retaining bolts.
17. Zip the curtain shut and re-
move the prop from the top. Then,
lock the top to the windshield header.
18. Tighten or loosen the tacking
strip retaining holts as required to
adjust the curtain tension and re-
move wrinkles.
19. Reposition the folding top
rear compartment trim and install
the retainer pins.
MUSTANG
1. Unhook the top from the wind-
shield header and prop the top up to
relieve tension.
2. Unzip the back curtain.
3. Remove the rear roof bow re-
tainer tips and pull the outside mould-
ing from the rear bow.
4. Remove the staples retaining
the top deck and quarter assemhly to
the rear roof bow tacking strip and
PART 18-3-CONVERTIBLE TOP
remove the retainer.
5. Mark the location of the right
and left case assembly. at the roof
how. then, remove the staples retain-
ing the right and left case assembly
to the rear roof bow.
6. Mark the location of the zipper
center at the rear roof bow with tail-
or's crayon. Then, pull the upper half
of the back curtain zipper from the
rear roof bow tacking strip.
7. Remove 3 screws retaining the
top compartment trim to the belt
front side tacking strip on each side.
Remove 5 screws retaining the com-
partment trim to the seat back (Fig.
9). Remove the top compartment
trim tension springs.
8. Pull the top compartment trim
hack and remove 8 bolts retaining the
center tacking strip. Mark the zipper
end locations on the top material with
tailor's crayon.
9. Remove the staples from the
webbing and the top quarter from
the tacking strip. Remove the back
curtain, well liner, and t:icking strip
as an assembly from the car.
1O. Mark the location of the zip-
per on the back curtain, then, remove
the zipper from the back curtain and
sew on a new zipper.
11. Locate the center and position
the upper half of the back curtain
zipper Forel
to thePublishing Company,
center of the LLC
rear roof
bow tacking strip and staple
Woodbridge, or tack
VA 22192
it securely to the tacking strip.
www.ForelPublishing.com
12. Position the right and left case
assemblies to the rear roof bow tack-
ing strip and staple or tack them se-
curely to the tacking strip.
13. Position the top deck and
quarter assembly to the rear roof
bow tacking strip and staple or tack
it securely to the tacking strip. work-
ing from the center outward.
14. Staple or tack the rear roof
how retainer securely to the rear roof
bow, then, insert the moulding in the
retainer.
15. Install the right and left rear
roof bow retainer tips (Fig. 13).
16. Position the back curtain in
the car and tack the webbing and
quarter assembly to the tacking strip.
17. Zip the curtain shut and re-
move the prop from the top, then,
lock the top to the windshield header.
18. Install the center tacking strip
bolts and tighten them until all
wrinkles are removed from the back
curtain and quarters. Then, install
the top compartment trim retaining
screws.
CONVERTIBLE TOP FABRIC
The convertible top consists of the
18-27
deck and two side quarters. bonded
into one piece of material. The bond-
ed seams eliminate the possibility of
leaks and also separation, due to
thread deterioration. In most cases
it will be advantageous to replace the
back curtain when replacing the top
fabric.
COMET, FAIRLANE
Removal
I. Place a protective cover across
the deck, cowl and hood to prevent
scratching the finish when replacing
the top.
2. Remove the rear seat cushion
and scat hack.
3. Raise the top to gain access to
the underside of the front bow.
4. Remove the No. I bow weath-
erstrip retainer (Fig. 10) and the
weatherstrip. Remove the windshield
header seal.
5. Remove both front side rail
weatherstrips and weatherstrip re-
tainers.
6. Remove the two center side
rail and the two rear side rail weath-
erstrips and weatherstrip retainers.
7. Remove the screw and washer
that secures each end of the folding
top compartment well to the pivot
bracket supports (Fig. 10).
8. Remove the retainer pins rc-
tain ing the folding top rear compart-
ment trim to the tacking strips and
position the trim away from the tack-
ing strips.
9. Remove the tip (Fig. I 0) from
each end of the moulding on the
rear bow. Carefully pull the mould-
ing out of the retainer. Pry the
moulding retainer off the bow.
10. To assure the proper location
of the tacking strips in the new top
assembly, back curtain assembly and/
or compartment trim assembly, mark
the following locations with tailor's
crayon:
Locate and mark the center of the
belt center tacking strip retainer.
Transpose this center mark to the
adjacent rear curtain and compart-
ment trim materials.
Mark the rear curtain along the
lower edge of the belt center tacking
strip.
Mark the belt center tacking strip
to indicate the rear window opening
at both sides.
Mark the top deck quarters along
the lower edge and at the ends of
each belt side front tacking strip.
11. Remove the bolts that attach
the top and back curtain tacking
strips to the body.
12. Remove the staples that secure
18-28 GROUP 1 8 - TRIM SEATS AND CONVERTIBLE TOP
I I

Forel Publishing Company, LLC

Woodbridge, VA 22192
www.ForelPublishing.com

..:
Cl)

E
0
'-'
I
c

-
.2
.E
-"'
-a
.E
E
·.:::
.....
a.
.....0
Cl)

-..
~
Cl)
>
c
0
'-'
I

-ci
0

....

the top material to the rear bow.
13. Carefully pull the top material
free from the underside of each side
rail.
14. Remove the staples that secure
the top material to the underside of
the front bow.
15. Remove the retainer screws
and carefully separate the top from
the listings on the No. 2 and 3 bows.
Remove the staples that secure the
top back stay-pads.
16. Remove the staples that secure
the upper end of the back curtain
to the rear bow. Remove the curtain.
Installation
1. Remove the tacking strips from
the old top and back curtain.
2. Staple them to the new top and
back curtain in the same location as
they were on the old top.
3. Center the dot on the back cur-
tain with the V mark (center) on the
rear bow and staple the upper half
of the zipper to the bow. Separate
the curtain from the upper half of
the zipper.
4. Retack the top back stay pads.
Fit the new top on the roof bows.
5. Working from the center out-
ward, staple the top deck to the rear
bow. Make sure that the rear section
of the slits is stapled to the bow be-
fore drawing and stapling the front
portion of the slits (Fig. 10).
6. Secure, and tighten the quarter
deck tacking strips to the body.
7. Center the top material and pull
it forward over the front bow to re-
move the wrinkles from the top deck
and quarters and to align the listings
with the No. 2 and 3 bows. While the
material is pulled over the front bow.
m1ke a reference mark on the ma-
terial at the leading edge of the bow
with a piece of chalk. The mark
should extend the entire length of
the bow.
8. Raise the top high enough to
gain access to the underside of the
front bow.
9. Align the reference mark to the
leading edge of the bow and staple
the material in place. Install the wind-
shield header seal.
10. Install the weatherstrip and
the retainers on the No. 1 bow.
11. Secure the flaps to the under-
side of the side rail with trim cement.
Trim the excess material from the
flaps.
12. Install the rear. center and the
front weatherstrip and retainers on
the side rails so that the end of the
weatherstrips are in alignment with
the side rail joints.
PART 18-3 - CONVERTIBLE TOP
13. Install a piece of tape across
the rear bow to cover the staples.
14. Install the moulding retainer,
moulding and the two tips on the
rear bow.
15. Secure the back curtain to the
upper part of the zipper.
16. Secure the back curtain tack-
ing strip in place with the attaching
bolts. Tighten the bolts as required
working from the center outward to
remove all wrinkles.
17. Reposition the folding top
rear compartment trim and install
the retainer pins.
18. Secure each end of the trim
to the pivot bracket supports with a
metal screw and washer.
19. Install the rear seat back and
cushion.
20. Install listing retainers in the
No. 2 and 3 bow listings and install
the screws.
21. Remove the protective covers
from the deck and the hood.
22. Clean all chalk and reference
marks from the top material.
MUSTANG
Removal
1. Protect the painted surfaces of
the upper hack panel, luggage com-
partment door and both quarter pan-
els with suitable covers.
Forel Publishing
2. Fabricate two how Company, LLC
locating
gauges to Woodbridge,
the dimensions VA 22192 in
shown
Fig. 11.
www.ForelPublishing.com
3. Remove the rear seat cushion
and seat back.
4. Remove the top compartment
trim side and front attaching screws
(Fig. 12).
5. Disengage the 2 retaining
springs from the rear compartment
trim support wire (Fig. 12).
6. Lower the top and remove the
weatherstrip retainer from the No.
1 bow.
7. Remove the front side weather-
strip attaching nuts from both front
side rails and remove the weather-
strip assembly (Fig. 13).
8. Remove the windshield header
seal assembly and the top material
from the No. I bow (Fig. 13).
9. Remove the center and rear
side rail weatherstrips (Fig. 2). Loos-
en the top quarter material flaps
which are cemented to the front and
rear side rails (each side).
10. Disengage the top material
hold-down cables from the rear side
rail attachment and pull the cables
forward until each is removed from
the retaining sleeve (Fig. 14).
11. Remove each side rail coat
hook.
18-29
12. Raise the top and clamp the
No. l bow to the header.
13• .Install the two fabricated bow
locating gauges as shown in Fig. 15.
14. Remove the No. 2 and No. 3
bow I isting retainer screws and re-
move both retainers from the listings
(Fig. 13).
15. Raise the compartment trim
up sufficiently to remove all of the
tacking strip attaching screws (Fig.
13).
16. Remove the No. 4 bow out-
side moulding end tips, moulding and
moulding retainer (Fig. 13).
17. Detach the top material from
the No. 4 bow. Peel the top material
back to expose the No. 4 bow and
mark the existing top back stay web-
bing location at the No. 4 bow and
the tacking strip (Fig. 14).
18. Detach the upper end of the
webbing from the No. 4 bow. Unzip
the rear curtain window and remove
the soft trim with tacking strips at-
tached. Place the assembly on a
bench.
19. Mark the No. 4 bow at both
ends of the zipper elastic material
and detach the upper half of the zip-
per assembly from the No. 4 bow.
20. To assure the proper location
of the tacking strips in the new top
assembly, back curtain window as-
sembly and/ or compartment trim as-
sembly, proceed as follows:
a. Locate the center punch mark
on the belt center tacking strip re-
tainer (Fig. 13, View A-A). Trans-
pose this center mark to the adjacent
rear curtain and compartment trim
materials.
b. Mark the rear curtain along the
lower edge of the belt center tacking
strip (Fig. 13, View BB and CC).
c. Mark the belt center tacking
strip to indicate the rear window
opening at both sides (Fig. 13, View
BB).
d. Mark the top deck quarters
along the lower edge and at the ends
of each belt side front tacking strip
(Fig. 13. View CC).
21. Carefully and without tearing
the material, detach the trim mate-
rial being replaced from the tacking
strips.
22. Trim off the selvage edge of
the old top deck quarter and/ or back
curtain material that extends below
the tacking strips. The selvage edge
must only be cut from the old parts
which are being replaced.
Installation
1. Lay the new rear curtain win-
dow assembly on a clean bench with
 ~FRONT-
...co
w
0

Q
~
0
.,,
c
...co
.....I
::::ia
GAUGE - FRONT END TEMPLATE GAUGE - REAR END TEMPLATE
iC
~

~
.....
Forel Publishing Company, LLC
~
Woodbridge, VA 22192
www.ForelPublishing.com >
:z
DEVELOP FRONT END OF GAUGE
USING THIS TEMPLATE DEVELOP REAR END OF GAUGE c
USING THIS TEMPLATE r'\
0
:z
FABRICATE GAUGE FROM A PIECE OF
PLYWOOD 34-3/4" X 4-7/8" X 112" DEVELOP CENTER PORTION OF GAUGE IN ,.,.,
<
(2 REQUIRED) ACCORDANCE WI TH PICTORIAL VIEW ABOVE
.....
::::ia

=
,.,.,
r-
.....
0
-a
.,__ _ _ _ _ _ _ _ _ _ ALIGN WITH
BOTTOM OF END AND
BOARD
A~bfri~ T~F E~A~~D - - - - - - - - -

~·
9rf'

I
FIG. 11-Bow Locating Gauge Fabrication
 PART 18-3 - CONVERTIBLE TOP 18-31

tacking strip holes in each quarter of

the new top, only. Do not trim off
the selvage edge.
4. Using the old compartment
trim as a template, transpose the
markings to the new compartment.
5. Align the belt center tacking
strip with the compartment trim
alignment marks and retain with
staples. The edge of the material
should be flush with the bottom of
the tacking strip.
6. Align the belt center tacking
strip with the rear curtain window
aligning marks and retain it with
COMPARTMENT REAR
TRIM REAR RETAINING SPRING staples.
7. Align the belt side front tacking
strip with the aligning marks on the
N1398-A top deck quarter (both sides) and re-
tain it with staples.
FIG. 12-Top Compartment Rear Trim Installation-Mustang 8. Position each top back stay
webbing on the belt center tacking
the interior surface up. Measure the tions. Carefully remove the old rear strip and retain it with staples (Fig.
width and mark the center of the curtain window assembly and cut out 14).
back window at the top, above the the tacking strip attaching holes in 9. Align the top deck quarter to
zipper, and at the bottom, at the the new curtain, only. the belt center tacking strip, maintain
tacking strip area (Fig. 13). 3. Using the old top assembly as proper rear curtain opening and re-
2. Using the old rear curtain win- a template, mark the new top quarter tain it with staples (Fig. 13, View
dow assembly as a template, mark deck to indicate the lower edge of BB).
the new curtain to indicate the lower the tacking strip. Also mark the tack- 10. Carefully position the upper
edge of the tacking strip. Also mark ing strip attaching hole locations. half of the zipper assembly on the
the tacking strip attaching hole loca- Discard the old top. Cut out the No. 4 bow aligning the bow and ma-

MASKING TAPE
WITH CL MARK
NO. J BOW OUTSIDE Forel Publishing Company, LLC
MOUL DING ASS EMBLY
Woodbridge, VA 22192
www.ForelPublishing.com

1L:.~±J;i;-E!:!.''.;J;J,:, 1 1 ,:,J,i.l 1
I

I - TOP 11ACK CURTAIN WINDOW ASS EMBLY

2 - BELT CENTER TACKING STRIP
3 - FOLDING TOP QUARTER DECK
4 - BELT SIDE FRONT TACKING STRIP
5 - WINDSHIELD HEADER SEAL ASSEMBLY
6 - NO. I BOW WEATHERSTRIP RETAINER
7 - FRONT SIDE RAIL WEATHERSTRIP ASSEMBLY
8 - NO. I BOW
9 - BOW LISTING RETAINER
10 - BOW LISTING
11 - FOLDING TOP CENTER DECK VIEW - CC
12 - NO. 2 AND/OR NO. 3 BOW
VIEW - EE 13 - SCREW #6-20 X 3/8" VIEW - DD N1399-A

FIG. 13-Top Trim Assembly Attachments-Mustang

18-32 GROUP 18 - TRIM, SEATS, AND CONVERTIBLE TOP
FIG. 14-Top Stay Pad Webbing and Quarter Deck Retainer Cable Attachments-Mustang
terial center marks. The edge of the
material should be flush with the
front edge of the No. 4 bow tacking
strip. Working from the center out-
board, secure the assembly with
staples. Both ends of the elastic strip
should correspond with the marks on
the No. 4 bow. Refer to Step 19
under Removal.
11. Position the rear curtain and
top assembly on the stack and engage
the zipper.
12. Position the top back stay
webbing on the No. 4 bow aligning
marks and secure it with staples
(Fig. 14).
13. Install a piece of masking tape
on the underside of the No. 4 bow
at the centerline punch mark located
in the bow. Mark the tape indicating
FIG. 15-Bow Locating Gauge Installation-Mustang
RETAINER CABLE
ADJUSTING NUT
the centerline.
14. Measure and mark the center
between the bond seams of the top
center deck at the No. 4 bow on the
underside of the material. Install a
6-inch piece of masking tape on the
top material inner surface at the
Forel Publishing
centerline of theCompany,
No. 4 bow.LLC Mark
theWoodbridge,
centerline along the entire length
VA 22192
of tape. (Refer to Fig. 13.)
www.ForelPublishing.com
15. With the bow locating gauge
in place ·(refer to Step 13 under Re-
moval and Fig. 15), install the belt
center tacking strip attaching screws
to approximately 1A to 1/i -inch from
the bottoming out position. Install
the belt side front tacking strip at-
taching screws and tighten to within
1A to 1/2-inch of bottoming.
16. Center the top material on
Nl400-B
the No. 4 bow and pull it forward
sufficiently to center the outboard
bond seam on the No. 4 bow (Fig.
13). Secure the top material to the
No. 4 bow with staples.
17. Install the two retainers in the
No. 2 and No. 3 bow listings (Fig.
13).
18. Route the quarter deck retain-
ing cables through the hold down
sleeves in the top material and re-
tain each cable at the rear (loosely)
with the attaching nut and washer
(Fig. 14).
19. Pull the top trim material for-
ward over the No. 1 bow until the
No. 2 and No. 3 bow listings (Fig.
13) are centered over their respective
bows. While maintaining tension on
the top trim. place a pencil mark on
the outer surface of the trim material
along the forward edge of the No.
1 bow.
20. Remove the two bow aligning
gauges and reinstall the coat hooks
(Fig. 4).
21. Fold the front edge of the top
material back from the No. 1 bow.
Disengage the No. 1 bow from the
windshield header and prop it up
about one foot above the header.
22. Apply an ample amount of
trim cement C2AZ-19C525-A across
the lower front surface of the No. 1
bow including the tacking strip and
to the adjacent inner surface of the
top material.
23. Lower the No. 1 bow onto
the header but do not clamp it. With

the top material properly centered
on the No. 1 bow, start at the outer
front corners and alternately pull th e
material forward to the pencil align-
ing mark. Make certain that a ll wri n-
kles are removed , and then fold and
cement the material to the underside
of the bow.
24. Position the windshield head-
er seal assembly (F ig. 13) and secure
the seal and top material with staples.
Trim off excess top material.
25. C ement the front and rear
flaps to each si de rail. Pierce holes in
the flaps for the weatherstrip attach-
ments.
26. Insta ll the front side rail
weatherstrip and the No. l bow re-
tainer.
27. Tighten the retainer cable ad-
justment n ut at each rear side ra il
sufficiently to hold the top material
tightly aga inst the rai l.
28. Install the intermediate and
rear side rail weatherstrips. Adjust as
required (Fig. 2).
29. With the No. 1 bow clamped
to the header, tighten a ll belt tacking
str ip attaching screws securely.
30. Engage the compartm ent trim
support wire to the luggage compart-
ment door hinge bracket springs
(Fig. 12).
31. Insta ll the compartment trim
to the belt side front tacking strip
with the attachi ng screws (Fig. 12).
32. Install the com partm ent trim
with the seat back support lower
ledge attaching screws (Fig. 12).
33. Insta ll the r ear seat back an d
c ushion.
34. Remove the interior cen terline
tape strips.
35. Install the No. 4 bow outside
mould ing r etainer, insert the m ould-
ing and insta ll the two end tips (Fig.
13).
PART 18-3 - CONVERTIBLE TOP
ROOF FRONT HEADER
WEATHERSTRIP
COMET, FAIRLANE
1. Release the toggle clamps and
lower the top.
2. Remove the screws attach ing
th e weatherstrip retainer to the No.
l bow and remove the retainer.
3. Remove the nuts retaining the
weatherstri p to the right and left
front side rails and remove the
weatherstrip assembly.
4. Position the weatherstrip as-
sembly to the No. I bow and install
the retainer and retaining screws.
5. Position the side rail sections
of the weatherstrip and install the
retai ning nuts.
6. Raise the top and lock it to the
windsh ield header.
MUSTANG
1. Release the toggle cla mps and
FRONT SIDE RAIL
WEATHERSTRIP
7653986
Forel Publishing Company, LLC
Woodbridge, VA 22192
www.ForelPublishing.com
FIG. 16-Side Rail Weatherstrip-Mustang
18-33
pa rtia lly lower the top.
2. Remove 12 screws attach ing
the weatherstrip r eta iner to the head-
er and remove the retainer.
3. Remove 2 scr ews attach ing the
wea therstrip to the header at each
corner (Fig. 16).
4. Remove 6 nuts and washers (3
each side) reta ining the weatherstr ip
to the roof s id e ra ils and remove the
weatherstrip.
5. Apply sea ler to the header and
roof side ra ils and place the new
weatherstrip in position.
6. Install the weatherstrip retain-
er with 12 screws and the 2 weather-
strip attaching screws at each corner.
7. Install 3 nuts and· washers at-
taching the weatherstrip to each s ide
rail. T rim the weatherstrip fo r a
watertight fit (Fig. 16).
8. Raise the top and Jock it to the
windsh ield hea der.
N1408-A
 19-1

MAINTENANCE GROUP
SCHEDULE 19
THOUSANDS OF MILES OR NUMBER OF MONTHS See
WHICHEVER OCCU RS FIRST (Except Where Noted) As Required 6 12 18 24 30 36 Ma nual
Page
ENGINE

Change engine oil and filter © x x x x x x 20- 1

Check engine oil level At Fuel Stops 20- 1
Replace fuel filter x 20- 1
Adj ust carburetor-idle speed, idle mixture and fast (cold)
id le speed (automatic choke only) x 20- 1
Adjust accelerator pump lever Seasonal 20- 5
Clean carbu retor air cleaner and filter (paper type only) x x x x x 20- 6
Replace carburetor air cleaner filter !Paper © x 20- 7
!Plastic © x x x 20- 7
Clean crankcase oil filler tube breather cap © x x x x x x 20- 7
Clea n emission system hoses, tu bes, oi l separator, fillings,
carburetor space r and replace em ission control valve x x x 20- 7
Replace thermactor air pump filter if so equipped x x x 20- 8
Check engine accessory drive belts x 20- 8
Lubricate exhaust control valve (390 CID only) x 20- 9
Valve tappet adjustment (Conventional) Musta ng
289-4V High Performance Engine x x x 20- 9
Check ignition timing x x x 20- 9
Check and adjust distributor points x 20- 9
Check spa rk plugs x 20- 10
Replace engine coolant (or every two years) Forel Publishing Company, LLC x 20- 10
Check engine coola nt level x
Woodbridge, VA 22192 20-10
www.ForelPublishing.com
TRANSMISSION
Adjust automatic transmission front (intermed iate ba nd) x 20-10
Adjust automatic transm ission rear (reverse)
band if so equ ipped x 20-10
Check transmission oil level x x x x x x 20-11
Check axle fluid level x x x x x x 20-1 1
Check clutch li nkage adjustment x 20-11

CHASSIS
Lubricate transmission linkage x 20-12
Lu bricate front suspension ball joints x 20-12
Lubricate universal joi nts x 20-12
Lu bricate power steering actuator valve and ball stud x 20-12
x

-
Check steering gea r pre-load 20-12
Check steeri ng gear pre-load (M ustang only) x 20-12
Check power steeri ng reservoir fl uid level x x x x x x 20-13
Check master cyl inder fluid level x x x x x x 20-13
Check brake lines and lining and clean and repack wheel bearings x 20-13
Check and adjust parking brake x 20-15
Check tire pressure x 20-16
Inspect and cross-switch wheels and tires x 20-16
Check front wheel alignment and linkage x 20-16
Check battery fluid level x 20-19
Check air cond itioning system Annually at Begi nning of A/ C Season 20-19

©On engine items, more frequent intervals wi ll be requi red if the vehicle is operated in extremely dusty areas for extended periods of idli ng or short runs
which p r ~ven t the engi ne from reach ing norma l operating temperatu res.
19-2 GROUP 19 - MAINTENANCE SCHEDULE

THOUSANDS OF MILES OR NUMBER OF MONTHS

WHICHEVER OCCURS FIRST (Except Where Noted) As Required 6 12 18 24 30 36 See
Manual
Page
BODY

Lubricate hood latch x 20-19

Lubricate hood hinge pivots x 20-19
Lubricate hood auxiliary catch x 20-19
Lubricate door lock cylinders x x x x x x 20-19
Lubricate luggage compartment lock cylinder x x x x x x 20-19
lubricate door hinge and hinge check x 20-19
Lubricate luggage compartment hinge pivots x 20-19
lubricate tailgate lock cylinders (Except Mustang) x x x x x x 20-19
lubricate tailgate support and hinges (Except Mustang) x 20-19
lubricate fuel filler door hinges (Comet, Fairlane only) x 20-20
lube weatherstrip rubber seals and seat track x 20-20
Clean body drain holes or examine dust valves for operation x 20-20
Replace windshield wiper blades x 20-20
Check convertible top operation (Except Falcon) x 20-20
Check convertible top fluid level (Except Falcon) x 20-20

Forel Publishing Company, LLC

Woodbridge, VA 22192
www.ForelPublishing.com
 20-1

MAINTENANCE GROUP
OPERATIONS 20
PART MAINTENANCE OPERATIONS
20 -1
Section Page Section Page
I. Engine .... . ... .... . . .... . .. . .. . . . . ... . . .. . . . 20- l 3. Chassis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20- 12
2. Transm issio n . .... .... .... . ... . . . . . . . . .. .... . 20- 10 4. Body .. . ... .. . .. . . .. . . .. . ... . ... . . . . .... . . . . 20-1 9

D ENGINE
CHANGE ENGINE OIL AND inl et hose a nd connect the hose to ADJUST CARBURETOR-IDLE
FILTER the filte r. Place a new gasket on the SPEED, FAST (COLD ) IDLE
new fuel filter a nd sc rew the fi lter SPEED AND IDLE MIXTURE
1. Raise the car .
into the carburetor inlet port. T ight- (AUTOMATIC CHOKE ONLY)
2. Remove t he oil pa n drain plug e n the filt er. AUTOMATIC CHOKE PLATE
a nd allow the e ngine oil to dra in in-
5. P osition the fue l line hose CLEARAN CE (PULL-DOWN)
to a contai ner. c lam p a nd c rimp the c la m p securely. AND FAST IDLE CAM LINK-
3. P lace a d rip pa n und er the 6. Sta rt the engine a nd check for AGE ADJUSTMENT
fi lter. Unscrew the fi lter fro m the fue l lea ks. Ford 1-V. T he a u tom atic choke
adapter fitti ng.
7. Install the a ir c lea ner. fast id le c am linkage mu st be prop-
4. Coa t the gasket on the fi lter
wi th oil. Place the fil ter in position
o n the a da pter fitting. H and tighte n Forel Publishing Company, LLC
the fi lter until t he gasket co n tacts
Woodbridge, VA 22192
the ad apter face , then a d va nce it
1/ 2 turn. www.ForelPublishing.comSP ECIFIED SIZE Or i II or Ga ug e BETWEEN
THROTTLE PLATE ANO THROTTLE BORE
5. Replace the oi l pa n drain plug
a nd tighten it securel y.
6. Refill t he crankcase with the
pro per a mount and grade of oil.
7. Lower the car .
8. Operate the engine at fast idle ,
and check for oi l leaks. If oil leaks
are evide nt, perform the necessar y
repairs to correct the leakage.

CHECK ENGINE OIL LEVEL

C heck the oil level d ipstick to be
sure it indicates the co rrect quantity
of oil in the c rankcase. Be sure the
oil is clean.

-
REPLACE FUEL FILTER
1. R emove the air cleaner.
2. Loosen the re tain ing cla m p
securing the fuel inlet hose to the
fuel fi lter. CHOKE IN FULL CLOSED POSITION
3. Unscrew the fue l fi lter from
the carburetor and discard th e gas-
ket. Disconnect the fue l fi lter from
the hose and discard the retaining
clamp. B2413 - B

4. Install a new cla mp o n the FIG. 1-Fast Idle Cam Linkage Adjustment-Ford 1-V
20-2 GROUP 20-MAINTENANCE OPERATIONS

erly adjusted before performing the SPECIFIED SIZE Drill or Goug e

BETWEEN CHOKE PLATE AND UPPER BODY
choke plate clearance (pull-down)
THROTTLE LEVER IN FAST IDLE POSITION
adjustment, because the posi tion of (F AST IDLE SCREW AGAINS T COLD
the pu ll-down rod is one of the de- POSITION ON FAST IDLE CAM)
term ining fac tors a ffe cting the throt-
tle to choke opening rela tionship.
1. In sert a gauge pin or drill of
the speci fied clearance (Part I 0-8)
thickness between the throttle pl::tte
and the side of the thro ttle bore.
H old the throttle pla te against the
gauge pin or dri ll (Fig. I). C lose the
c hoke pla te and turn the fast id le
screw inward until it just co ntacts
the fast id le cam.
2. Place a drill or ga uge of the
sa me thickness as the spec ified clear-
ance (Pa rt I 0-8) between the choke
plate a nd th e upper bod y wa ll (Fig.
2). C lose the c hoke pla te on the
d rill or gauge and hold it securely.
3. C lose the throttle until the
fast idle screw touches the fast idle
ca m. Adjust the plastic nut to just
contact the swivel on the choke lev-
er assembly.
Ford 2-V a nd 4-V.
1. If the ai r cleaner, hea ter hose
a nd mo unting bracket ha ve no t been 62414 - B
removed previ ously, remove them
fro m the carburetor.
2. Position the fas t idle (rpm) FIG. 2-Choke Plate Clearance (Pull-Down) Adjustment-Ford 1-V
ad justme nt screw on th e index mark
of the fast idle cam (Fig. 3).
Forel
GougePublishing
OF SPECIFIEDCompany, LLC
CLEARA NCE SIZE
3. Turn the c hoke th ermosta tic
spring housi ng cover 90 ° ric h Woodbridge, VA 22192
(counterclockwise) a nd c heck the www.ForelPublishing.com
ADJUST SCREW TO OBTAIN
clea rance between the front of th e SPECIFIED CLEARA NCE BETWEEN
choke pl ate and the a ir horn (Fig. CHOKE PLATE AND AIR HORN
3). Adjust the clearance to specifi-
cat ion (Part I 0-8), if required. Turn
the fast idle cam lever adjusting
screw clockwise (inward) to in-
crease the clearance and counter-
clockwise (outward) to decrease the
clearance. Make certain the fas t idle
screw remains o n the index mark
(kickdown step) of the fast idle cam
during the adjustment procedure.
4. Be nd a specified s ize (Part
I 0-8) wire gauge (tool) a t a 90 °
angl e, a pprox imate ly Ya inch from
its end (Fig. 4).
S. Remove the c hoke the rmostatic
spring housing. Block the throttle
about ha lf-open so that the fas t
id le cam does not contact the fast
idle adj ustment screw.
6. Insert the ben t end of the
gauge between the lower edge of the
piston slot and th e upper edge of THERMOSTA TIC SPRING HOUSING
the right ha nd slot in the choke POSITIONED 90° RICH
housing (Fig. 4), a nd pul l the B2592 · A
choke coun tc rshaft lever cou nter-
clockwise unti l th e gauge is snug in FIG. 3 - Fast Idle Cam Linkage Adjustment-Ford 2-V and 4-V
 PART 20-1-MAINTENANCE OPERATIONS
the piston slot. H o ld the wire gauge
in place by exerting light pressure
on the countershaft lever , a nd adj ust
the choke plate clevis (pull -down)
adjusting nut to obta in the specified
clearance (Part 10-8) between the
front of the choke plate and the air
horn (Fig. 4).
7. Install the choke thermostatic
spring housing and gasket. Insta ll
the housing retainer and the retain-
ing screws.
8. Set the choke thermosta tic
spring housing to the specified index
mark. If no other ca rburetor adjust-
ments are required, adj ust the en-
gi ne idle speed and idle fu el mix-
ture, and the dashpot (if so
equipped.)
MANUAL C HOKE PLATE
CLEARANCE (PULL-DOWN)
ADJUSTMENT-FORD 4-V
1. Remove the air clea ner assem-
bly (Part I 0-5) if it has not been
previously removed.
2. P ull the choke cam and lever
to the full choke position. Insert
the specified size gauge o r drill
(Part 10-8) between the downward
side of the choke plate and the air
horn wall. The gauge or drill will
open the choke plate against the
Gauge OF SPECIFIED CLEARANCE SIZE
ADJUST NUT TO OBTA IN
SPECIF IED CLEARANCE
BETWEEN CHOKE PLATE
AND AIR HORN
FIG. 4-Choke Plate Clearance (Pull-Down) Adjustment-(Typical}
Ford 2-V and 4-V
IDLE MIXTURE SCREW
( NEEDLE )
B241 5· A
FIG. 5-ldle Fuel Mixture
Adjustment-Ford 1-V
pull-down spri ng tension. Adjust
the choke operatin g (pull-down) rod
adjusting nut to just contact the
p lastic sw ive l.
3. If the choke pla te clearance
adj us tment was performed with the
carburetor install ed on the car, in-
stall the air cleaner assembly (Part
10-5) if other carburetor adjust-
men ts are not requi red.
IDLE FUEL MIXTURE AND
IDLE (HOT ENGINE) SPEED
ADJUSTMENTS
It is of utmost importa nce th at
~
Forel Publishing Company, LLC
Woodbridge, VA 22192
~j www.ForelPublishing.com
Gauge B259 1·A
20-3
the id le fuel system on 2-V and 4-V
carburetors be ba lanced as closely
as possible in order to ob tain a
sa tisfactory, stable. id le a nd fu el
mi xture adjustment. This is achiev-
ed by establishing initial id le speed
and m ixtu re adjustments before
proceeding with the final id le speed
and mixture adjustment, and the
fast (cold engine) idle speed adjust-
ment.
W it h th e air clea ner removed,
make the idle adjustments in the
following sequence:
Initial Idle Speed and F uel Mix-
ture Adjustm ents. Refer to Figs. 5
and 6 for views of the F o rd 1-V
carburetor id le fue l mixture and id le
(hot engine) speed adjust ment sc rews.
The id le fuel mixture and id le
(h ot engi n e) s p eed ad ju st ment
screws for the Fo rd 2-V and 4-V
carburetors a re shown in Fi gs. 7
and 8.
J. Set th e initia l id le fue l mix -
ture by turning the idle mixture
screw(s) (needle) inward (clockwise)
until ligh tl y seated; then , turn the
FAST (COLD ENGINE) IDLE SPEED
ADJUSTMENT SCRE W B24 16 · A
FIG. 6-ldle Speed Adjustments
-Ford 1-V
FIG. 7-ldle Fuel Mixture
Adjustments-Typical for Ford 2-V
or 4-V
20-4 GROUP 20-MAINTENANCE OPERATIONS
screw(s) outward (counterclockwise)
the specified turns (Part 10-8). Do
not tum the needle(s) tightly against
their seat(s) as they may groove the
end(s). If a needle is damaged, it
must be replaced before a satisfac-
tory fuel mixture can be obtained.
2. Position the choke mechan-
ism so that the choke plate is fully
open. Seat the throttle plate in the
throttle bore. It may be necessary
to back off on the dashpot (if so
equipped) adjustment screw to seat
the throttle plate in the throttle
bore. Set the idle speed adjustment
screw to just make contact with the
stop on the carburetor lower body,
and turn the screw inward (clock-
wise) the specified (Part 10-8) turns.
Final Idle (Hot Engine) Speed
and Mixture Adjustments. The en-
gine idle speed is adjusted to set-
tings for a hot engine and a cold
engine (fast idle speed during choke
operation). All final idle speed and
mixture adjustments must be made
on a hot, normalized engine.
Refer to Figs. 5, 6, 7 and 8 for
views of the idle fuel mixture and
idle (hot engine) speed screws for
the various carburetor applications.
1. Operate the engine until en-
gine temperatures are stabilized. On
a car with an air conditioner, oper-
ate the engine for twenty minutes
before setting the engine idle speed.
The engine idle speed is adjusted
with the air conditioner operating.
2. Position the transmission lever
in neutral. Allow the throttle to
drop back to the normal idle speed
position. Attach a tachometer to the
engine. Set the parking brake.
3. Turn on the headlamps. It is
necessary to place the alternator un-
der a load condition in this man-
ner in order to obtain the specified
engine idle speed during the adjust-
ment procedure.
4. On a car with a manual shift
transmission, the engine idle speed
is checked and adjusted with the
gear shift lever in neutral position.
On a car with an automatic trans-
mission, the engine idle speed is
checked and adjusted first with the
transmission selector lever in the
neutral position and adjusted with
the transmission selector lever in
the drive range position. Adjust
and check the engine idle speed. Be
sure the dashpot (if so equipped) is
not interfering with the throttle
lever. On an automatic choke
equipped carburetor, make sure the
fast idle screw is not contacting the
FIG. 8-Accelerating Pump Stroke and Idle (Hot Engine) Speed
Adjustments-Typical for Ford 2-V and 4-V
fast idle cam. On a manual choke
equipped carburetor, make sure the
choke cam and lever is in the slow
position, with the fast idle screw not
contacting the cam.
On a carburetor equipped with
a bot idle compensator, be sure the
compensator is seated to allow for
proper idle adjustment.
Forel Publishing
Adjust Company,
the engine idle LLC
speed to
specifications
Woodbridge, (Part 10-8) by turn-
VA 22192
ing the engine idle speed screw
www.ForelPublishing.com
(Figs. 6 or 8) inward to increase
the speed or outward to decrease
the speed.
5. Turn the idle mixture needle(s)
(Figs. 5 or 7) inward until the en-
gine rpm begins to drop, due to the
lean mixture. On a car equipped
with a Thermactor exhaust emis-
sion system, turn the needle(s) out-
ward 1/1 turn. The outward adjust-
ment of the idle fuel mixture
needles is the final adjustment re-
quired. On a car without the
Thermactor s y s tem, turn the
need le(s) outward until the engine
rpm increases and begins to drop;
then turn the idle mixture needle(s)
inward for maximum rpm and en-
gine smoothness. On Ford 2-V and
4-V carburetors, the needles should
be turned evenly and alternately
approximately the same amount.
The final setting may vary about 1/2
turn difference between needles.
6. After the correct engine idle
mixture has been obtained, check
the idle speed with the transmission
selector lever in neutral and man-
ually opening and closing the
RET AINER CLI P
NO. l
IDLE (HOT ENGINE) SPEED SCREW B2294-B
throttle. Adjust the idle speed to
specification, if required.
If the car is equipped with an
automatic transmission, position the
selector lever in drive range to
check and adjust the idle speed to
specification (Part 10-8), if neces-
sary.
The final engine idle speed may
be varied to suit the conditions un-
der which the car is to be operated.
7. Shut off the engine. Check
the fast (cold engine) idle speed.
FAST (COLD ENGINE) IDLE
SPEED ADJUSTMENT-
AUTOMATIC CHOKE
On a Ford 1-V carburetor, the
fast (cold engine) idle adjustment
screw (Fig. 6) is located on the left
side of the carburetor.
On a Ford 2-V and 4-V carbu-
retor, the fast (cold engine) idle ad-
justment screw (Fig. 9) is located
on the right side of the carburetor.
The fast idle adjusting screw
contacts one edge of the fast idle
cam. The cam permits a faster en-
gine idle speed for smoother run-
ning when the engine is cold dur-
ing choke operation. As the choke
plate is moved through its range
of travel from the closed to the
open position, the fast idle cam
pick-up lever rota tes the fas t idle
cam. Each position on the fast idle
cam permits a slower idle rpm as
engine temperature rises and chok-
ing is reduced.
Make certain the idle (hot en-
gine) speed and mixture is adjusted
 PART 20-1 -MAINTENANCE OPERATIONS
FAST IDLE ADJUSTING SCREW
FAST IDLE CAM
B2595-A
FIG. 9-Fast (Cold Engine) Idle
Speed Adjustment-Ford 2-V and
4-V
to specification before attempting to
set the fast idle speed.
1. W ith the engine operating
temperature normalized (hot), air
cleaner removed and the tachom-
eter attached, m anually rotate the
fast idle cam until the fast idle ad-
justing screw rests adjacent to the
shoulder of the highest step (screw
aligned with arrow mark) on the
cam .
. 2. Start the engine and turn the
fas t id le adjusting screw inward or
outward as requ ired to obtain the
specified idle rpm (Part I 0-8).
3. Place the transmission selec-
tor lever in neutral and turn off the
engine. Switch off the head lamp s
and the air conditioner (if so equip-
ped). Remove the tachometer.
4. If the car is eq uipped with an
automatic transm ission, check the
anti-stall dashpot for proper adj ust-
ment.
FAST (COLD ENGINE) IDLE
SPEED ADJUSTMENT-
MANUAL CHOKE
The ad justing screw on the right
side of the carburetor contacts one
edge of the choke cam and lever
(Fig. 10). T he cam permits a faster
engine idle speed fo r smoother run-
ning when the engine is cold during
choke operation. As the choke cam
and lever is moved through its
range of travel from the open to
the closed position, the fas t id le
pick-up lever rotates the throttle
shaft.
1. Manua lly rotate the choke
cam and lever until the fast idle
adjusti ng screw rests on the index
20-5
CHOKE CAM AND LEVER
FAST IDLE ADJUSTME NT SCREW
B2357 -A
FIG. 10-Manual Choke Fast
(Cold Engine) Idle Speed
Adjustment
mark (arrow) on the cam (Fig. l O).
2. Turn the fas t idle adjust in g ADJUST THROTTLE TO HOT
screw inward or outward (as re- ID LE POSITION PRIOR TO
ADJUSTING DASHPOT B2417 - A
quired) so that the fas t idle ad just-
in g screw just contacts the fas t idle
cam at the index mark to obtain th e
FIG. 11-Anti-Stall Dashpot
specified fast id le rpm (Part 10-8). Adjustment-Ford 1-V
3. lf the car is equipped with an
automa tic transm ission, check the clearance between the throttle lever
dashpot for proper adj ustment. and the plunger tip with a fee ler
gauge of the specified clearance di-
ANTI-STALL DASHPOT (AUTO- mens ion (Part 10-8). Turn the anti-
MATIC TRANSMISSIONS) stall dashpot in its bracket in a
ADJUSTMENT d irection to provide th e specified
The anti-stall dashpot adjustmen t clearance between the tip of the
Forelwith
is made Publishing
the air Company, LLC
cleaner re- pl unger and the th rottle lever. Tight-
Woodbridge,
moved (Part VA 22192
10-5, Section 2) from en the lock nut to sec ure the ad-
the car. www.ForelPublishing.com justme nt.
3. C heck the accelerating pump
Ford 1-V stroke for proper adjustment, if re-
1. Adjust th e throttle pos ition to quired. Ins tall the air cleaner as-
the hot idle setting. Turn the dash- sembly (Part 10-5, Section 2).
pot adjusting screw outward unt il Adjust Accelerating Pump Lever
it is clear of the dashpot plunger -Ford 1-V. T he pump stroke is
assembly (Fig. 1 1). controlled by changing location of
2. Turn the dashpot adjusting the ro ll pin in the lever stop hole
screw in ward until it ini tially con-
tacts the dashpot plunger assembly;
then , turn the adjusting screw in-
ward (clockwise) the specified (Part
l 0-8) number of turns against the
dashpot d iaphragm plunger assem-
bly.
3. Check the accelerat ing pump
lever and stroke for proper adjust-
ment, if required. Install the air
cleaner (Part 10-5, Section 2).
Ford 2-V and 4-V
1. With the engine idle speed
and mixture properl y adjusted, and
the engine at normal operating tem-
perature, loosen the anti-stall dash- B2296 - A
pot lock nut (Fig. 12).
2. Hold the throttle in the closed FIG. 1 2-Anti-Stall Dashpot
position and depress the plunger Adjustment-Typical for Ford 2-V
with a screwd river blade. Check the and 4-V
20-6
50° F AND BELOW
B24 19 · A
FIG. 13-Accelerating Pump
Stroke Adjustment-Ford 1-V
(Fig. 13).
1. For operation in ambient tem-
peratures 50°F and below, p lace
the roll pi n in the lever hole marked
Hl (lower hole).
For best performance and econ-
omy at normal ambient tempera-
tures and high altitude (above 50° F
and/ or above 5,000 feet altitude),
place the roll pin in the LO (upper
hole) of the lever.
2. Check the vent valve for pro-
per ad justment.
Adjust Accelerating Pump Lever
-Ford 2-V and 4-V. The primary
throttle shaft lever (overtravel lever)
has 4 holes and the accelera ting
pump link has 2 holes (Fig. 8) to
control the accelerating pump
stroke for various ambient temper-
atures and operating cond itions of
the engine.
The accelerating pump operating
rod should be in the specified (Part
10-8) hole in the overtravel lever
and the inboard hole (hole closest
to the pump p lunger) in the accel-
erating pump link (Fig. 8).
1. To release the rod from the
retainer clip, press the tab end of
the clip toward the rod; then, at the
same time, press the rod away from
the .clip until it is disengaged.
2. Position the clip over the spe-
cified (Part 10-8) hole in the over-
tra vel lever. Press the ends of the
clip together and insert the operat-
ing rod through the clip and the
overtravel lever. Release the clip
to engage the rod.
VENT VALVE ADJUSTMENT-
FORD 1-V
The vent va lve adjustment is al-
ways performed after the acceler-
ating pump adjustment has been
completed.
I. With the air cleaner removed ,
GROUP 20 - MAINTENANCE OPERATIONS
set the throttle linkage to the hot NOTCH ON VEN T VALVE ROD
idle position. The groove in the TO ALIGN WITH EDGE OF HOLE,
W ITH THROTILE IN
vent valve rod should now be even HOT IDLE POSITION
with the open end of the vent (Fig.
14). Bend the arm on the vent valve
rod actuating lever (where it con-
tacts the accelerating pump lever)
to align the groove with the edge
of the bore.
2. Install the air cleaner (Part
10-5, Section 2).
CLEAN CARBURETOR AIR
CLEA NER AND FILTER
REMOVAL
1. Disconnect the crankcase ven-
tilation system hose, if so equipped,
from the air cleaner body.
2. Remove the wing out retain-
ing the air cleaner assembly to the
carburetor. On ca rs equ ipped with
a hot and cold air intake duct, re-
move the 2 wing-t ype screws tha t
secure the air duct and thermosta t
assembly to the air cleaner.
BEND ACTUA TING LEVER TO
3. Remove the air cleaner assem- OBTA IN CORRECT ROD POSITION
bly, then remove the cover and li ft 81810-B
the filter element out of the air FIG. 14-Vent Valve Adjustment
cleaner bod y.
CLEANING F ILTER ELEMENT spect it fo r any sp lits or cracks. If
The polyeurethene filter elemen t the filter is sp lit or cracked, replace
on a "closed" cra nkcase ventilation it.
system equipped car cannot be
BODY AND COVER
cleaned; it must be rep laced.
ForelT he
Publishing
celluloseCompany,
fiber fil terLLC
element C lean the air clea ner body and
Woodbridge, VA 22192 the cover with a solvent or com-
used on an "open" crankcase ven-
pressed a ir. If th e air cleaner con-
tilation system equipped car must
www.ForelPublishing.com
never be cleaned with a solvent or tains an opening for the crankcase
cleaning solution. Also, oil must not ventilation sysLem a ir flow, probe the
be add ed to the surfaces of the filter opening to assure removal of deposits.
element or air cleaner body. Wipe the ai r cleaner dry if a solvent
There are two procedu res that is used. lnspecL the air cleaner body
and cover for distortion or damage at
can be used to clean the air filter
the gasket mating surfaces. Replace
element. One method is performed
wi th the use of compressed air. The the cover or body if they are damaged
other is performed by tapp ing the beyond repair.
element on a smooth horizonta l INSTALLATION
surface. 1. Ins tall a new ai r cleaner
mo unting gasket on the carburetor,
Compressed Air Me thod. Direct
if required.
a stream of compressed air through
2. Position the air cleaner body
the element in the direction opposite
that of the intake air flow, th at is on the carburetor, and make certain
from the inside outward. Extreme the body is properly seated on the
care must be exercised to prevent gasket.
rupture of the clement material. 3. Connect the a ir inlet duct and
Tapping Meth od. Ho ld the ele- va lve assembly, if so equipped, to
ment in a vertical posit ion and tap the air cleaner with the wing-type
it li ghtly against a smooth , horizonta l retaining screws. T ighten the screws.
surface to shake the d ust and dirt 4. P lace the filter element on the
out. Do not deform the element or the air cleaner body. M ake sure the
damage the gasket surfaces by tap- filter is properly seated. If the word
ping too hard. Rotate the filter after TOP is indicated on the filter ele-
each tap until the entire outer sur- ment, make sure the word T OP
face has been cleaned. faces up. Install the cover and tight-
Inspection. H o ld the filter in front en the retaining wing nut.
of a back-up light and carefu lly in- 5. Connect the crankcase vent
 PART 20- 1- MAINTENANCE OPERATIONS
hose, if so equipped, to the a ir
c lea ner and tighten the retainin g
clamp.
REPLACE CARBURETOR AIR
CLEANER FILTER
REMOVAL
1. Disconnect the c ra nkcase ven-
tilation system hose, if so equipped,
fro m the air cleaner bod y.
2. Remove the wing nut retain-
ing the air cleaner assem bly to the
carbu retor. On cars equipped with
a hot and cold air intake duct, re-
move the 2 wing-type screws tha t
secure the air duct and thermostat
assembly to the air clea ner.
3. Remove the air cleaner assem-
bly, then remove the cover and lift
the filter element out of the air
cleaner body.
INSTALLATION
1. Insta ll a new a ir cleaner
mountin g gasket on the carburetor
if requi red.
2. Position the air cleaner body
on the carburetor, and make certa in
the body is properl y sea ted on the
gasket.
3. Connect the air inlet duct and
valve assembly, if so equipped , to
the air cleaner with the wing-t ype
retainin g screws. Tigh ten the screws.
4. Place the filter element on the
ai r clea ner body. Make sure the
filter is properly seated. If the word
TOP is indicated on the filter cle-
ment, make sure the word TOP
faces up . Install the cover and ti ght-
en the retaining wing nut.
5. Connect the crankcase vent hose,
if so equi pped, to the air cleaner
and tighten the retainin g clamp.
CLEAN CRANKCASE OIL
FILLER BREATHER CAP
Remove the cap and wash 1t 111 a
low-volatility, petroleum-base sol-
vent. Probe the breather ho le(s) to
assure removal of any accumul ated
deposits. Shake the ca p d ry and
insta ll it. Do not dry with com-
pressed air as air pressure may dam-
age the filter clement.
CLEAN EMISSION SYSTEM
HOSES, TUBES, OIL
SEPARATOR (427 C.l.D.
ENGINE), FITTINGS,
CARBURETOR SPACER AND
REPLACE EMISSION CONTROL
VAL VE. REPLACE
THERMACTOR AIR PUMP
FILTER IF SO EQUIPPPED.
REMOVAL
170 and 200 Six
1. On a closed venilation system,
remove the inlet hose from the a ir
cleaner and filler cap.
2. Remove the air cleaner.
3. G rasp the crankcase vent hose
near the rocker arm cover grommet
(F ig. 15) and pull to remove the
regulator valve fro m the rocker arm
cover.
4. Using hose clamp pliers, slide
both hose clamps toward the center
of the vent hose. Remove the regu-
lator valve from the vent hose and
remove the vent hose from the hose
filling in the intake manifold.
5. Remove the vent hose fitting
from the intake man ifold.
289 V-8
1. On a closed ventilati on system,
remove th e venti lation system air
intake hose from the air clea ner
and the oil filler cap (Fig. 16).
2. Remove the air cleaner and
intake duct assembly.
3. Us ing hose clamp pliers, slide
both cran kcase vent hose clamps to-
war d the center o f the ven t hose.
Slide the vent hose clamps away
from the hot idle compensator (if so
equipped).
4. P ull the regulator valve and
fittin g (elbow) out o f the va lve rocker
a rm cover mo unting grommet.
ForelCLPublishing
OSED SYSTEM Company,
ONLY
Woodbridge, VA 22192
www.ForelPublishing.com
OIL F IL LER CAP /
~ -._ INLET HOSE
~ f\
CLAMP
HOSE FITIIN G
~tO~)i
;,e-
r \
FIG. 1 5-Crankcase Vent System (Six)
20-7
CLEANING
Do not attempt to clean the crank-
case ventilation regulator valve. It
should be r eplaced at th e specified
mileage intervals.
Clean the crankcase ventilation
system connection on the carburetor
spacer by probing the inlet nipple
with a flex ible wire or bottle brush.
Clea n the rubber hoses with low-
volatility, petroleum-base solvent and
dry with compressed air.
INSTALLATION
170 and 200 Six
1. Install the vent hose fitt ing in
the intake mani fold .
2. Position the hose clamps on
the vent hose. Install the hose on the
fitting in the intake m anifold and the
regulator valve in the hose. Us ing
hose clamp pliers, slide the clamps
into position.
3. Insert the regula tor va lve into
the rocker arm cover mounting
grommet.
4. Insta ll the a ir cleaner.
5. On a closed ventilati on system,
connect the inl et hose to the air
cleaner and the filler cap.
6. Operate the engine and check
for leaks.
LLC
I f
~
A201 2 -C
20-8 GROUP 20- MAINTENANCE OPERATIONS

289 V-8
1. Insert th e regula tor valve and
fitting (elbow) into the valve rocker
arm cover mounting grommet.
2. P osition the hose clamps on
OIL FILLER CA.P -B~\
th e vent hose. Connect the vent hose
to the carburetor spacer regulator
valve and h ot idle compensator (if
so equipped). Using hose clamp pli-
ers, slide the clamps into position.
CRANKCASE VENT HOSE
--
3. Install the air cleaner and in-
take duct assembly.
4. l nstall the venti lation system
intake hose to the air cleaner a nd
the oil filler cap.
5. Operate the engine and check
fo r leaks.
REPLACE THERMACTOR AIR
PUMP FILTER
1. Remove the wing nut (Fig.
17) and. a ir horn assembly. Rem ove
the filter element fro m the air horn
assembl y.
2. Wipe the a ir horn assembly
and a ir cleaner with a clean, dirt-

. y free cloth to remove a ny accumu-

lated dirt or foreign matter. Under
extremel y d irty conditions it may

\~----,
be necessa ry to wash both the ai r
horn and body in low-volatility
m inera l spirits. Be sure the p arts arc
,.-
I
dry before insta lling them.
3. T he filter element is not clea n-

~,~:ow
able. Place a new filte r elemen t on
HOT IDLE COMPENSATOR the air horn assembly. Position the
assembled air horn and fi lter ele-
ment in the ai r c leaner body. Be
REGULAT~
sure the tang is fitted in the slot
(Fig. 17). In stall the wing out.

\. ""' ~ CHECK ENGINE ACCESSORY

DRIVE BELTS
GROMMET_.® BELT TENSION
HOSE CLAMPS
-,(l J
Forel Publishing Company, LLC
P roperly tensioned drive belts
minimize noise and a lso prolong
Woodbridge, VA 22192 serv ice life of the belt. Therefo re,
www.ForelPublishing.com it is recommended that a belt ten-
NON -THE RMACTO R s ion ga uge be used to check and
A I R C 0 N 0 I TI 0 N E 0 28 9 adjust the belt tension. A ny belt tllat
(2-V) MODE L S ONLY
has op erated for a minimum of 1.0
minutes is considered a used belt,
A 1995 -C
a nd w hen adjusted, it must be ad-
justed to the reset tension shown in
th e specifica tions.
FIG. 16-Crankcase Vent System (V-8) 1. Io stall the belt tension tool on
the drive bel t (Fig. 18) and check
the tensi on follow ing the instructions
of the tool m anufacturer.
Due to th e inaccessibility of the
alternator belt on a Comet equipped
with air conditioning and power
steering, a belt tension gauge cannot
be used. T herefore, it m ust be ten-
sioned by the deflection method.
Deflection sh ould not exceed l/4 inch
wh en thumb pressure is a pplied.
2. If adjustment is necessa ry,
loosen the a lternator mounting and
adjusting a rm bolts. Move the alter-
nator toward or away from the en-
gine unti l the correct tension is
obtained. Tighten the alternator ad-
justing arm and the mounting bolts.
Check the belt tension.
DRIVE BELT R EPLACEMENT
FIG. 17-Thermactor Exhaust Emission System Air Cleaner 1. On a car with power steerin g,
 PA RT 20-1-MAINTENANCE OPERATIONS
loosen the power steering pump
bracket at the water pump and re-
inove the drive belt.
On a car with an air conditioner,
remove the compressor drive belt.
2. Loosen the alternator mounting
and adjusting arm bolts. Move the
alternator toward the engine. Re-
move the belt(s) from the alternator
and crankshaft pulleys, and lift them
over the fan.
· 3. Place the belt(s) over the fan .
Insert the belt(s) in the water pump
pulley, crankshaft pulley and alter-
nator or generator pulley grooves.
Adjust the belt tension to specifica-
tions.
4. On a car with an air condi-
tioner, install and adjust the com-
pressor drive belt to specifications.
5. On a car with power steering,
install the power steering pump drive
belt and tighten the pump bracket
to the water pump. Adjust the drive
belt tension to specifications.
LUBRICATE EXHAUST
CONTROL VAL VE
(390 CID ENGINE)
Lubrica te the shaft bushings with
FoMoCo Exhaust Gas Control
Valve Solvent (COAA-19A501-A)
or a penetrating oil and graphi te
mixture, while operating the va lve
manually until it operates with com-
plete freedom.
VAL VE TAPPET ADJUSTMENT
(CONVENTIONAL) (289-4V)
1. Be sure the engine is at nor-
mal operating temperature before
attempting to set the valve lash.
2. Remove the air cleaner.
3. Remove the valve rocker arm
covers and gaskets.
4. With the engine idling, set the
valve lash (Fig. 19) using a step-
type feeler gauge only ("go" and " no
go"). The final (hot) intake and
exhaust valve lash settings are listed
in the Specifications Section.
For example, to obtain the correct
setting if the valve lash is 0.019 inch,
use a step-type feeler gauge of 0.018
inch ("go") and 0.020 inch ("no go").
The "go" step should enter, and the
"no go" step should not enter. The
resu ltant setting will be to the re-
quired setting (0.01 9 inch).
5. Install the va lve rocker arm
cover gaskets and covers.
6. Install the air cleaner.
CHECK IGNITION TIMING
To check and adjust the timing
with a Rotunda 13-07 power timing
Tool- T63L·8620·A
FIG. 18-Checking Drive Belt
Tension
light, proceed as fo llows:
1. Remove the plug wire from
the number 1 spark plug.
2. Install the spark p lug ada ptor
on the spark plug.
3. Connect the plug wire to the
spark plug adaptor.
4. Clamp the timing light spark
plug lead to the spark plug adaptor.
5. Connect the timing light bat-
tery leads to the battery terminals.
6. Disconnect the distributor vac-
uum line (if so equipped).
7. If necessary, clean and mark
Forelmarks.
the timing Publishing Company, LLC
8. Operate the engineVA
Woodbridge, at 22192
the spe-
cified idle rpm a nd point the tim-
www.ForelPublishing.com
ing light at the timing pointer.
9. If the timing is incorrect,
loosen the distributor hold down
bolt and rotate the distributor until
the desired initial advance is ob-
ta ined.
10. Tighten the distributor hold
down bolt and check the timing
again.
11. Turn off the engine.
12. Remove the timing light and
connect the vacuum line.
FIG. 19-Valve Lash Adjustment
20-9
CHECK DISTRIBUTOR POINTS
AND ADJUST
Unsnap the distributor cap retai n-
ing c lips, lift the distributor cap off
the distributor housing, and position
the cap out of the way (if necessary,
remove the ai r cleaner and/ or the
high tension wire to gain access to
the distributor).
Lift the rotor off the cam. Re-
move the dust cover (trans istorized
ign it ion).
INSPECTION
Replace the distributor point as-
sembly if the contacts are badly
burned or excessive metal transfer
between the points is evident. Metal
transfer is considered excessive when
it equals or exceeds the ga p setting.
REMOVAL
1. Remove the primary distribu-
tor-transistor lead and condenser
wire (i f equipped) from the breaker
plate.
2. Remove the screw attaching
the ground wire to the distributor
point assemb ly.
3. Remove the screw nearest the
distr ibutor points, then remove the
d istributor point assembly.
INSTALLATION
1. When installing new distributor
points, reverse the procedure for re-
moval and make sure that the ground
wire is attached to the distributor
point assemb ly attaching screw which
is furthest from the d istributor points.
2. If the used points are serv ice-
able, set the gap using a dwell meter
as fo llows:
Connect the dwell meter following
the manu fac turer's instructions. In a
car equipped with transistor ignition,
make sure that the dwell meter is
connected to the tach ometer block
rather than the coil.
Operate the engine at id le speed
and note the reading on the dwell
meter.
Stop the engine and adjust the
gap (decreasing the gap increases
the dwell). Now check the dwell
again.
Repeat this procedure until speci-
fied dwell is obtained.
If new points are installed, set
the gap to specifications using a
feeler gauge.
3. Install the dust cover (transis-
torized igni tion).
4. Install the rotor. Install the dis-
tributor cap on the distributor hous-
ing and snap the retain ing clips in
place.
20-10
FIG. 20-Cleaning Plug
Electrode
5. Install the air cleaner and/ or
the high tension lead if either was
removed.
CHECK SPARK PLUGS
REMOVAL
1. Remove the wire from each
spark plug by grasping, twisting and
pulling the moulded cap of the wire
only. Do not pull on the wire be-
cause the wire connection inside the
cap may become separated or the
weather seal may be damaged.
2. Clean the area around each
spark plug port with compressed air,
then remove the spark plugs.
3. Examine the firing ends of the
spark plugs, noting the type of de-
posits and the degree of electrode
erosion.
4. Clean the plugs on a sand blast
cleaner, following the manufacturer's
instructions. Do not prolong the use
of the abrasive blast as it wiIJ erode
EJ TRANSMISSION
ADJUST AUTOMATIC
TRANSMISSION
FRONT (INTERMEDIATE) BAND
C-4 TRANSMISSION
1. Clean all the dirt from the
band adjusting screw area. Loosen
the lock nut several turns.
2. With the tool shown in Fig. 23
tighten the adjusting screw until the
tool handle clicks. The tool is a pre-
set torque wrench which clicks and
overruns when the torque on the ad-
justing screw reaches 10 ft-lbs.
GROUP 20- MAINTENANCE OPERATIONS
FIG. 21-Gapping Spark Plug
the insulator and electrodes.
5. Clean the electrode surfaces
with a small file (Fig. 20). Dress the
electrodes to secure flat parallel sur-
faces on both the center and side
electrodes.
6. After cleaning, examine the
plug carefully for cracked or broken
insulators, badly pitted electrodes,
and other signs of failure. Replace
as required.
ADJUSTMENT
Set the spark plug gap to specifica-
tions by bending the ground elec-
trode (Fig. 21).
INSTALLATION
1. Install the spark plugs and
torque each plug to specifications.
ForelWhen
Publishing Company,
a new spark plug isLLC
installed
in Woodbridge,
a new replacement cylinder head,
VA 22192
torque the plug to 20-30 ft-lbs.
www.ForelPublishing.com
2. Connect the spark plug wires.
REPLACE ENGINE COOLANT
To drain the radi ator, open the
drain cock located at the bottom of
the radiator. The cylinder block of
a V-8 engine has a drain plug lo-
cated on both sides of the block
(Fig. 22). The six cylinder engines
have one drain plug located at the
right rear of the cylinder block.
3. Back off the adjusting screw
exactly l1/2 turns.
4. Hold the adjusting screw from
turning and torque the locknut to
specification.
C-6 TRANSMISSION
1. Raise the car on a hoist or
jack stands.
2. Clean the threads of the inter-
mediate band adjustment screw.
3. Loosen the adjustment screw
lock nut.
4. Tighten the band adjustment
DRAIN PLUG
FIG. 22-Typical Cylinder Block
Drain Plug
To fill the cooling system, close
the radiator drain cock and install
the drain plugs in the block. Fill
the system to just below the filler
neck of the radiator supply tank.
Disconnect the heater outlet hose
at the water pump to bleed or re-
lease trapped a ir in the system.
When the coolant begins to escape,
connect the heater outlet hose.
Operate the engine until normal
operating temperature has been
reached. After the initial fill, the
coolant level will drop approximate-
ly one quart after the engine has
been operated about 20 minutes at
2000 rpm. This is due to the dis-
placement of entrapped air. Add
more coolant to fill the radiator sup-
ply tank.
CHECK ENGINE COOLANT
LEVEL
The coolant level should be kept
one inch below the filler neck open-
ing.
screw as shown in Fig. 24 until the
wrench overruns, then back it off
1'h turns. Tighten the adjustment
screw lock nut to specification being
careful not to disturb the ad just-
ment screw setting.
5. Lower the car.
ADJUST AUTOMATIC
TRANSMISSION REAR
(REVERSE) BAND
C-4 TRANSMISSION
1. Clean all the dirt from the ad-
 PART 20-1 - MAINTENANCE OPERATIONS
justing screw area. Loose n the lock
nut several turns.
2. With the tools shown in Fig.
25, tighten the adjusting screw unti l
the tool handle clicks. The tool is a
preset torque wrench which clicks
and overruns when the torque on the
adjusting screw reaches 10 ft-lbs.
3. Back off the adjusting screw
exactly 3 full turns.
4. Hold the adjusting screw from
turning and torque the lock nut to
specification.
CHECK AUTOMATIC
TRANSMISSION FLUID LEVEL
1. Make sure that the car is stand-
ing level. Then fi rmly apply the
parking brake.
2. Run the engine at norm al idle
speed. If the transmission fluid is
cold, run the engine at fast idle
Toof-T59P-77370-B or 7345
01460-A
FIG. 23-lntermediate Band
Adjustment
UNDERSIDE OF SPR ING RETAINER
FIG. 24-Adjusting Intermediate
Band
Toof-T59P-77370-B or 7345
FIG. 25-Low-Reverse Band
Adjustment
speed (about 1200 rpm) until the
fluid reaches its normal operating
temperature. When the fluid is warm,
slow the engine down to normal idle
speed.
3. Shift the selector lever through
all positions, and place the lever at
P. Do not turn off the engine during
the flu id level checks.
4. C lean a ll dirt from the trans-
mission fluid dipstick cap before re-
movin g the dipstick from the filler
tube.
5. Pull the dipstick out of the
tube, wipe it clean, and push it all
Forel Publishing Company, LLC
the way back into the tube. Be sure
Woodbridge,
it is properly seated. VA 22192
www.ForelPublishing.com
6. Pull the dipstick out of the
tube again, and check the fluid level.
If necessary, add enough fluid to the
transmission through the filler tube
to raise the fluid level to the F (full)
mark on the dipstick. Do not overfill
the transmission.
CHECK MANUAL SHIFT
TRANSMISSION OIL LEVEL
1. Remove the filler plug from
the side of the case.
2. lf lubricant does not flow from
the filler hole, fill the case with the
specified lubricant until it is level
with the lower edge of the filler hole.
3. Install the filler plug.
CHECK REAR AXLE FLUID
LEVEL
The lubricant level should be
maintained at the lower edge of the
filler plug hole with the specified
lubricant.
CHECK CLUTCH LINKAGE
ADJUSTMENT
MANUAL
1. Measure the total travel of the
20-ll
pedal (Fig. 26). If the travel is not
within specification , move the clutch
pedal bumper and the bracket up or
down until the travel is within speci-
fied limits. Always check and ad-
just to tal travel before checking free
travel.
2. With the clutch pedal against
its bumper (pedal release), measure
the overall length of the spring. The
overall length should be as specified
in Part 5-4.
3. With the engine idling, depress
the pedal just enough to take up the
free travel and note the reading on
the tape (Fig. 26). The difference
between this reading and the read-
ing where the pedal is released is
the clutch pedal free travel. If the
free travel is not within specification,
ad just the clutch pedal to equalizer
C1466-A
FIG. 26-Typical Clutch Pedal
Free-Travel
rod. (Fig. 27). To increase the free
travel loosen the rearward adjusting
nut and tighten the forward out. To
reduce the free travel, loosen the for-
ward nut and tighten the rearward
nut. Both nuts must be tightened
against the trunnion after making
the adjustment.
4. As a final check, measure the
pedal free travel with the transmis-
sion in neutral and the engine run-
ning at about 3000 rpm. If the free
travel at this speed is not 1h inch, re-
adjust the clutch pedal to equalizer
rod to obtain the specified free
travel. Otherwise, the release fingers
may con tact the release bearing con-
tinuously, resulting in premature
bearing and clutch fa ilure. Free
travel must be exactly to specifica-
tion.
INTERLOCK (OVERDRIVE
MODELS ONLY)
Be sure that the clutch linkage is