Académique Documents
Professionnel Documents
Culture Documents
1962-63
ERCURY MONTEREY
1963
GALAXI and
MONTEREY
SUPPIEMWT
PAGE 3
SHOP
MANUAL
SUPPLEMENT
Reproduced under license agreement
with Ford Motor Company."
License #5001 3-1-94
SERVICE
DEPA
RTMENT
COMPANY
FIRST PRINTINGSEPTEMBER, 1962
1962 FORD MOTOR COMPANY, DEARBORN, MICHIGAN
1962
MONTEREY
SUmEMCNT
PAGE 191
FOREWORD
This supplement is divided into two parts: 1963 Ford Galaxie
and Mercury Monterey information, and 1962 Mercury
Monterey information. When used with the 1962 Ford
Galaxie Shop Manual and the 1961 Mercury Maintenance
Manual this supplement provides the necessary information
for servicing the 1963 Ford Galaxie and Mercury Monterey.
Complete 1963 maintenance information and specifications
are included.
The descriptions and specifications contained in this supplement were in effect at the time the manual was approved for
printing. The Ford Motor Company reserves the right to discontinue models at any time, or change specifications or
design, without notice and without incurring obligation.
SERVICE
DEPARTMENT
FORD MOTOR
COMPANY
GROUP INDEX
GALAXIE AND MONTEREY
FORD
GALAXIE and
MERCURY
MONTEREY
SUPPLEMENT
.'-'. T.*.*
piiW|P
wtm*
MAINTENANCE AND LUBRICATION
SPECIFICATIONS
GALAXIE IDENTIFICATION
GALAXIE IDENTIFICATION
3S63X100001
M1090-A
BODY
Gaiaxie
54B
62B
4-Door Sedan
2-Door Sedan
Gaiaxie 500
54A
62A
65A
65B
75A
76A
76B
4-Door
2-Door
2-Door
2-Door
4-Door
2-Door
2-Door
Sedan
Sedan
Hardtop
500XL Hardtop
Hardtop
Convertible
500XL Convertible
Station Wagons
71A
71B
71C
71E
4-Door
4-Door
4-Door
4-Door
9-Passenger
6-Passenger
9-Passenger
6-Passenger
Country
Country
Country
Country
Squire
Sedan
Sedan
Squire
COLOR
N1319-A
VEHICLE DATA
Example (Fig. 1):
(65A
65A
FM..
22
27H
11
1
3
EM
22
27H
11
3)
2-Door Hardtop
Viking Blue and Corinthian White
Med. Blue Gleam Cloth and Lt. Blue D/L Crush
Vinyl
27th day August
Boston District
3.00:1 Ratio Axle
Fordomatic
Two-tone paint codes use the same symbols as the single colors except that
two symbols are used. The lower body color code will appear first in the
warranty plate paint color space.
If a special paint is used, the paint color space will not be stamped.
Code
A
D
E
H
1
J
M
P
T
V
W
X
Y
Z
*M-30-J
Number
Color
Sales Name
1724.... Black
Raven Black
1451.... Medium Turquoise Metallic. Ming Green
1448... Medium Blue Metallic
Viking Blue
1447... Dark Blue Metallic
Oxford Blue
1459... Gold Metallic
Champagne
1515.... Red
Rangoon Red
1238... White
Corinthian White
1454.... Medium Green Metallic
Silver Moss
1543... Honey Beige
Sandshell Beige
1470... .Chestnut Metallic
Chestnut
1555... Light Pink Metallic
Rose Beige
1444... .Maroon Metallic
Heritage Burgundy
1553... .Light Blue
Glacier Blue
1427... Beige Metallic
Fieldstone Tan
GALAXIE IDENTIFICATION
DISTRICT CODE (Continued)
TRIM
Deviation trim sets will use existing trim codes plus a suffix. A trim code with
a numerical suffix is not serviced, while a trim code with an alphabetical
suffix is serviced.
Code
Trim Schemes
Puff Stripe B/C and Crush Vinyl
12
Med. Blue and Lt. Blue Met.
14
.. Lt. Beige and Pearl Beige
15
Red and Red
Med. Turquoise and Lt. Turquoise Met.
17
18
Lt. Gold and Lt. Gold Met.
Gleam B/C and Crush Vinyl
22
. . . M e d . Blue and Lt. Blue D/L
24
Lt. Beige and Pearl Beige
25
Red and Red
Black and Black
26
27
Med. Turquoise and Lt. Turquoise D/L
28
Lt. Gold and Lt. Gold D/L
Vinyl and Brick Patt. B/C
32
Lt. Blue and Med. Blue
35
Red and Red
38
Lt. Gold and Lt. Gold
Basket Weave Vinyl and Crush Vinyl
Med. Blue Met. and Lt. Blue Met.
42
44
Med. Beige Met. and Pearl Beige
45
Red and Red
Crush Vinyl
80
Lt. Rose Beige D/L
82
Lt. Blue D/L
85
...Red
Black
86
Lt. Turquoise D/L
87
88
Lt. Gold D/L
89
Med. Chestnut D/L
Vachette Vinyl and Crush Vinyl
66
Black and Black
69
Med. Chestnut D/L and Lt. Chestnut D/L
94
Lt. Beige D/L and Pearl Beige
95
Red and Red
97
Med. Turquoise D/L and Lt. Turquoise D/L
98
Lt. Gold D/L and Pearl Gold
Rib Vinyl (Police and Taxi)
03
Med. Green
04
Med. Beige
05
Red
DATE
The code letters for the month are preceded by a numeral to show the day
of the month when the car was completed. The second year code letters are
to be used if 1963 model production exceeds 12 months.
First
Second
Model
Model
I
Year
Month
Year
Jar
January
A
N
Fel
February
B
P
Ma
March
C
Q
Ap
April
D
R
Ma
May
E
S
Jui
F
T
June
Jul
G
July
u
Au
V
H
August
Sei
J
..W
September
Od
K
X
October
No
L
Y
November
Da
M
December
Z
DSO
Domestic Special Orders, Foreign Special Orders, and Pre-Approved Special
Orders have the complete order number recorded in this space. Also to
appear in this space is the two-digit code number of the District which ordered
the unit. If the unit is regular production, only the District code number
will appear.
DISTRICT
Code
11
12
13
14
15
21
CODE
District
Boston
Buffalo
..New York
Pittsburgh
Newark
Atlanta
Code
22
23
24
25
26
31
District
Charlotte
Philadelphia
Jacksonville
Richmond
Washington
Cincinnati
Code
32
33
34
35
36
41
42
43
44
45
51
52
53
54
55
District
Cleveland
Detroit
Indianapolis
Lansing
Louisville
Chicago
Fargo
Rockford
Twin Cities
Davenport
Denver
Des Moines
Kansas City
Omaha
St. Louis
Code
61
62
63
64
65
71
72
73
74
81
83
84
85
89
90
District
Dallas
Houston
Memphis
New Orleans
Oklahoma City
Los Angeles
SanJose
Salt Lake City
Seattle
Ford of Canada
Government
Home Office Reserve
American Red Cross
Transportation Services
Export
AXLE
A number designates a conventional axle, while a letter designates an EquaLock differential.
Code
Ratio
Code
Ratio
1
4
5
7
8
9
3.00:1
3.25:1
3.50:1
3.80:1
3.89:1
4.11:1
3.00:1
E
G
3.50:1
3.80:1
4.11:1
TRANSMISSION
Code
1
2
3
4
5
Type
3-Speed Manual-Shift
Overdrive
Fordomatic
Cruise-O-Matic
4-Speed Manual-Shift
MODEL YEAR
The number 3 designates 1963.
ASSEMBLY
Code
Letter
D
E
G
J
N
PLANT
Assembly
Plant
Dallas
Mahwah
Chicago
LosAngeles
Norfolk
Code
Letter
P
S
U
W
Z
Assembly
Plant
Twin Cities
Pilot Plant
Louisville
Wayne
St. Louis
MODEL
The model code number identifies the product line series and the particular
body style: the first of the two digits shows the product line, and the second
digit shows a two-door style by an odd number or a four-door style by an
even number.
Ford 300
53
2-Door Sedan
54
4-Door Sedan
Galaxie
51
2-Door Sedan
52
4-Door Sedan
Galaxie 500
61
2-Door Sedan
62
4-Door Sedan
63
2-Door Hardtop
64
4-Door Hardtop
65
2-Door Convertible
67
500XL 2-Door Hardtop
69
500XL 2-Door Convertible
Station Wagons
72
4-Door 6-Passenger Country Sedan
74
4-Door 9-Passenger Country Sedan
76
4-Door 6-Passenger Country Squire
78
4-Door 9-Passenger Country Squire
GALAXIE-MONTEREY IDENTIFICATION
ENGINE
ENGINE (Continued)
Code
Code
B
E
F
G
P
V
X
Z
8-Cylinder
6-Cylinder
8-Cylinder
8-Cylinder
.8-Cylinder
6-Cylinder
.8-Cylinder
8-Cylinder
5
8
9
MONTEREY IDENTIFICATION
NTY
NUMB
3S53Y500001
MONTEREY
C/brd
N1267-A
BODY
Monterey
54A
62A
63A
65A
75A
Monterey Custom
54B
63B
63C
65B
65C
75B
75C
76A
76B
Station Wagon
71B
71D
4-Door
2-Door
2-Door
2-Door
4-Door
Sedan
Sedan
Fastback Hardtop
Hardtop
Hardtop
4-Door
2-Door
2-Door
2-Door
2-Door
4-Door
4-Door
2-Door
2-Door
Sedan
Fastback Hardtop
"S55" Fastback Hardtop
Special Hardtop
"S55" Hardtop
Special Hardtop
"S55" Hardtop
Convertible
"S55" Convertible
COLOR
Two-tone paint codes use the same symbols as the single colors except that
two symbols are used. The lower body color code will appear first in the
Warranty Plate Paint Color Space.
If a special paint is used, the paint color space will not be stamped.
N1268-A
F I G . 4-Monterey Vehicle
Identification Number Location
VEHICLE DATA
Example (Fig. 3):
(65A
HM
22
65A
HM
22
27H
11
1
4
27H
11
1
4)
2-Door Hardtop
Blue Satin and Sultana White
Med. Blue Dot Pattern Cloth and Light Blue
Met. Crush Vinyl
27th Day August
Boston District
3.00:1 Ratio
Multi-Drive
Code
A
B
D
E
H
1
J
M
P
R
T
W
X
Y
Z
*M-30-J
Number
Color
1724... .Black
1613... .Lt. Turquoise
1451...Med. Turq. Met
1448... Med. Blue Met
1447. ...Dark Blue Met
1459...Gold Met
1515...Red
.1238... .White
1454... .Med. Green Met
1456... Yellow
1543... Honey Beige
1555....Pink Met
1444... Maroon Met
1553... .Lt. Blue
1427.... Beige Met
Sales Name
Presidential Black
Peacock Turquoise
Ocean Turquoise
Pacific Blue
Blue Satin
Castilian Gold
Carnival Red
Sultana White
Scotch Green
Jamaica Yellow
Champagne
Pink Frost
Black Cherry
Cascade Blue
Desert Frost
MONTEREY IDENTIFICATION
TRIM
AXLE
Deviation trim sets will use existing trim codes plus 2 suffix. A trim code
with a numeral suffix is not serviced, while a trim code with an alphabetical
suffix is serviced.
Code
10
12
14
16
17
18
22
24
26
27
50
52
54
55
56
57
58
03
04
05
Trim Schemes
Block Pattern Cloth and Crush Vinyl
Med. Rose and Lt. Rose D/L
Med. Blue and Lt. Blue D/L
Med. Beige and Pearl
Black and Black
Med. Turquoise and Lt. Turquoise D/L
Med. Gold and Lt. Pearl Gold
Dot Pattern Cloth and Crush Vinyl
Med. Blue and Lt. Blue Met.
Med. Beige and Lt. Pearl Beige
Black and Black
Med. Turquoise and Lt. Turquoise Met.
Crush Grain Vinyl and Crush Grain Vinyl
Lt. Rose D/L and Med. Rose D/L
Lt. Blue and Dk. Blue D/L
Lt. Beige Pearl and Lt. Beige D/L
Red
Black
Lt. Turquoise D/L and Dk. Turquoise D/L
Lt. Gold D/L and Med. Gold D/L
Rib Crush Vinyl (Police and Taxi)
Med. Green
Med. Beige
Red
DATE
The code letters for the month are preceded by a numeral to show the day
of the month when the car was completed. The second year code letters
are to be used if 1963 model production exceeds 12 months.
First
Model Year
A
B
C
D
E
F
G
H
J
K
L
M
January
February
March
April
May
June
July
August
September
October
November
December
Second
Model Year
N
P
Q
R
S
T
U
V
W
X
Y
Z
DSO
Domestic Special Orders, Foreign Special Orders, and Pre-Approved Special
Orders have the complete order number recorded in this space. Also to
appear in this space is the two-digit code number of the District which
ordered the unit. If the unit is regular production, only the District code
number appears.
DISTRICT CODE
Code
11
12
13
14
21
22
24
25
31
32
33
34
District
Boston
Philadelphia
New York
Washington
Atlanta
Dallas
Jacksonville
Memphis
Buffalo
Cincinnati
Cleveland
Detroit
Code
35
41
43
44
45
51
52
53
54
81
84
90-99
District
Pittsburgh
Chicago
Kansas City
St. Louis
Twin Cities
Denver
Los Angeles
Oakland
Seattle
Ford of Canada
Home Office Reserve
Export
Code
1
5
Ratio
Code
Ratio
.3.00:1
.3.50:1
7..
9..
.3.80:1
.4.11:1
TRANSMISSION
Code
1..
4..
5..
Type
.3-Speed Manual-Shift
.Automatic (Multi-Drive)
.4-Speed Manual-Shift
MODEL YEAR
The number " 3 " designates 1963.
ASSEMBLY PLANT
Code
Letter
Assembly
Plant
E
S
W
Z
Mahwah
Pilot Plant
Wayne
St. Louis
MODEL
The model code number identifies the product line series and the particular
body style.
Monterey
51
52
53
54
57
2-Door
4-Door
4-Door
4-Door
2-Door
Sedan
Sedan
Hardtop
Hardtop
Fastback Hardtop
Monterey Custom
60
62
63
64
65
66
67
68
69
4-Door
4-Door
2-Door
4-Door
2-Door
2-Door
2-Door
2-Door
2-Door
"S55" Hardtop
Sedan
Special Hardtop
Special Hardtop
Convertible
Fastback Hardtop
"S55" Hardtop
"S55" Fastback Hardtop
"S55" Convertible
Station Wagon
76
76
ENGINE
Code
B
G
P
Y
Z
9
GROUP 1
DESCRIPTION
VALVE TRAINSPECIAL
POLICE AND TAXI
SPECIAL ENGINES
The intake and exhaust valves are
the rotating type. The tappets are the
solid steel mushroom-type. Conventional rocker arms with self-locking
adjustment screws are used in the
engine. A specified valve lash (clearance) between the pads of the rocker
arms and the valve stems is main-
A1735-A
A1733-A
A1736-A
A1734-A
GROUP 1
and will not permit sufficient flow of
oil, the pressure acting on the inner
face of the valve drops. If the pressure difference between the valves is
great enough to overcome the spring
pressure, the valve will open. Oil then
by-passes the element, maintaining
an emergency supply of oil to the
engine.
The timing gear sprockets are
lubricated at a flat on the No. 1 camshaft bearing.
Oil under full-jet metered pressure
is fed through a drilled passage in the
cylinder block at the No. 3 camshaft
bearing. The passage in the block indexes with a hole in the cylinder
head. An oil inlet tube directs the oil
into the hollow rocker shaft through
the No. 4 valve rocker arm support.
The oil from the shaft flows through
drilled holes in each rocker arm to
lubricate the rocker arm pads and
valve stems, rocker arm shaft bores,
and the ball ends of the rocker arm
adjusting screws and valve push rods.
A1737-A
CRANKCASE VENTILATION
Vent Tube-Type Crankcase Ventilation System. The vent-tube type
crankcase ventilation system is standard for 1963 Mileage Maker Six Special Police and Taxi Special engines
only. A heavy-duty breather cap is
located on the front of the valve rocker arm cover (Fig. 10).
The engine has a full-flow replaceable oil filter element (cannistercover type) which filters the entire
output of the oil pump before the oil
enters the engine (Fig. 9).
A by-pass system provides oil to
the engine in case the filter element
becomes clogged. The by-pass is located in the hollow center bolt of the
filter assembly and consists of a
spring-loaded valve. When the filter
is clean and oil will flow through it,
the pressure difference between the
inner and outer faces of the valve is
A1216-D
GROUP 1
ventilating air allowed into the fuel
induction system of the engine.
IN-CHASSIS REPAIR
OPERATIONS
Engine Front Supports. The front
supports are located on each side of
the cylinder block (Fig. 13). The procedures given apply to a right or left
installation.
A1738-A
REMOVAL
1. Remove the support insulator
to frame nut and lock washer.
2. Position a support jack and a
wood block under the oil pan. Raise
the jack to relieve the weight of the
engine.
3. Remove the 3 bolts and lock
washers securing the support bracket
to the engine.
4. Raise the engine and remove
the support bracket and insulator as
a unit.
5. Remove the 2 nuts and lock
washers securing the insulator assembly to the support bracket and separate the two units.
INSTALLATION
1. Install the insulator on the rear
support bracket and secure it with the
2 lock washers and retaining nuts.
Torque the nuts to specifications.
A1729-A
GROUP 1
10
CROSS MEMBER
SUPPORT
INSULATOR
ASSEMBLY
RIGHT SUPPORT
BRACKET
-\
A1739-A
F I G . 13Engine Supports
2. Install the insulator and support
in the frame side member.
3. Secure the support bracket to
the engine with the 3 retaining bolts
and lock washers. Torque the bolts to
specifications.
4. Lower the engine and remove
the jack. Install the insulator to
frame member retaining nut and
washer. Torque the nut to specifications.
5. If only one support was removed, tighten the other support.
Engine Rear Support. The rear
support is located at the transmission
extension housing (Fig. 13).
REMOVAL
1. Remove the support flange to
cross member retaining bolt and nut.
2. Raise the transmission with a
jack to obtain clearance at the transmission extension housing; then, remove the 2 retainer and support assembly mounting bolts and washers.
Remove the support assembly and
the retainer.
INSTALLATION
1. Position the support assembly
and retainer; then, install the 2
mounting bolts and lock washers
Torque the bolts to specifications.
OIL INLET
TUBE
/
SEAL
SPRING
WASHER
ROCKER SHAFT
FRONT
F I G . 14Valve Rocker Arm and Shaft AssemblySpecial Police and Taxi Special Engines
COTTER
co
^
PIN
A1422-B
11
GROUP 1
the adapter with clean carburetor solvent. Clean the hose in low volatility
petroleum base solvent. Dry the hose
and adapter with compressed air. Inspect the cylinder block opening and
remove any sludge deposits which
could restrict the flow of crankcase
gases.
Cylinder Front Cover and Timing
REMOVAL
1. Drain the cooling system and
crankcase. On a car with an automatic transmission, disconnect the oil
cooled lines at the radiator.
2. Disconnect the radiator upper
hose at the radiator supply tank and
the radiator lower hose at the water
pump. Remove the radiator.
3. Remove the fan, drive belt, and
pulley.
On a car with power steering, remove the power steering pump drive
belt. Remove the power steering
pump pulley from the crankshaft
damper.
4. Remove the cap screw and
washer from the end of the crankshaft; then, remove the damper
(Fig. 15).
TIMING MARKS
A1534-A
A1532-A
Tool-6316-FEE
INSTALLATION
A1533-A
11. Remove the camshaft gear retaining bolt, washers, and the timing
gears.
A1531-B
12
GROUP 1
REAR BEARING
SCREW
PLUG
CAMSHAFT
LOCKWASHER
SCREW
A1538-A
Tool-T52L-6059-AAE
A1740-A
Tool-T52L-6306-AEE
^ ^
A1741-A
REMOVAL. The camshaft and related parts are shown in Fig. 22.
1. Remove the crankshaft damper
and cylinder front cover. Follow the
"Cylinder Front Cover and Timing
Gears" procedure outlined in this
section of this manual.
2. Remove the grille and the
grille center support. Remove the air
cleaner assembly support bracket.
3. Remove the valve rocker arm
cover and the valve rocker arm shaft
assembly as outlined in the 1962
Galaxie Shop Manual. Remove the
valve push rods in sequence.
4. Disconnect the primary wire
and the high tension wire at the coil.
A1539-A
13
GROUP 1
secure them with spring-type clothes
pins or window regulator spring
clips. Turn the engine until the timing marks on the gears are positioned
as shown in Fig. 18.
10. Remove the camshaft thrust
plate, Woodruff key and spacer.
Carefully remove the camshaft by
pulling it toward the front of the engine. Use caution to avoid damaging
the bearings.
INSTALLATION
1. Oil the camshaft and apply Lubriplate to all the lobes. Carefully
slide the camshaft through the bearings.
2. Install the camshaft spacer and
Woodruff key. Be sure the chamfer
on the spacer is to the rear or faces
the camshaft journal.
3. Install the thrust plate. Torque
the retaining screws to specifications.
4. Position the timing gears on the
crankshaft and camshaft. Be sure the
timing marks on both timing gears
are positioned as shown in Fig. 18.
Install the camshaft sprocket cap
screw and washer. Install the crankshaft front oil slinger.
5. Replace the crankshaft front oil
seal. Install the cylinder front cover,
crankshaft damper, and related parts
by following the procedures in this
section of the manual.
6. Install the grille and center support.
7. Clean the oil pan and oil pump
inlet tube screen. Install the oil pump,
inlet tube, and the oil pan and related
parts. Install a new oil filter element.
8. Release the tappets. Apply lubriplate to both ends of the push
rods. Install the push rods in sequence and position the lower ends of
the rods in the tappet sockets.
9. Install the valve rocker arm
shaft assembly by following steps 1
through 5 of the "Valve Rocker Arm
Shaft Installation" procedure in this
section of the manual.
10. Clean the valve push rod cover.
Cement a new gasket to the valve
push rod chamber cover with neoprene adhesive. Install the cover and
ignition wiring clip.
The cover is tightened in 2 steps.
First, torque the retaining bolts to
specifications. Two minutes after the
initial tightening, torque the bolts to
the same specifications. Connect the
coolant sending unit wire to the sending unit and install the wire in the retaining clip.
11. Install the fuel pump and connect the fuel lines.
12. Crank the engine until the No.
1 piston is on TDC after the compression stroke. Position the distributor in the block with the rotor at the
No. 1 firing position and the breaker
points open. Install the distributor
hold-down bolts.
13. Perform a preliminary (cold)
valve lash adjustment. To perform
this operation, refer to the procedure
contained in this section of the manual
supplement.
14. Connect the distributor primary wire and the vacuum line. Install the distributor cap; then, connect the spark plug wires and the coil
high tension le#d.
15. Fill and bleed the cooling system. Fill the crankcase to its required
level with the specified lubricant.
16. Start the engine and adjust the
ignition timing to specification. Connect the distributor vacuum line. Operate the engine at fast idle and check
all hose connections and gaskets for
leaks. After engine temperatures have
stabilized, perform a final valve lash
adjustment to obtain the specified
clearance. Adjust the engine idle
speed and fuel mixture.
17. Install the valve rocker arm
cover and tighten it in 2 steps. First,
torque the retaining bolts to specifications. Two minutes after the initial
tightening, torque the bolts to the
same specification. Install the air
cleaner.
Oil Filter Element Replacement
Special Police and Taxi Special Engines. The oil filter assembly is shown
in Fig. 24.
1. Place a drip pan under the filter. Remove the filter center bolt,
then remove the filter assembly and
gasket. Discard the gasket.
2. Remove the filter element, neoprene gasket, spring and seat; then,
remove the center bolt from the container and the fiber gasket from the
bolt. Discard the element and gaskets.
3. Wash all parts in solvent. Make
sure the openings in the bolt are
clean.
4. Install the new filter element in
the housing, following the instructions furnished with the new element.
5. Clean the cylinder block filter
recess. Install a new gasket.
6. Place the filter assembly in position and thread the center bolt into
the adapter finger-tight.
7. Rotate the filter assembly
slightly, in each direction, to make
sure the gasket is seated evenly.
8. Torque the bolt to specifications. Do not over-torque the bolt.
GASKET
NEOPRENE
GASKET
SPRING
RETAINER
SPRING
FIBER
GASKET
CENTER BOLT
A1071-B
14
WORK STAND REPAIR
OPERATIONS
GROUP 1
STEP l-SET NO. 1 PISTON ON T.D.C. AT END OF COMPRESSION
STROKE, ADJUST NO. 1 INTAKE AND EXHAUST.
STEP 4-ADJUST NO. 6 INTAKE AND EXHAUST.
STEP 2-ADJUST
INTAKE
STEP 5-ADJUST
INTAKE
NO.
AND
NO.
AND
5
EXHAUST.
2
EXHAUST.
STEP 3-ADJUST
INTAKE
STEP 6-ADJUST
INTAKE
NO. 3
AND EXHAUST.
NO. 4
AND EXHAUST.
A1415-B
A1OO1-A
F I G . 2 6 - V a l v e Lash Adjustment
Mileage Maker Six Special Police
and Taxi Special Engines
GROUP 1
tility petroleum base solvent and dry
it with compressed air.
6. Install the oil separator and
hose and tighten the hose clamps.
ENGINE TESTS AND
ADJUSTMENTS
15
A1719-A
A1718-A
3
Ai6i6-B
A1717-A
16
GROUP 1
AIR INLET
A158O-B
CYLINDER HEADS
The cylinder head assemblies contain the valves and the valve rocker
arm assemblies. The valve guides and
push rod guides are machined in the
head with a cast combustion chamber. The valve arrangement from
front to rear on the left bank is
E-I-E-I-E-I-E-I and on the right bank
I-E-I-E-I-E-I-E (Fig. 34).
CYLINDER BLOCK
The cylinders are numbered from
front to rear, on the right bank 1, 2,
3 and 4 and on the left bank 5, 6,
7 and 8. The firing order is 1-5-4-26-3-7-8.
1, 4, 6, AND 7
2, 3, 5, AND 8
^
^
A1579-B
LEFT BANK
A1632-A
GROUP 1
LIFTER BODY
VALVE OPEN
17
oil gallery supplies oil to each individual main bearing, through drilled
passages in the block. Passages are
drilled from each main bearing to
each camshaft bearing. Number 1
main bearing feeds No. 1 camshaft
bearing, and No. 2 main bearing
feeds No. 2 camshaft bearing, etc.
The oil then flows through notches
or grooves in the main bearings to
lubricate the crankshaft journals. The
timing chain and sprockets are lubricated by oil deflected from the front
camshaft bearing by an oil drip
trough on the cylinder front cover.
VALVE CLOSED
PLUNGER
CHECK VALVE
CHECK VALVE
RETAINER
BASE CIRCLE
A1575-A
18
GROUP 1
A1581-B
19
GROUP 1
FROM
CRANKCASE
OUTLET
H I G H SPEED O P E R A T I O N
LOW INTAKE AAANIFOLD VACUUM
L O W SPEED O P E R A T I O N
HIGH INTAKE MANIFOLD VACUUM
A1583-B
A1576-B
retor spacer (Fig. 37). The valve regulates the amount of air to meet
changing operating conditions.
and to the full open position. This increases the flow of ventilating air.
During idle, intake manifold vacuum is high. The high vacuum overcomes the tension of the spring pressure and seats the valve (Fig. 38).
With the valve in this position, all the
ventilating air passes through a calibrated orifice in the valve. With the
valve seated, there is minimum ventilation. As engine speed increases
and manifold vacuum decreases, the
spring forces the valve off its seat
COOLING SYSTEM
The coolant is drawn from the bottom of the radiator by the water
pump which delivers the coolant to
the cylinder block (Fig. 39).
The coolant travels through cored
passages to cool the entire length of
each cylinder wall. Upon reaching the
rear of the cylinder block, the coolant
is directed upward into the cylinder
The engine removal and installation procedures are for the engine
only without the transmission attached.
ill
A1584-B
F I G . 39Cooling System
REMOVAL
1. Drain the cooling system and
the crankcase. Remove the oil filter.
2. Remove the hood, air cleaner
and intake duct assembly. Disconnect
the battery ground cable at the cylinder head.
3. Disconnect the radiator upper
hose at the coolant outlet housing and
the radiator lower hose at the water
pump.
On a car with an automatic transmission, disconnect the transmission
oil cooler lines at the radiator.
4. Remove the radiator. Remove
the fan, spacer, belt and pulley.
5. Disconnect the wires at the generator or alternator. Loosen the gen-
GROUP 1
20
erator or alternator adjusting bolts to
allow the generator or alternator to
swing down and out of the way.
6. Disconnect the oil pressure
sending unit wire at the sending unit,
and the flexible fuel line at the fuel
tank line. Plug the fuel tank line.
7. Disconnect the accelerator rod
at the bellcrank.
On a car with an automatic transmission, disconnect the throttle valve
vacuum line at the intake manifold.
Disconnect the manual shift rod at
the bellcrank and remove the retracting spring. Disconnect the transmission filler tube bracket at the cylinder
block.
On a car with an air conditioner,
isolate and remove the compressor as
outlined in Part 12-3 of the 1962
Galaxie Shop Manual.
On a car with power steering, disconnect the power steering pump
bracket from the cylinder head. Remove the drive belt. Wire the power
steering pump out of the way and in a
position that will prevent the oil from
draining out. Disconnect the brake
vacuum line at the intake manifold.
8. Disconnect the heater hoses at
the water pump and intake manfold.
Disconnect the water temperature
sending unit wire at the sending unit.
9. Remove the flywheel or converter housing to engine upper bolts.
10. Disconnect the primary wire
at the ignition coil and position the
wire out of the way. Disconnect the
ground strap at the block.
11. Raise the front of the car. Disconnect the starter cable at the starter.
Remove the starter and dust seal.
12. Disconnect the muffler inlet
pipes from the exhaust manifolds.
Disconnect the engine support insulators at the brackets on the frame
underbody.
On a car with a manual-shift transmission, remove the remaining flywheel housing to engine bolts. Disconnect the clutch pedal retracting
spring. Remove the clutch equalizer
bar bracket retaining bolts and remove the clutch release rod at the
release lever.
On a car with an automatic transmission, remove the converter housing inspection cover. Disconnect the
flywheel from the converter. Secure
the converter assembly in the housing. Remove the remaining converter
housing to engine bolts.
Tool
T53L-300-A
Tool
T62F-6085
A1588-B
GROUP 1
On a car with power steering, install the drive belt and power steering pump bracket. Install the bracket
retaining bolts. Adjust the drive belt
tension to specifications. Connect the
brake vacuum line.
12. Remove the plug from the
fuel tank line. Connect the flexible
fuel line and the oil pressure sending
unit wire.
13. Install the pulley, belt, spacer
and fan. Adjust the belt tension to
specifications.
14. Tighten the generator or alternator adjusting bolts. Connect the
generator or alternator wires and the
battery ground cable.
15. Install the radiator. Connect
the radiator upper and lower hoses.
On a car with an automatic transmission, connect the transmission oil
cooler lines.
16. Install the oil filter. Fill and
bleed the cooling system. Connect
the heater hose at the water pump.
Fill the crankcase with the proper
grade and quantity of oil.
17. Adjust the transmission throttle linkage. Operate the engine at fast
idle and check all gaskets and hose
connections for leaks. Install the air
cleaner and intake duct assembly.
18. Install and adjust the hood.
21
DUST SHIELD
/SUPPORT INSULATOR
A
ASSEMBLY
A1725-A
ROCKER ARM
- STUD NUT
FULCRUM
SEAT
IN-CHASSIS REPAIR
OPERATIONS
Removal
1. Remove the engine support insulator to frame nut and lock washer.
2. Raise the engine slightly with
a jack and a wood block placed under the oil pan.
3. Remove the engine support insulator to cylinder block retaining
bolts and lock washers. Remove the
engine support insulator assembly.
Removal
1. Remove the support insulator to
cross member retaining bolt and lock
washer.
2. Remove the support insulator
to transmission extension housing
bolts and lock washers.
3. Raise the transmission with a
floor jack. Remove the support insulator and retainer.
Installation
1. Position the engine support insulator assembly to the cylinder block
Installation
1. Position the support insulator
and retainer. Lower the transmission.
FRAME
CROSS MEMBER
A1634-A
F I G . 4 4 - V a l v e Rocker Arm
Assembly
Removal
1. Remove the air cleaner and intake duct assembly.
2. Disconnect the spark plug wires
at the spark plugs by grasping the
moulded cap only. Remove the wires
from the bracket on the valve rocker
arm cover(s) and position the wires
out of the way.
To remove the right valve rocker
arm cover, remove the automatic
choke heat tube.
3. Remove the valve rocker arm
cover(s).
4. Remove the valve rocker arm
stud nut, fulcrum seat, and rocker
arm.
If removal of the ro'cker arm stud
is necessary, refer to the procedure
under "Cylinder Head Repairs."
Installation. If the rocker arm
stud was removed, install the stud
following the procedure under "Cylinder Head Repairs."
1. Apply Lubriplate to the top of
the valve stem and at the push rod
guide in the cylinder head.
GROUP 1
22
2. Install the valve rocker arm, fulcrum seat, and stud nut. Adjust the
valve clearance following the procedure under "Engine Tests and Adjustments."
3. Clean the valve rocker arm coverts) and the cylinder head gasket surface. Apply oil resistant sealer to one
side of new cover gasket(s). Lay the
cemented side of the gasket(s) in
place in the cover(s) as shown in
Fig. 45.
EXHAUST TUBE
REGULATOR VALVE
CLAMP
-CONNECTION
CLAMP
*
---"
^^CARBURETOR
SPACER
GASKET
*
A1635-A
MANIFOLD-TO-BLOCK
REAR SEAL
f\
WATER TEMPERATURE
SENDING UNIT
INTAKE MANIFOLD
THERMOSTAT
MANIFOLD-TO-HEAD GASKET
GASKET
MANIFOLD-TO-BLOCK FRONT SEAL
A1589-B
GROUP 1
carburetor as an assembly. Remove
the intake manifold gaskets and seals.
11. If the manifold is to be disassembled, remove the coolant outlet housing, gasket, thermostat,
crankcase ventilation system and oil
separator element at the rear top of
the manifold. Remove the temperature sending unit, carburetor, spacer,
and gaskets.
Installation. Intake manifold alignment tools are required when installing the intake manifold on the cylinder block and cylinder heads. Fabricate two alignment tools according to
the specifications shown in Fig. 47.
n 75 r*
DIA-* /
BRAZE- 7
0.368
0.366 DIA.
0.253
0.251 DIA.
23
3 on
Aligning Tools
JL
0.50
ht
A1658-B
24
19. Adjust the transmission throttle linkage. Install the air cleaner and
intake duct assembly.
Cleaning and Inspection. Clean
the manifold and the crankcase ventilation oil separator element in a suitable solvent, then dry them with
compressed air.
Inspect the manifold for cracks,
leaks, loose baffle plates on the underside of the manifold, or other defects
that would make it unfit for further
service. Replace all studs that are
stripped or otherwise damaged. Remove all filings and foreign matter
that may have entered the manifold
as a result of repairs.
EXHAUST MANIFOLDS
Removal
1. Remove the air cleaner and intake duct assembly.
2. Disconnect the exhaust manifold at the muffler inlet pipe.
3. Remove the automatic choke
heat tube from the right exhaust
manifold.
4. Remove the retaining bolts and
tab washers and remove the exhaust
manifold.
Installation
1. Clean the mating surfaces of the
exhaust manifold and cylinder head.
Scrape the gasket material from the
mounting flange of the exhaust manifold and muffler inlet pipe.
2. Apply graphite grease to the
mating surface of the exhaust manifold.
3. Install a new gasket on the studs
of the exhaust manifold.
4. Position the exhaust manifold
on the cylinder head and install
the retaining bolts and tab washers.
Working from the center to the ends,
torque the bolts to specifications.
Lock the bolts by bending one tab of
the washer over a flat on the bolt.
5. Place new gaskets on the muffler inlet pipe. Position the muffler inlet pipe to the manifold. Install and
torque the retaining nuts to specifications.
6. Install the automatic choke heat
tube on the right exhaust manifold.
Install the air cleaner and intake duct
assembly.
7. Start the engine and check for
exhaust leaks.
Cleaning and Inspection. Inspect
the manifolds for cracks, leaks, or
other defects that would make them
unfit for further service.
GROUP 1
On the right exhaust manifold,
make sure the automatic choke air
inlet and outlet holes are completely
open. Clean the maze screen in the
passage by pouring cleaning solvent
through the holes. Then blow out the
passage and the automatic choke air
heat tube with compressed air.
POSITIVE CRANKCASE
VENTILATION SYSTEM
Removal
1. Disconnect the crankcase ventilation exhaust tube from the regulator
valve assembly. Remove the exhaust
tube retaining bolts at the crankcase
outlet and remove the exhaust tube
and gasket (Fig. 50). Remove the
crankcase ventilation oil separator
element at the crankcase outlet.
CONNECTOR
CONNECTION
REGULATOR VALVE
EXHAUST TUBE
SPRING
VALVE
BODYA1636-B
A1600-A
GROUP 1
outlined in Part 12-3 of the
Galaxie Shop Manual.
1962
25
A1593-A
A1591-A
Disassembly
1. Clean the carbon out of the cylinder head combustion chambers before removing the valves.
2. Compress the valve springs
(Fig. 55). Remove the spring retainer
locks and release the spring.
A1594-A
Tool-6513-EE
F I G . 55Compressing Valve
SpringOn Bench
3. Remove the spring retainer,
spring, stem seal and valve. Discard
the valve stem seals. Indentify all
valve parts.
4. If removal of the rocker arm
stud(s) is necessary, refer to the procedure outlined under "Rocker Arm
Stud Replacement."
Assembly
1. Install each valve (Fig. 56) in
the port from which it was removed
or to which it was fitted. Install a new
stem seal on the valve.
2. Install the valve spring over the
valve, and then install the spring retainer. Compress the spring and install the retainer locks (Fig. 55).
3. Measure the assembled height
of the valve spring from the surface
of the cylinder head spring pad to the
underside of the spring retainer with
dividers (Fig. 57). Check the dividers against a scale. If the assembled
GROUP 1
26
EXHAUST
VALVE
INTAKE
VALVE
A1596-A
Tool
T62F-6A527-A2
or A3
A1654-A
ToolT62F-6A527-A 7
Tool
T62F-6A527-A4
A1597-A
A1653-A
A1655-A
GROUP 1
2. Crank the engine until the applicable piston is on TDC after the compression stroke. Be sure that both
valves are closed. Be sure that the
piston is on TDC to prevent the
crankshaft from turning when the
air is applied.
3. Install an air line with an adapter in the spark plug hole and turn
on the air supply.
4. Remove the applicable valve
rocker arm stud nut, fulcrum seat,
valve rocker arm and push rod. Install the stud nut and position the
compressor tool (T62F-6565-A) as
shown in Fig. 61. Compress the valve
spring and remove the retainer locks,
spring retainer and valve spring.
27
7. Install the push rod. Apply Lubriplate to the tip of the valve stem
and at the push rod guide in the cylinder head.
8. Install the valve rocker arm, fulcrum seat and stud nut. Adjust the
valve clearance following the procedure under "Engine Tests and Adjustments."
9. Turn off the air and remove the
air line and adapter. Install the spark
plug.
10. Clean and install the rocker
arm cover. Connect the spark plug
wire. Install the air cleaner and intake
duct assembly.
CYLINDER FRONT COVER
AND TIMING CHAIN
Removal
1. Drain the cooling system and
the crankcase. Remove the air cleaner and intake duct assembly. Disconnect the battery ground cable.
Air Line
A1598-A
ToolT62F-6565-A
F I G . 6 1 Compressing Valve
SpringIn Chassis
5. Remove and discard the valve
stem seal (Fig. 62).
6. Install a new valve stem seal
(Fig. 62). Place the spring in position over the valve and install the
valve spring retainer. Compress the
valve spring and install the valve
spring retainer locks. Remove the
compressor tool and stud nut.
Tool-T58P-6316-A
Air Line
SEAL
A1599-A
A1720-A
A1602-B
28
GROUP 1
15. Remove the camshaft sprocket cap screw, washers and fuel pump
eccentric. Slide both sprockets and
the timing chain forward, and remove
them as an assembly (Fig. 66).
16. Remove the oil pan and oil
pump following the procedure under
"Oil Pan Removal" and "Oil Pump
Removal."
Front Oil Seal Replacement. It is
good practice to replace the oil seal
each time the cylinder front cover
is removed.
1. Drive out the old seal with a
pin punch. Clean out the recess in
the cover.
2. Coat a new seal with grease,
then install the seal (Fig. 67). Drive
the seal in until it is fully seated in
the recess. Check the seal after installation to be sure the spring is
properly positioned in the seal.
DOWEL
Tool T53L-200-A
CRANKSHAFT FRONT OIL SLINGER
A1638-B
TIMING MARKS
A1603-B
A16O4-B
OIL SEAL
A1637-A
A1721-A
GROUP 1
29
Tool-T52L-6306-AEE
BEARINGS
THRUST
PLATE
TIMING CHAIN AND
CAMSHAFT SPROCKET
FLAT
WASHER
CAMSHAFT
REAR BEARING
BORE PLUG
CAMSHAFT
IA1722-A
A16O5-B
CAMSHAFT
8. Disconnect the water temperature sending unit wire at the sending unit and the engine ground strap
at the engine.
Magnet
A1606
.A
30
the engine. Use caution to avoid damaging the camshaft bearings.
Installation
1. Oil the camshaft and apply
Lubriplate to the lobes. Carefully
slide the camshaft through the bearings. Install the camshaft thrust
plate.
2. Install the valve lifters in the
bores from which they were removed.
3. Install the push rods in their
original position. Apply Lubriplate
to the valve stem tips and the push
rod guides in the cylinder head. Position the rocker arms over the push
rods.
4. Install the intake manifold and
related parts by following steps 1
thru 6 under "Intake Manifold Installation."
5. Connect the water temperature
sending unit and the engine ground
strap.
6. Install the bellcrank assembly
and accelerator retracting spring.
Connect the accelerator rod.
7. Install the radiator.
On a car with an automatic transmission, connect the transmission oil
cooler lines and throttle valve vacuum
line.
8. Connect the heater hose at the
intake manifold. Position and connect the fuel line.
9. Replace the crankshaft front
oil seal. Install the timing chain, cylinder front cover and related parts
following steps 1 thru 13 under
"Cylinder Front Cover and Timing
Chain Installation."
10. With No. 1 piston on TDC
at the end of the compression stroke,
position the distributor in the block
with the rotor at the No. 1 firing
position and the points open. Install
the hold down clamp.
11. Perform a valve clearance adjustment as outlined under "Engine
Tests and Adjustments."
12. Clean the valve rocker arm
covers and the cylinder head gasket
surface. Apply oil resistance sealer
to one side of new cover gaskets.
Lay the cemented side of the gaskets
in place in the covers.
13. Position the covers on the
cylinder heads. Make sure the gasket seats evenly all around the head.
Install the bolts. The cover is tightened in two steps. Torque the bolts
to specifications. Two minutes later,
torque the bolts to the same specifications.
GROUP 1
14. Install the automatic choke
heat tube. Install the ignition coil
and connect the wires.
15. Install the distributor cap. Position the spark plug wires in the
harness brackets on the valve rocker
arm covers and connect the spark
plug wires. Connect the high tension
lead at the coil.
16. Fill and bleed the cooling
system. Fill the crankcase with the
proper grade and quantity of engine
oil.
17. Start the engine and check
and adjust the ignition timing. Connect the distributor vacuum line at
the carburetor.
18. Operate the engine at fast
idle and check all hose connections
and gaskets for leaks. Operate the
engine until engine temperatures
have stabilized and adjust the engine
idle speed and idle fuel mixture.
19. Adjust the transmission
throttle linkage. Install the air cleaner and intake duct assembly.
CAMSHAFT REAR BEARING
BORE PLUG REPLACEMENT
1. On a car with a manual-shift
transmission, remove the transmission, clutch pressure plate and disc
following the procedures in Part 5-1
and Part 5-2 of the 1962 Galaxie
Shop Manual.
On a car with an automatic transmission, remove the transmission and
converter housing following the procedure in Part 6-4 of the 1962 Galaxie Shop Manual.
2. Remove the flywheel retaining
bolts and remove the flywheel.
3. Drill a Vi-inch hole in the
camshaft rear bearing bore plug and
remove the plug using the tools
shown in Fig. 92.
4. Clean out the plug bore recess
thoroughly and coat the flange of a
new plug with water resistant sealer.
Install the new plug with the flange
facing out. Drive the plug in until
it is slightly below the chamfer in
the bore (Fig. 95).
5. Coat the flywheel retaining
bolts with oil resistant sealer. Position the flywheel on the crankshaft
flange. Install and torque the retaining bolts in sequence across from
each other to specifications.
On a car with a manual-shift
transmission, install the clutch pressure plate, disc and the transmission
31
GROUP 1
Disassemble and assemble each lifter
separately. Keep the lifter assemblies
in proper sequence so that they can
be installed in their original bores.
1. Grasp the lock ring with needle
nose pliers to release it from the
groove. It may be necessary to depress the plunger to fully release the
lock ring.
2. Remove the push rod cup,
metering valve (disc), plunger and
spring.
3. Invert the plunger assembly
and remove the check valve retainer
by carefully prying up on it with a
screw driver. Remove the check valve
(disc or ball check) and spring.
Valve Lifter Assembly. A typical
hydraulic valve lifter assembly is
shown in Fig. 73.
PUSH ROD CUP
METERING VALVE
CHECK VALVE
PLUNGER SPRING
PLUNGER
CHECK VALVE
RETAINER
A1651-A
SEALER
A1641-A
GROUP 1
32
PLACE Plastigage FULL CHECK WIDTH OF
WIDTH OF JOURNAL ^ ^ Plastigage^
ABOUT VA INCH
OFF CENTER
INSTALLING
Plastigage
0.0015"
CLEARANCE
\
MEASURING
Plastigage
A1642-A
GROUP 1
11. Install the oil pump and the
oil pan.
12. Install the cylinder heads following steps 1 thru 6 under "Cylinder Head Installation."
13. Refer to ' Intake Manifold Installation" and install the intake
manifold.
A1608-A
Tool6149-A
Defa7 7
A1607-A
A1609-A
GROUP 1
34
Disassembly
1. Remove the bearing inserts
from the connecting rod and cap.
2. Mark the pistons and pins to
assure assembly with the same rod
and installation in the same cylinders from which they were removed.
3. Remove the piston pin from
the piston and connecting rod (Fig.
78). Remove the piston rings.
Assembly. The piston, connecting
rod and related parts are shown in
Fig. 79. Check the fit of a new piston
in the cylinder bore before assembling the piston and piston pin to
the connecting rod.
The piston pin bore of a connecting rod and the diameter of the piston pin must be within specifications.
Refer to Group 15.
1. Apply a light coat of engine oil
to all parts. Assemble the piston to
the connecting rod with the oil squirt
hole in the connecting rod and the
UPPER
COMPRESSION
RING
LOWER
COMPRESSION
RING
RIGHT BANK
LEFT BANK
i NOTCHES TOWARD*
FRONT OF ENGINE
rod and cap are clean. Foreign material under the inserts may distort
the bearing and cause a failure. Install the bearing inserts in the connecting rod and cap with the tangs
fitting in the slots provided.
FLYWHEEL
A1723-A
Removal
1. On a car with a manual-shift
transmission, remove the transmission, clutch pressure plate and disc
following the procedures in Part 5-1
and Part 5-2 of the 1962 Galaxie
Shop Manual.
On a car with an automatic transmission, remove the transmission
and converter housing following the
procedure in Part 6-4 of the 1962
Galaxie Shop Manual.
2. Remove the flywheel retaining
bolts and remove the flywheel.
Installation
1. Coat the threads of the flywheel retaining bolts with oil resistant sealer. Position the flywheel on
the crankshaft flange. Install and
torque the bolts in sequence across
from each other to specifications.
2. On a car with a manual-shift
transmission, install the clutch pressure plate, disc and the transmission
following the procedures in Part 5-1
and Part 5-2 of the 1962 Galaxie
Shop Manual.
BEARING
INSERTS
NUT
A1610-A
A1612-A
GROUP 1
On a car with an automatic transmission, install the transmission and
converter housing following the procedure in Part 6-4 of the 1962 Galaxie Shop Manual.
CLUTCH PILOT BUSHING
REPLACEMENT
1. Remove the transmission,
clutch pressure plate and disc following the procedures in Part 5-1
and Part 5-2 of the 1962 Galaxie
Shop Manual.
2. Remove the pilot bushing as
shown in Fig. 96.
3. Coat the pilot bushing bore
in the crankshaft with a small quantity of wheel bearing lubricant. Avoid
using too much lubricant as it may
be thrown onto the clutch disc when
the clutch revolves.
4. Install the pilot service bearing as shown in Fig. 97.
5. Install the clutch pressure plate,
disc and the transmission following
the procedures in Part 5-1 and Part
5-2 of the 1962 Galaxie Shop
Manual.
35
GASKET
FILTER
ELEMENT
OIL PAN
Removal
1. Drain the crankcase. Remove
the oil level dipstick.
2. Disconnect the starter cable at
the starter. Remove the starter and
dust seal.
3. Remove the oil pan retaining
bolts and crank the engine as required to obtain clearance and remove the oil pan.
4. Remove the oil pump inlet tube
and screen assembly.
FILTER
HOUSING
FIBER
GASKET
Installation
1. Clean and install the oil pump
inlet tube and screen assembly.
CENTER BOLT
A1071-B
GASKET
A1200-A
REAR SEAL
FRONT SEAL
A1613-A
36
2. Clean the gasket surfaces of
the block and oil pan. The oil pan
has a two-piece gasket. Coat the
block surface and the oil pan gasket
surface with sealer. Position the oil
pan gaskets on the cylinder block
(Fig. 84).
3. Position the oil pan front seal
on the cylinder front cover (Fig.
84). Be sure the tabs on the seal
are over the oil pan gasket.
4. Position the oil pan rear seal
on the rear main bearing cap (Fig.
84). Be sure the tabs on the seal
are over the oil pan gasket.
5. Hold the oil pan in place
against the block and install a bolt,
finger-tight, on each side of the oil
pan. Install the remaining bolts.
Torque the bolts from the center
outward in each direction to specifications.
5. Install the starter and dust seal.
Connect the starter cable.
7. Install the oil level dipstick.
Fill the crankcase with the proper
grade and quantity of engine oil.
Operate the engine and check for
oil leaks.
GROUP 1
tor shaft. To align, rotate the intermediate drive shaft into a new position. Torque the oil pump retaining
screws to specifications.
4. Clean and install the oil pump
inlet tube and screen assembly (Fig.
85).
A
OIL RELIEF VALVE
/
ASSEMBLY
INLET TUBE
ASSEMBLY
(^tf~%
ASSEMBLY
f^Vj
PLATE
A1643-B
OIL PUMP
Removal
1. Remove the oil pan and related parts as outlined under "Oil
Pan Removal."
2. Remove the oil pump inlet tube
and screen assembly.
3. Remove the oil pump retaining bolts and remove the oil pump,
gasket and intermediate drive shaft.
Installation
1. Prime the oil pump by filling
either the inlet or outlet port with
engine oil. Rotate the pump shaft to
distribute the oil within the pump
body.
2. Position the intermediate drive
shaft into the distributor socket. With
the shaft firmly seated in the distributor socket, the stop on the shaft
should touch the roof of the crankcase. Remove the shaft and position
the stop as necessary.
3. Position a new gasket on the
pump housing. With the stop properly positioned, insert the intermediate drive shaft into the oil pump.
Install the pump and shaft as an
assembly. Do not attempt to force
the pump into position if it will not
seat readily. The drive shaft hex
may be misaligned with the distribu-
CRANKSHAFT
The crankshaft and related parts
are shown in Fig. 87.
Removal
1. Disconnect the spark plug
wires at the spark plugs and remove
the wires from the ignition harness
brackets on the valve rocker arm
covers. Remove the distributor cap
and spark plug wire assembly. Remove the spark plugs to allow easy
rotation of the crankshaft.
2. Remove the fuel pump and oil
filter. Slide the water pump by-pass
hose clamp toward the water pump.
Remove the generator or alternator,
shield and mounting bracket.
3. Remove the crankshaft pulley
from the crankshaft vibration damper. Remove the cap screw and
washer from the end of the crankshaft. Install the puller on the crankshaft vibration damper (Fig. 63) and
remove the damper.
4. Remove the cylinder front
cover and water pump as an
assembly.
5. Remove the crankshaft front
oil slinger. Check the timing chain
deflection, then remove the timing
GROUP 1
37
FLYWHEEL.
M A I N BEARING INSERTS
CRANKSHAFT SPROCKET
FRONT OIL SLINGER
WASHER
BOLT
A1724-A
Too/T62F-6701-A
A1644-A
GROUP 1
38
Fig. 88 and complete the seal installation. After installation, cut the
ends of the seals flush.
8. Carefully lower the crankshaft
into place. Be careful not to damage
the bearing surfaces.
9. Check the clearance of each
main bearing as follows:
Place a piece of Plastigage on the
crankshaft journal the full width of
the journal and about VA inch off
center (Fig. 89). Follow steps 12
thru 15 under "Main Bearing Replacement."
PLACE Plastigage FULL
WIDTH OF JOURNAL
ABOUT y 4 INCH
OFF CENTER
INSTALLING
PLASTIGAGE
CHECK WIDTH
OF Plastigage
0.002"
CLEARANCE
MEASURING
PLASTIGAGE
A1023-A
A1652-A
HOLD CRANKSHAFT
FORWARD
TIGHTEN CAP
A1617-A
GROUP 1
26. Install the timing chain and
sprockets, cylinder front cover and
crankshaft pulley and adaptor, following steps 1 thru 6 under "Cylinder
Front Cover and Timing Chain Installation."
39
Tool T62F-6266-A
Tool T62F-6250-A
Detail I
ToolT53L-200-A
Detail 2
A1648-A
ENGINE DISASSEMBLY
A1646-A
Tool
T58L-101-A
F I G . 93Camshaft Bearing
Replacement
A1645-A
A1647-A
40
The internal parts of each hydraulic valve lifter assembly are matched
sets. Do not intermix the parts. Keep
the assemblies intact until they are to
be cleaned.
9. Remove the exhaust manifolds
and the spark plugs.
10. Install the cylinder head holding fixtures (Fig. 53). Remove the
cylinder head bolts and lift the cylinder heads off the block. Do not pry
between the head and the block. Discard the cylinder head gaskets.
11. Remove the crankshaft pulley
from the crankshaft vibration damper. Remove the cap screw and washer
from the end of the crankshaft. Install the puller on the crankshaft vibration damper (Fig. 63) and remove
the vibration damper.
12. Remove the oil pan to cylinder
front cover retaining bolts. Remove
the cylinder front cover retaining
bolts and remove the cylinder front
cover and water pump as an assembly. Discard the gasket and remove
the crankshaft front oil slinger.
13. Check the timing chain deflection and remove the timing chain
and sprockets by following steps 12
thru 15 under "Cylinder Front Cover
and Timing Chain Removal." Remove the crankshaft sprocket key.
14. Remove any ridge and/or carbon deposits from the upper end of
the cylinder bores. Move the piston
to the bottom of its travel and place
a cloth on the piston head to collect
the cuttings. Remove the cylinder
ridge with a ridge cutter. Follow the
instructions furnished by the tool
manufacturer. Never cut into the
ring travel area in excess of 1/32
inch when removing ridges. After the
ridge has been removed, remove the
cutter from the cylinder bore.
On a flywheel for a manual-shift
transmission, remove the clutch pressure plate and disc.
15. Remove the flywheel and rear
cover plate. Remove the clutch pilot
bushing (Fig. 96).
16. Invert the engine. Remove the
oil pan and discard the gaskets and
seals.
17. Remove the oil pump and inlet tube as an assembly. Remove the
intermediate drive shaft. Discard the
oil pump gasket.
18. Make sure all connecting rods
and caps are marked so that they can
be installed in their original locations.
Turn the crankshaft until the con-
GROUP 1
7oo/ T58L-101-A
Tool-T59L-100-B
A1649-A
GROUP 1
13. Install the thrust bearing cap
and check crankshaft end play by
following steps 11 thru 18 under
"Crankshaft Installation."
14. Turn the engine on the work
stand so that the front end is up.
15. Install the pistons and connecting rods by following steps 1 thru
9 under "Piston and Connecting Rod
Installation."
16. Position the sprockets and
timing chain on the camshaft and
crankshaft (Fig. 66). Be sure the timing marks on the sprockets are positioned as shown in Fig. 65.
17. Lubricate the timing chain
and sprockets with engine oil.
18. Install the fuel pump eccentric, washer and camshaft sprocket
cap screw. Torque the sprocket cap
screw to specifications. Install the
crankshaft front oil slinger (Fig. 68).
19. Clean the cylinder front cover
and the cylinder block gasket surfaces. Install a new crankshaft front
oil seal (Fig. 67).
20. Coat the gasket surface of the
block and cover and the cover bolt
threads with sealer. Position a new
gasket on the block.
21. Install the alignment pilot tool
on the cylinder front cover so that
the keyway in the pilot aligns with
the key in the crankshaft. Position
the cover (and water pump) and pilot
over the end of the crankshaft and
against the block (Fig. 69).
22. Install the cylinder front cover
bolts finger-tight. While pushing in
on the pilot, torque the cover bolts to
specifications. Remove the pilot.
23. Lubricate the crankshaft with
a white lead and oil mixture and lubricate the oil seal rubbing surface
with grease.
24. Line up the crankshaft vibration damper keyway with the key on
the crankshaft, then install the vibration damper on the crankshaft (Fig.
70). Install the damper cap screw and
washer, and torque the screw to
specifications. Install the crankshaft
pulley.
25. Using a new gasket, install the
fuel pump.
26. Turn the engine on the work
stand so that the top of the engine
is up.
27. Clean the cylinder head and
block gasket surfaces. Install the
head gasket over the cylinder head
dowels.
28. Place the cylinder head on the
engine, then remove the holding fix-
41
39. Be sure the holes in the manifold gaskets and manifold are in
alignment. Position the intake manifold alignment tools (Fig. 47) in the
front and rear (Nos. 10 and 12) bolt
holes on the left bank of the manifold.
40. Install the intake manifold retaining bolts. Working from the center to the ends, torque the bolts in
sequence (Fig. 49) to 3-5 ft-lbs.
41. Remove the manifold alignment tools from the front and rear
bolt holes (Nos. 10 and 12). Install
the two remaining bolts and torque to
3-5 ft-lbs.
42. Torque all the manifold retaining bolts in sequence to 11-14 ftlbs. Finally, torque all the retaining
bolts in sequence to 14-16 ft-lbs.
43. Install the water pump by-pass
hose on the coolant outlet housing.
Slide the clamp into position and
tighten the clamp.
44. Rotate the crankshaft until the
No. 1 piston is on TDC, then position
the distributor in the block with the
rotor at the No. 1 firing position and
the points open. Install the hold down
clamp.
45. Install the ignition coil. Position and install the generator or alternator, shield and mounting bracket.
46. Clean the valve rocker arm
covers and the cylinder head gasket
surface. Apply oil resistant sealer to
one side of new cover gaskets. Lay
the cemented side of the gaskets in
place in the covers.
47. Position the covers on the cylinder heads. Make sure the gasket
seats evenly all around the head. Install the bolts. The cover is tightened
in two steps. Torque the bolts to
specifications. Two minutes later,
torque the bolts to the same specifications.
48. Install the automatic choke
heat tube. Install the distributor cap.
Position the spark plug wires in the
brackets on the valve rocker arm
covers. Connect the spark plug wires.
49. Connect the carburetor fuel
inlet line and pump outlet line.
50. Prime the oil pump by filling
either the inlet or outlet port with
engine oil. Rotate the pump shaft to
distribute the oil within the pump
body.
51. Invert the engine on the work
stand. Position the intermediate drive
shaft into the distributor socket. With
the shaft firmly seated in the distributor socket, the stop on the shaft
should touch the roof of the crank-
GROUP 1
42
case. Remove the shaft and position
the stop as necessary.
52. With the stop properly positioned, insert the intermediate drive
shaft into the oil pump.
53. Position a new gasket on the
pump housing and install the pump
and shaft as an assembly. Do not attempt to force the pump into position if it will not seat readily. The
drive shaft hex may be misaligned
with the distributor shaft. To align,
rotate the intermediate shaft into a
new position. Torque the oil pump
retaining screws to specifications.
54. Clean the gasket surfaces of
the block and oil pan. Coat the block
surface and the oil pan gasket surface with sealer. Position new gaskets
on the block and position a new seal
on the cylinder front cover and rear
main bearing cap. Make sure the tabs
on the seal are over the oil pan gasket. Install the retaining screws and
torque them from the center outward
to specifications.
55. Clean the oil filter adapter gasket surface. Coat the gasket on the
filter with oil. Place the Rotunda filter in position on the adapter fitting.
Hand tighten the filter until the gasket contacts the adapter face, then
advance it Vi turn.
56. Install the clutch pilot service
bearing (Fig. 97). Coat the threads of
the flywheel retaining bolts with oil
resistant sealer. Position the rear
cover plate on the block and the flywheel on the crankshaft flange. Install and torque the bolts to specifications.
On a flywheel for a manual-shift
transmission, use tool 6392-N to lo-
VALVE CLEARANCE
1. Position the crankshaft as outlined in steps 2 and 3. Loosen the
rocker arm stud nut until there is
end clearance in the push rod, then
tighten the nut to just remove all the
push rod to rocker arm end clearance. This may be determined by
rotating and/or moving the push rod
with the fingers as the stud nut is
tightened (Fig. 98). When the push
rod end clearance has been eliminated, tighten the stud nut an additional 2 turns to place the hydraulic
lifter plunger in the center of its
travel.
A1657-A
ToolT52T-1217 5-AJD
A1650-A
A1656-A
GROUP 1
CAMSHAFT LOBE LIFT
1. Remove the air cleaner and the
valve rocker arm cover(s). Remove
the rocker arm stud nut, fulcrum
seat and rocker arm.
2. Make sure the push rod is in
the tappet socket or the lifter push
rod cup. Install a dial indicator in
such a manner as to have the ball
socket adapter of the indicator on the
end of the push rod and in the same
plane as the push rod movement
(Fig. 100).
43
COMPRESSION TEST
1. Be sure the battery is properly
charged. Operate the engine for a
minimum of 30 minutes at 1200 rpm.
Turn the ignition switch off, then
remove all the spark plugs. Remove
the coil high tension lead at the distributor cap.
2. Set the throttle plate(s) and
choke plate in the wide open position.
3. Install a compression gauge in
No. 1 cylinder.
4. Using a remote starter switch,
crank the engine several times and
record the highest reading recorded.
Note the number of compression
strokes required to obtain the highest
reading.
5. Repeat the test on each cylinder, cranking the engine the same
number of times for each cylinder
as was required to obtain the highest
reading on the No. 1 cylinder.
TEST CONCLUSIONS
A variation of 20 pounds from
specified pressure is satisfactory.
However, the compression of all
cylinders should be uniform within
10 pounds.
A reading of more than the allowable tolerance above normal indicates
excessive deposits in the cylinder.
A reading of more than the allowable tolerance below normal indicates leakage at the cylinder head
gasket, piston rings, or valves.
Engine Conditions
16 inches260 V-8
Normal.
Loss of power in all cylinders caused possibly by late ignition or valve timing, or loss
of compression due to leakage around the
piston rings.
Very low.
Intermittent
fluctuation.
Improper idle mixture adjustment, carburetor, spacer, or intake manifold gasket leak.
44
A low even compression in two
adjacent cylinders indicates a cylinder head gasket leak. This should be
checked before condemning the rings
or valves.
To determine whether the rings
or the valves are at fault, squirt the
equivalent of a tablespoon of heavy
oil into the combustion chamber.
Crank the engine to distribute the oil
and repeat the compression test. The
oil will temporarily seal leakage past
the rings. If approximately the same
reading is obtained, the rings are
satisfactory, but the valves are leaking. If the compression has increased
10 pounds or more over the original
reading, there is leakage past the
rings.
During a compression test, if the
pressure fails to climb steadily and
remains the same during the first two
successive strokes, but climbs higher
on the succeeding strokes, or fails
to climb during the entire test, it
indicates a sticking valve.
GROUP 1
cated on each side of the crankcase
(Fig. 101), and the rear support is
located at the transmission extension
housing.
Engine Front Support. The procedures given apply to either a right or
left installation.
REMOVAL
1. Remove the insulator to frame
nut and lock washer. If only one support is being removed, loosen the
other support.
2. Raise the engine with a jack
and a wood block placed under the
oil pan.
3. Remove the insulator to engine
bolts and lock washers and remove
the insulator.
On a car with an automatic transmission, the transmission fluid cooler
tubes bracket is fastened to the engine right front support.
INSTALLATION
1. Position the insulator assembly
on the engine and install the insulator
to engine bolts and lock washers
finger-tight.
SUPPORT ASSEMBLY
INSULATOR ASSEMBLY
VALVE TRAIN
The 352 V-8 and 390 V-8 employ hydraulic valve lifters to provide zero valve lash. The 406 V-8
and the 390 Police Interceptor engines have mechanical valve lifters.
On these engines, valve lash is maintained by self-locking adjusting
screws.
ETAINER
IN-CHASSIS REPAIR
OPERATIONS
ENGINE SUPPORTS
The engine front supports are lo-
A1746-A
GROUP 1
3. Remove the valve rocker arm
cover(s).
If the left cover is removed, position the wire loom out of the way.
4. Crank the engine until the No.
1 piston is at TDC at the end of the
compression stroke. Rotate the
crankshaft damper an additional 45
(identified by "XX" on the damper).
5. Starting at the No. 4 cylinder,
loosen the right valve rocker arm
shaft support bolts in sequence, two
turns at a time. After the bolts are
all loosened, remove the valve rocker
arm shaft assembly and the oil baffle
plate. Starting at the No. 5 cylinder,
follow the same procedure on the left
valve rocker arm shaft support bolts.
This procedure must be followed to
avoid damage to the valve mechanism.
RemovalMechanical
Valve Lifters.
1. Follow steps 1 thru 3 under
"RemovalHydraulic Valve Lifters."
2. Release the spring tension on
the valve rocker arm by loosening
the adjusting screws.
3. Remove the shaft support bolts.
Remove the shaft assembly and the
baffle plate.
InstallationHydraulic
Valve Lifters.
1. Apply Lubriplate to the pad end
of the rocker arms, to the tip of the
valve stems, and to both ends of the
push rods.
2. Crank the engine until the No.
1 piston is on TDC at the end of the
compression stroke.
3. Rotate the crankshaft damper
an additional 45 (identified by "XX"
on the damper).
4. Position the baffle plate and the
valve rocker arm shaft assembly on
the cylinder heads with the valve
push rods in place and the rocker
shaft support bolts fingertight. Be
sure the shaft is turned so that the oil
holes are to the bottom.
5. Starting at the No. 4 cylinder,
tighten the bolts in sequence, two
turns at a time, until the supports
fully contact the cylinder head.
Torque the bolts in sequence to specifications.
6. Starting at the No. 5 cylinder,
follow the same procedure for the
left valve rocker arm shaft support
45
6. Follow steps 7 thru 9 under
"InstallationHydraulic Valve Lifters".
Disassembly
1. Remove the cotter pins from
each end of the valve rocker arm
shaft. Remove the flat washer and
spring washer from each end of the
shaft.
2. Slide the rocker arms, springs,
and the supports off the shaft. Be
sure to identify all the parts.
3. If it is necessary to remove the
plugs from each end of the shaft,
drill or pierce one plug. Then insert
a steel rod through the plug and
knock out the plug on the opposite
end. Working from the open end,
knock out the remaining plug.
Assembly
1. Oil all the moving parts with
engine oil. Apply Lubriplate to the
pad of the valve rocker arms.
2. If the plugs were removed from
the ends of the shaft, use a blunt tool
or large diameter pin punch and install a plug, cut side out, in each end
of the rocker arm shaft.
3. Install the rocker arms, supports, and springs in the order shown
in Figs. 102 or 103. Be sure the oil
holes in the shaft are facing downward. Complete the assembly by installing the remaining flat washer,
the spring washer, and the cotter pin.
CYLINDER FRONT COVER
AND TIMING CHAIN
Removal
1. Drain the cooling system and
the crankcase. Remove the air cleaner. Disconnect the battery ground
cable.
2. Disconnect the radiator upper
hose at the radiator supply tank. Disconnect the radiator lower hose at
the water pump.
On a car with an automatic transmission, disconnect the transmission
oil cooler lines at the radiator.
3. Remove the radiator.
4. Disconnect the heater hose at
the water pump. Slide the water
pump by-pass hose clamp toward the
engine.
On a car with power steering, disconnect the power steering pump
bracket from the water pump and
remove the drive belt. Wire the pump
GROUP 1
46
O^BOIT
jj
SPRING WASHER
>* LOCKWASHER
WASHER
ROCKER ARM
SUPPORT
OIL BAFFLE
SUPPORT BOLT HOLES
PLUG
ROCKER SHAFT
A1261-B
BOLT.
SELF-LOCKING
ADJUSTING SCREWS
COTTER PIN
ROCKER SHAFT
A1456-A
GROUP 1
REFERENCE POINT
Too1-T58P-6316-A or 6306-AG
47
A1257-C
1. Position the sprockets and timing chain on the camshaft and crankshaft (Fig. 108). Be sure the timing
place the oil seal each time the cylinder front cover is removed.
1. Drive out the old seal with a
pin punch. Clean out the recess in
the cover.
Tool-T56P-6362-A
A1258-B
TIMING MARKS
A1283-B
A1286-C
48
FUEL PUMP ECCENTRIC
CRANKSHAFT FRONT
OIL SLINGER
GROUP 1
CAMSHAFT
The camshaft and related parts are
shown in Fig. 113.
DOWEL
A1285-B
Tool-T61P-6019-B or 6059-F
A1287-C
Tool-T52L-6306-ABE
or 6306-AC
A1289-C
Removal
1. Remove the cylinder front cover
and the timing chain and sprockets
following steps 1 thru 11 under
"Cylinder Front Cover and Timing
Chain Removal."
2. Remove the grille.
3. Refer to "Valve Rocker Arm
Shaft Assembly Removal" and remove the valve rocker arm covers
and the valve rocker arm shaft assemblies.
4. Disconnect the coil high tension
lead at the coil. Remove the distributor cap and spark plug wire assembly. Disconnect the distributor
vacuum line at the distributor. Remove the distributor hold down bolt
and clamp and remove the distributor.
5. Remove the valve push rods in
sequence and place them in a rack
so that they can be installed in their
original positions.
6. Position an inspection light
through a push rod opening and into
the valve push rod valley (Fig. 114).
Remove the valve lifters or tappets
with a magnet through the push rod
openings. In some cases it will be
necessary to transfer the lifter or
tappet over to an adjoining push rod
opening in order to remove it. Place
the lifters or tappets in a rack so that
they can be installed in their original
positions.
7. Remove the oil pan and oil
pump screen by following the procedure under "Oil Pan Removal."
8. Install a dial indicator so the
indicator point is on the camshaft
sprocket retaining screw. Push the
camshaft toward the rear of the engine and set the dial indicator on
zero. Pull the camshaft forward and
release it. Compare the indicator
reading with the specifications. If the
end play is excessive, check the
spacer for correct installation before
it is removed. The side of the spacer
having a chamfer on the ID must be
against the camshaft front journal.
If the spacer is installed correctly,
replace the thrust plate.
9. Remove the dial indicator. Remove the timing chain and sprockets
following steps 12 thru 17 under
"Cylinder Front Cover and Timing
Chain Removal."
GROUP 1
10. Remove the camshaft thrust
plate and spacer. Carefully remove
the camshaft by pulling it toward the
front of the engine. Use caution to
avoid damaging the camshaft bearings.
Installation Engines with
Hydraulic Valve Lifters
1. Oil the camshaft and apply
Lubriplate to the lobes. Carefully
slide the camshaft through the bearings. Install the thrust plate and
spacer. The chamfered ID of the
spacer must be towards the camshaft
front journal. Be sure the thrust plate
oil groove is up and towards the front
(next to camshaft sprocket).
2. Follow the procedure in step 8
of Camshaft Removal and check the
camshaft end play.
3. Position the sprockets and
timing chain on the camshaft and
crankshaft (Fig. 108) with the timing
marks on the sprockets aligned as
shown in Fig. 107.
4. Install the fuel pump eccentric
and the camshaft sprocket cap screw
(Fig. 110). Torque the sprocket cap
screw to specifications. Install the
front oil slinger.
5. Replace the crankshaft front
oil seal. Install the cylinder front
cover, the crankshaft damper, and
related parts following steps 3 thru
14 under "Cylinder Front Cover and
Timing Chain Installation."
49
BEARINGS
ROUND-HEAD SCREW
AND WASHER
A1275-B
GROUP 1
50
13. Connect the brake booster
vacuum line. Install the carburetor
choke heat tube.
14. Connect the spark plug wires.
VALVE LIFTER OR TAPPET
REPLACEMENT
The following procedure is applicable for removing one or all of the
valve lifters and it applies to either
hydraulic valve lifters or solid valve
tappets. This procedures cannot be
used if the valve lifters or tappets are
stuck in their bore by excessive varnish, etc. In this case, it will be
necessary to remove the intake manifold. After the intake manifold has
been removed, remove the valve
lifters or tappets.
1. Refer to "Valve Rocker Arm
Shaft Assembly Removal" and remove the valve rocker arm covers
and the valve rocker arm shaft assemblies by following steps 1 thru 5
under "Hydraulic Valve Lifters" or
steps 1 thru 3 under "Mechanical
Valve Lifters."
2. Position an inspection light
through a push rod opening and into
the valve push rod valley (Fig. 114).
Remove the valve lifters or tappets
with a magnet through the push rod
openings. In some cases it will be
necessary to transfer the lifter or
Magnetic Lifter
STEP 1-SET N O . 1 PISTON O N T.D.C.
AT END OF COMPRESSION STROKE
-ADJUST N O . l , 4, 5 EXHAUST &
N O . 1, 8, 7 INTAKE.
Light
A1471-B
GROUP 1
51
Galaxie
Al 466-A
No. 3 Exhaust
No. 7 Exhaust
No. 8 Exhaust
No. 2 Intake
No. 3 Intake
No. 6 Intake
Monterey
Cyl.
C.I.D.
Carb.
Sedan
Convertible
Station
Wagon
223
IV
260
2V
Single
Single
Single
Dual
Single
Dual
Dual
Dual
Dual
Dual
Dual
Dual
Dual
Single
Single
Single
Dual
Dual
Dual
Dual
Dual
Single
Yes
Dual
Dual
Yes*
352
2V
390
4V
390 f
4V
406
4V
406
6V
390
2V
390
4V
Single
Dual
Yes*
Yes*
Yes*
Yes*
No
Yes*
Yes*
fPolice Interceptor
Resonator
EXHAUST SYSTEMS
(Part 1 -5)
DESCRIPTION
The dual exhaust system on conventional V-8 cars and station wagons consists of a muffler inlet pipe
and a separate inlet extension pipe
and muffler for each exhaust manifold. The 2 branches of the inlet pipe
are connected to a welded balance
(cross-over) tube.
On convertibles, the dual exhaust
system has a separate muffler inlet
pipe, resonator, inlet extension pipe,
and muffler (with integral outlet pipe)
for each exhaust manifold.
REPLACEMENT
The procedures given apply to all
car models and to both right and left
assemblies on a dual-exhaust system.
The exhaust systems are shown in
Figs. 117 thru 122.
Muffler and Outlet Pipe Assembly
1. Remove the inlet extension pipe
clamp at the muffler.
2. Remove the bolts that attach
the rear-end of the muffler assembly
to the frame mounted bracket.
3. Remove the inlet extension
pipe to muffler clamp. Separate the
muffler from the inlet extension pipe
and remove the muffler and outlet
pipe assembly.
4. Position the inlet extension pipe
clamp. Slide the new muffler and outlet pipe assembly on the inlet extension pipe.
52
GROUP 1
INLET PIPE
A1428-D
INLET PIPE
A1728-A
GROUP 1
53
MUFFLER AND OUTLET
PIPE ASSEMBLY
A1429-D
FIG.
119Y-8 Single Exhaust SystemExcept Mercury Monterey 390-2V Engine and Convertible
54
GROUP 1
A1732-A
A1430-D
GROUPS 1-2-3
INLET EXTENSION PIPES
55
MUFFLER AND OUTLET
PIPE ASSEMBLIES
A1431-D
IOC of the 1961 Mercury Maintenance Manual and the 1962 portion
of this manual remain the same for
1963.
GROUP 3
56
4. Lowered the fuel level in the
primary and secondary fuel bowls.
FUEL SYSTEM
MAINTENANCE
(Part 3-1)
UPPER
SECTION
GASKET
406 V-8
The fuel filter for the 406 V-8
engine is located in the line between
the fuel pump and the carburetor,
and is mounted on the front of the
left cylinder head (Fig. 123). A replaceable element is used in conjunction with the fuel filter.
FILTER
ELEMENT
LOWER
SECTION
B1420-A
B1O89-B
IDLE SPEED
ADJUSTMENT SCREW
GROUP 3
57
ABOVE 50F A N D / O R
5000 FEET ALTITUDE
50 F AND BELOW
IDLE MIXTURE SCREW
B1812-A
B1809-A
F I G . 1 26Ford Single-Barrel
Idle Fuel Mixture Adjustment
F I G . 129Ford Single-Barrel
Accelerating Pump Lever
Adjustment
B1810-A
F I G . 127Ford Single-Barrel
Float Bowl Vent Valve Adjustment
Acceleration requirements in various climates are satisfied by controlling the amount of fuel discharged by
the accelerating pump. The pump
stroke is controlled by changing the
location of the roll pin in the lever
stop hole (Fig. 129).
WITH THROTTLE PLATE FULLY CLOSED,
For operation in ambient temperatures 50F. and below, place the roll
pin in the hole of the pump operating
lever marked "HI" (lower hole). For
best performance and economy at
normal ambient temperatures 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.
Anti-Stall Dashpot Adjustment
1. Adjust the throttle position to
the hot idle setting. Turn the dashpot
adjusting screw outward until it is
clear of the dashpot plunger assembly.
2. Turn the dashpot adjusting
screw (Fig. 130) inward until it ini-
B1811-A
F I G . 128Ford Single-Barrel
Accelerating Pump Adjustment
DASHPOT
ADJUSTING SCREW
ADJUST THROTTLE TO
HOT IDLE POSITION
PRIOR TO ADJUSTING DASHPOT
B1813-A
F I G . 130Anti-Stall Dashpot
Adjustment
58
GROUP 3
BEND TAB
O N FLOAT ARM TO OBTAIN1
CORRECT FLOAT HEIGHT
B1815-A
Float Adjustment
1. With the carburetor upper body
and mounting gasket removed from
the carburetor assembly, turn the
upper body upside down.
2. Measure the distance from the
gasket surface of the upper body to
the crown (extreme top) of the float
(Fig. 132). If the float adjustment is
not within the specified dimension,
bend the float arm tab, as necessary,
to obtain the specified dimension. Do
not apply pressure on the fuel inlet
needle. The viton tip of the fuel inlet
needle may be damaged through undue pressure exerted on it and thus
Gauge OR Drill OF
SPECIFIED CLEARANCE SIZE
BETWEEN CHOKE PLATE
AND BODY
CHOKE LEVER IN
FULL CHOKE POSITION
ADJUST PLASTIC NUT
TO JUST CONTACT SWIVEL
B1814-A
GROUP 3
Accelerating Pump Stroke
260 V-8 ENGINE. For average
ambient temperature operation (4080F) place the accelerator pump operating rod in the No. 3 hole position (third hole from the throttle
shaft) of the overtravel lever (Fig.
133). 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.
For low ambient temperature operation (below 40F) place the pump
operating rod in the No. 4 hole position (hole farthest from the throttle
shaft) of the overtravel lever.
For high ambient temperature operation and/or high altitude operation (above 80F and/or 5000 feet
altitude) the pump operating rod may
be placed in the No. 1 or No. 2 hole
position to suit individual operating
conditions.
352 AND 390 V-8 ENGINE. For
average ambient temperature operation (40 to 80 F) place the accelerator pump operating rod in the No.
2 hole (second hole from the throttle
shaft) position of the overtravel lever
(Fig. 133). 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.
For low ambient temperature operation (below 40F) place the pump
operating rod in the No. 3 hole (third
hole from the throttle shaft) position
of the overtravel lever.
For extremely low ambient temperature operation (15F and below) the pump operating rod may be
placed in the No. 4 hole (fourth hole
PUT ROD IN
INSIDE HOLE
59
RETAINER
CLIP
B1424-C
GROUP 3
60
steps on the fast idle cam during the
engine warm-up period and controls
the fast idle speed (Fig. 135). Steps on
one edge of the fast idle cam permit
a faster engine idle speed for smoother running when the engine is cold.
As the choke plate is moved through
its range of travel from the closed to
the open position, the fast idle cam
pick-up lever rotates the fast idle
cam. Each step on the fast idle cam
permits a slower idle rpm as engine
temperature rises and choking is reduced.
Set the fast idle speed with the engine at normal operating temperature. Align the kickdown step of the
fast idle cam with the adjusting
screw, and turn the adjusting screw
to obtain the specified fast idle speed
(rpm).
Remove the tachometer if the idle
fuel mixture is not going to be adjusted. If the idle fuel mixture is to
be adjusted, leave the tachometer installed so that the idle speed can be
checked after the idle fuel mixture
has been adjusted.
B143O-A
3. Install an engine speed tachometer. Start the engine; move the transmission shift lever to the neutral
position, and set the parking brake.
Adjust the engine idle speed to the
specified rpm by turning the idle
BELLCRANK
LEVER
PRIMARY
THROTTLE LEVER
PUMP
LEVER
SCREW
IDLE FUEL
MIXTURE
LOCK
NUT
ANTI-STALL
DASHPOT
PUMP STROKE
SUMMER- PUT SCREW IN HOLE 1
WINTER- PUT SCREW IN HOLE 2
B1429-A
GROUP 3
WIDE-OPEN THROTTLE STOP
61
PRIMARY CARBURETOR
OVERDRIVE KICKDOWN SWITCH
\
SECONDARY CARBURETORS
IDLE
ADJUSTING
SCREW
CHOKE THERMOSTAT
HOUSING
FAST
IDLE
CAM
B1730-A
PRIMARY
THROTTLE ROD
ACCELERATOR-TO-BELLCRANK
ROD
BELLCRANK LEVER
GAGING HOLES
B1530-B
2. Operate the engine for 30 minutes at 1200 rpm to normalize engine temperatures. Install an engine
speed tachometer. Start the engine.
Move the transmission shift lever in
neutral position, and set the parking
brake. Adjust the engine idle speed
to the specified rpm by turning the
idle speed adjusting screw on the primary carburetor only.
3. Set the fast idle speed (coJd
engine) with the engine at normd
operating temperature. Align the
high step on the fast idle cam wi
the adjusting screw (Fig. 138). Tuin
the screw inward to increase or outward to decrease the idle speed to
obtain the specified rpm.
Throttle Lever Synchronization.
the throttle linkage is disassembled tir
it is improperly synchronized, the following procedure is recommended
for synchronizing the throttle levels
on the three carburetors.
1. Insert a Vs-inch diameter ro|d
through the gauging holes (Fig. 13
provided in the bellcrank lever and
GROUP 3
62
COVER
REMOVABLE ELEMENT
B1745-A
spin the element for 2 minutes within the splash shield. Do not use solvent.
3. Remove the element from the
fixture. The appearance of the filter
element, after being serviced in the
above manner, does not impair its
effectiveness. Inspect the element for
any cracks or splits in the filtering
area. If any splits or cracks are
found, the filter element must be replaced.
4. Clean the interior and exterior
of the air cleaner body before replacing the element. Solvents or compressed air can be used for this purpose.
5. Carefully install the air cleaner
gasket in position. Install the air
cleaner body and element.
Oil Bath Air Cleaner. Drain the
air cleaner reservoir. Wash the air
cleaner components in a suitable
cleaning solvent and dry them with
compressed air. Saturate the filter
with engine oil. Fill the oil reservoir
to the indicated level with recommended viscosity engine oil.
MILEAGE MAKER S I X STANDARD ENGINE
Removal
1. To remove the entire air cleaner, remove the positive crankcase
ventilation system outlet hose from
the air cleaner. Remove the bolt retaining the bracket to the air cleaner.
2. Remove the wing nut retaining
the air cleaner assembly to the carburetor. Remove the air cleaner assembly, then remove the cover and lift
the filter element out of the air cleaner body.
Installation
1. Position the air cleaner body on
GROUP 3
duct to the air cleaner with two wingtype bolts. Tighten the bolts.
2. Place the element in the body.
Install the cover and wing nut.
Tighten the nut.
260 V-8 AIR INTAKE DUCT
Removal
1. Remove the air duct and shroud
retaining nut and washer from the
exhaust manifold.
2. Remove the two wing-type
screws that secure the air duct and
thermostat assembly to the air
cleaner. Carefully lift the air duct,
shroud and tube as an assembly from
the engine.
Installation
1. Install the thermostat and air
duct assembly, and the shroud and
tube assembly on the exhaust manifold as a unit.
2. Secure the thermostat and air
duct assembly to the air cleaner with
the two wing-type screws. Install the
air duct to exhaust manifold retaining nut and washer.
Disassembly
1. Loosen the retaining screw and
separate the shroud and tube assembly from the air cleaner duct and
valve assembly (Fig. 140).
2. Check the operation of the
thermostat and air duct assembly.
Refer to "Tests and Adjustments" for
the proper procedure. If inspection
reveals that the valve plate is binding,
or the thermostat is malfunctioning,
remove the thermostat and valve plate
as follows:
Detach the valve plate tension
VALVE PLATE
RETAINER NUT
CLEANER
ASSEMBLY
B1746-A
63
move to the "heat on" position after
being dried with compressed air.
352, 390 AND 406 V-8 ENGINES
Removal
1. Remove the wing nut retaining
the air cleaner on the carburetor. Disconnect the choke clean air tube,
(except 406 V-8 engine) and lift the
air cleaner off the carburetor.
2. Remove the cover and lift the
element out of the air cleaner body.
Installation
1. Place the air cleaner body on
the carburetor so that the word
"FRONT" faces the front of the car.
Connect the choke clean air tube to
the air cleaner (except 406 V-8).
2. Place the element in the air
cleaner body. Install the cover.
CARBURETORS
(Part 3-2)
FORD SINGLE-BARREL
CARBURETOR
The 1963 Ford single-barrel carburetor is used on the Standard Mileage Maker Six, and the Mileage
Maker Six Special Police and Taxi
Special engines (Fig. 141).
An economy single-barrel carburetor is available for Mileage Maker
Six Special Police and Taxi Special
engines. This carburetor, unlike the
single-barrel carburetor, does not
have a spark control valve.
The carburetors consist of two
main assemblies, the main (upper)
body and the throttle (lower) body.
The upper body assembly contains
the major metering components of
the carburetor; the main and idle fuel,
power valve (except on Special Police and Taxi Special engines), float
chamber vent, and fuel inlet systems.
The lower body assembly contains
the fuel bowl, accelerating pump assembly, idle mixture adjusting screw,
and spark valve (if so equipped). A
hydraulic dashpot is also included
in the lower body for use on car models equipped with an automatic transmission.
A manual choke system is standard equipment on all car models.
This section applies to both the
conventional and the Special Police
and Taxi Special carburetors. Differences in the operation and overhaul
procedures are given when they exist.
64
GROUP 3
FUEL BOWL VALVE
AND LINK
NEEDLE VALVE SEAT AND GASKET
FUEL
INLET
FITTING
MANUAL <
CHOKE
N,.
LINKAGE
FLOAT ASSEMBLY
INLET FITTING
AND SCREEN
NEEDLE VALVE
a
DISTRIBUTOR VACUUM FITTING
ANTI-STALL DASHPOT
(AUTOMATIC TRANSMISSION
EQUIPPED CARS)
B1816-A
B1818-A
GROUP 3
65
ANTI-SIPHON AND FUEL/AIR MIXING HOLE
\ Jl
FUEL/AIR
MIXING HOLES
MAIN FUEL
DISCHARGE TUBE
MAIN
METERING JET
MAIN VENTURI
FUEL
^ 3 FUEL A N D A I R
IDLE TRANSFER HOLES
4n VACUUM
B1819-A
B1820-A
fuel. The air flow through the carburetor responds almost immediately
to any increase in carburetor throttle
valve opening. The fuel within the
metering passages will lag momentarily in its response to the pressure
difference created by this increased
air flow. This lag in fuel response
will cause a temporary leanness in
the fuel-air mixture that results in a
hesitation in engine acceleration. A
mechanically - operated accelerating
pump system (Fig. 145) supplies
added fuel to provide a richer fuelair mixture for this brief period of
time.
The accelerating pump, located on
the side of the lower body assembly,
POWER VALVE.
DIPTAkl
>^ V
PISTON
- DISCHARGE
NOZZLE
i Wmw 1
yWb\
1
W
OPERATING
LEVER
^FUEL
| N L E
I
;
<>AIR
PISTON RETURN
SPRING
JsK
Hi
in i
mf i
CALIBRATION SHIMS
6-i
BALL
CHECK VALVE
^OUTLET BALL
CHECK VALVE
,, A N D WEIGHT
< AIR
^ i FUEL
FUEL INLET J j y
PASSAGE X - |
i'
B1821-A
<JlD VACUUM
BALL
POWER
fel
^
VALVE
MAIN METERING JET
B1822-A
66
to pass into the chamber while the
discharge ball check closes preventing entry of air. A bleed hole is located in the body casting to allow
vapor and excess pressure to escape
from the diaphragm chamber.
Power Fuel System (Except Special Police and Taxi Special Engines).
When the engine is required to deliver more power to meet an increased
road load demand or wide-open
throttle operation, the carburetor
must deliver a richer fuel-air mixture than supplied during the operation of the main fuel system. When
the engine is running under a high
power demand, intake manifold vacuum is low. The vacuum below the
carburetor throttle plate approximates intake manifold vacuum. The
carburetor power valve (Fig. 146)
will open when the manifold vacuum
drops below a predetermined value.
The fuel-air mixture is thus automatically enriched to meet the increased
engine power demands.
Manifold vacuum is transmitted
from an opening below the throttle
plate through a channel to the upper body assembly and to the top of
the power valve piston. At idle and
normal engine speeds the manifold
vacuum is great enough to hold the
power valve piston up.
The power valve rod is connected
to the piston. The foot of the rod
controls the spring loaded power
valve ball check. With the piston held
up by manifold vacuum, the ball
check closes the power jet inlet channel.
A power valve spring is located on
the rod. The spring is shim calibrated to overcome the vacuum above
the piston when manifold vacuum
drops below a predetermined level.
Upon demand for more power, the
manifold vacuum drops below this
level. The spring tension moves the
rod down and allows the power valve
ball check to open. Air pressure
above the fuel bowl forces fuel to
flow through the power jet, adding to
fuel in the main fuel system, enriching the fuel-air mixture.
As the demand for power decreases and manifold vacuum increases, the vacuum above the piston
overcomes the spring tension. The
piston and rod move up and the ball
check closes the power jet channel.
Fuel Bowl Vent System. The fuel
bowl requires venting (Fig. 147) to
provide proper operation for the
various systems. Fuel vapors may
GROUP 3
form in the fuel bowl when a hot engine is stopped, idling, or operating
at very low speeds. By venting the
fuel bowl to the atmosphere, engine
performance is improved. At higher
engine speeds, venting to the carburetor air horn prevents calibration
changes due to normal air cleaner
contamination.
A valve, connected through the
linkage to the throttle shaft, and located in a bore over the fuel bowl,
is at the inward position during
closed or part throttle operation. In
this position, the valve allows venting only to the atmosphere.
At normal or wide open throttle
operation, the rod moves outward
sealing the external vent and opening
the vent to the carburetor throat.
Spark Control Valve System (Except Special Police and Taxi). The
degree of spark advance in the distributor is determined by the strength
of the vacuum acting on the distributor diaphragm. Vacuum to the distributor diaphragm is the result of a
combination of venturi vacuum and
manifold vacuum.
Venturi vacuum is available to the
distributor through the pick-up tube
in the carburetor main venturi. Manifold vacuum enters a hole above the
throttle plate (Fig. 148) and is channeled to the spark valve. In normal
operation, the combination of manifold vacuum, a calibrated spring in
the spark valve, and atmospheric
EXTERNAL VENTING
,ROD AND VALVE IN
FUEL BOWL
/RETURN SPRING
B1823-A
GROUP 3
67
M A I N VENTURI
INLET BALL CHECK VALVE
VENTURI VACUUM
PICK-UP TUBE
OUTLET RESTRICTION
DASHPOT LEVER
AND ADJUSTING
SCREW
RESTRICTION
DISTRIBUTOR VACUUM
TUBE ADAPTOR
<=JAIR
<pa VACUUM
MANIFOLD
VACUUM PICK-UP
B1824-A
DIAPHRAGM AND
RETURN SPRING
fiFUEL
B1825-A
CARBURETOR REMOVAL
1. Remove the air cleaner from
the air horn of the carburetor.
2. Disconnect the accelerator rod,
choke control cable, fuel line, and the
distributor vacuum line.
3. Remove the carburetor and gasket from the intake manifold. Discard
the gasket.
CARBURETOR INSTALLATION
1. Clean the gasket surface of the
intake manifold and carburetor (if
necessary). Position a new gasket on
the intake manifold.
2. Install the carburetor and
tighten the retaining nuts.
3. Connect the choke cable and
throttle linkage to the carburetor.
Adjust the cable and linkage, if necessary.
4. Connect the fuel inlet line and
the distributor vacuum line. Install
the air cleaner.
5. Adjust the idle fuel mixture,
engine idle speed, if necessary, and
adjust the anti-stall dashpot (automatic transmission).
IN-CHASSIS ADJUSTMENTS
The carburetor "In-Chassis Adjustments" are covered in this group.
CARBURETOR DISASSEMBLY
A disassembled view or the carburetor is shown in Fig. 150. Use a sep-
Upper Body
1. Remove the float retaining pin
and the float assembly.
68
GROUP 3
arate, if necessary, the pump diaphragm and spring from the cover
or body.
CARBURETOR ASSEMBLY
A disassembled view of the carburetor is shown in Fig. 150.
3. Depress the tab on the accelerating pump lever and rod retaining
clip and slide the rod out of the
lever. Remove the clip from the
lever.
Upper Body
1. If the choke plate and the shaft
were removed, insert the choke shaft
assembly into the air horn, with the
lever pointing toward the accelerating pump side of the carburetor.
Refer to the line previously scribed
on the choke plate and insert the
choke plate into its original position
with the plate indentation facing upward and toward the accelerating
pump side of the carburetor. Install
the choke plate retaining screws snug,
but not tight.
Check for proper plate fit, binding
in the air horn and free rotation of
the shaft by moving the plate from
the closed position to the open position. If it moves freely, tighten the 2
choke plate screws while holding the
plate in the fully-closed position.
Stake the screws. When staking the
screws, support the shaft and plate
on a block of wood or a metal bar
to prevent bending of the shaft.
2. Install the fuel inlet screen and
adapter in the fuel inlet of the body.
3. Install the main jet in the main
fuel well.
4. Install the needle valve seat
gasket and the seat within the tapped
seat hole. Tighten the needle valve
seat firmly. Insert the needle valve
into the needle valve seat, with the
viton tip toward the seat.
5. Position the float assembly in
the body, with the tab on the arm located over the needle valve and the
hinge of the arm lined up between
the hinge bracket holes in the upper
body casting. Insert the float hinge
pin through the holes in the upper
body and the float assembly.
6. Check the float setting. Refer to
"Carburetor In Chassis Adjustments" in this group of the manual.
7. Insert the air cleaner bracket in
the channels of the air horn and install the bracket retaining pins.
Lower Body
1. If the throttle plate and shaft
were removed, slide the throttle shaft
into the lower body, with the lever
on the throttle shaft located opposite
the fuel bowl.
Refer to the line previously scribed
on the throttle plate and insert the
plate through the slot in the throttle
shaft. The plate indentation must face
the bottom of the body and point toward the accelerator pump. Install
the throttle plate screws snug, but
not tight.
Rotate the throttle shaft while
lightly slapping the throttle plate
within the throttle bore. Check for
free rotation of the throttle shaft.
Hold the lower body up to the light.
Little, or no light should show between the throttle plate and throttle
bore. When the plate is properly located, hold the throttle plate closed;
then, tighten and stake the retaining
screws. When staking the screws,
support the shaft and plate on a block
of wood or a metal bar to prevent
bending of the shaft.
2. Install the distributor vacuum
outlet fitting.
3. If the lever and rod were removed from the accelerating pump
cover, position the top hole of the
lever between the top bracket holes
in the cover; then, install the retaining roll pin.
Position the vent rod lever over
the pump cover bracket. Line up the
hole in the lever with the holes in the
bracket and install the retaining roll
pin.
Install the roll pin in the "HI" (upper) lever stop hole.
Position the small diameter end of
the diaphragm return spring into the
boss in the accelerating pump chamber. Position the diaphragm assembly
into the accelerating pump cover and
line up the holes. Position the cover
and diaphragm over the return spring
and onto the body. Install the cover
retaining screws finger tight. Push
the diaphragm assembly inward and
tighten the screws.
4. Position the accelerating pump
actuating rod retaining clip over the
hole in the accelerating lever, with
the tab side of the clip toward the
carburetor barrel. Depress the tab
and insert the shorter end of the rod
through the lever and clip. Release
the tab when the rod is inserted. Perform the "Accelerating Pump Adjustments" after the carburetor is assembled. Refer to the "Carburetor
In-Chassis Adjustments" in this
group of the manual for the proper
procedure.
5. If the carburetor is equipped
with a dashpot, proceed with the following steps:
If the lever was removed from the
dashpot cover, position the hole in
the lever between the holes in the
bracket on the cover. Install the lever
GROUP 3
69
&**
GASKET
VENT
ACTUATING
LEVER
ACCELERATING PUMP
CONTROL ROD
STOP PIN
ACCELERATING PUMP
COVER
ACCELERATING PUMP
DISCHARGE WEIGHT
ACCELERATING
PUMP LINK
'
RETAINING
CLIP
OVERTRAVEL
SPRING
<S^<
RETAINER
WASHER
ROLL PIN
*DASHPOT
CONTROL ROD
ACCELERATING PUMP
DIAPHRAGM
DASHPOT
DIAPHRAGM
'
*DASHPOT
COVER
* DASHPOT LEVER
SPRING
# GASKET
IDLE MIXTURE
SCREW
ADJUSTING
SCREW
DISTRIBUTOR
VACUUM ADAPTER
* RETAINING CLIP
FAST IDLE
ADJUSTING SCREW
SPRING
* USED O N AUTOMATIC TRANSMISSION
f ECONOLINE ONLY
THROTTLE SHAFT
AND LEVER ASSEMBLY
F I G . 1 50Single-Barrel CarburetorDisassembled
B1826-A
70
GROUP 3
retaining roll pin. Install the adjusting screw in the lever, if necessary.
Position the small diameter of the
diaphragm return spring into the boss
in the dashpot chamber. Position the
diaphragm into the dashpot cover
and line up the holes. Position the
cover and the diaphragm over the
return spring and onto the body. Install the cover retaining screws finger
tight. Push the diaphragm assembly
inward and tighten the screws.
Position the dashpot actuating rod
retaining clip over the hole in the
dashpot lever, with the tab side of
the clip facing toward the carburetor barrel. Depress the tab and insert the shorter end of the rod
through the lever and clip; then, release the tab when the rod is inserted.
Perform an "Anti-Stall Dashpot Adjustment" after the carburetor is assembled. Refer to the "Carburetor
In-Chassis Adjustments" in this
group of the manual for the proper
procedure.
6. Position the overtravel spring
on the accelerating pump lever and
hook the tang of the spring on the
lever. Position the overtravel lever
and spring onto the throttle shaft
and insert the accelerating pump actuating rod and dashpot actuating
rod (if so equipped) into the two
holes in the lever. Install the washer
and retaining ring.
Install the overtravel tension retaining pin in the throttle shaft. Pull
the arm of the overtravel spring over
the retaining pin to apply spring tension to the overtravel lever.
7. If the carburetor is equipped
with a spark valve, position the
spark valve gasket over the spark
valve and install them into the lower
body. Tighten the valve securely. A
loose valve will cause poor engine
operation.
8. Install the idle mixture adjusting screw in the lower body. Turn
the screw inward until it bottoms on
the lower body; then, back it off the
specified amount of turns.
CARBURETOR CLEANING
AND INSPECTION
The cleaning and inspection operations in the 1962 Ford Galaxie Shop
Manual apply to the single barrel
carburetor; however, the following
additions must be observed during
the operation:
To prevent damage, the diaphragms, spark valve, and float
Manual Choke
1. Position the choke cable bracket
assembly onto the lower body assembly and install the stud.
2. Insert the threaded end of the
choke shaft to cam lever rod through
the cam lever swivel. Install the
spring and adjusting nut onto the rod.
3. Position the rod end into the
keyhole in the choke shaft lever;
then, insert the rod and turn it
counterclockwise.
4. Position the cam lever assembly
over the stud and install the retainer.
Perform a "Manual Choke Adjustment" prior to installation of the carburetor. Refer to "Carburetor InChassis Adjustments" in this group
of the manual for the proper procedure.
CARBURETOR BENCH
ADJUSTMENTS
All carburetor adjustments, with
the exception of the Final (Hot) Engine Idle and Idle Fuel Mixture adjustments can be performed prior to
installing the carburetor in the car.
FLOAT ADJUSTMENT
Adjust the float so that it is
parallel (y64 inch) with the top of
the fuel bowl, with the fuel bowl inverted (Fig. 151). This is a preliminary adjustment, check the fuel level
on the engine (See "Carburetor InChassis Adjustments").
FAST (COLD) IDLE
ADJUSTMENT
Align the fast idle adjusting screw
with the lowest step on the fast idle
FLOAT PARALLEL
TO BOWL TOP
B1445-C
71
GROUP 3
cam and adjust the screw to obtain 0.008 inch clearance between
the screw and the cam. Final adjustment of the fast idle speed should
be to the specified rpm on the engine.
Refer to "Carburetor In-Chassis Adjustments".
FLOAT ADJUSTMENT
1. Remove the air horn.
2. With the float raised and the
fuel inlet needle seated, check the
distance from the top surface of the
main body to the top of the free end
of the float for conformance to specifications. If necessary, bend the tab
on the float arm to bring the float
setting within limits. This should
provide the proper fuel level, but it
must be checked on the engine (Refer to "In-Chassis Adjustments").
3. Replace the air horn.
PULSATOR
COVER
PULSATOR
DIAPHRAGM
FUEL PUMPS
(Part 3-3)
MILEAGE MAKER SIX
(GALAXIE)
Taxi Special and Special Police.
The 1963 Carter design fuel pump
for the Mileage Maker Six Taxi
Special and Special Police installation is basically the same as the 1962
pump, with the following exceptions:
The pump has been inverted with respect to its original mounting position, and the mounting flange has
been repositioned at an 11-degree
angle to its original vertical position.
The 1963 fuel pump also incorporates pressure leak-down bleed
holes in the valves to prevent excessive pressure build-up in the fuel line
(Fig. 152).
Passenger Car. The 1963 fuel pump
for the Mileage Maker Six passenger
car installation is an AC design pump
with a long-life, disposable fuel filter
element. The filter is integrally
mounted on the top side of the fuel
pump body. The lower pump body
DIAPHRAGM
AND SPRING
ASSEMBLY
Soft Jaws
Tool-T56L-9350-A
Detail 3
ROCKER
ARM
RETURN
SPRING
ROCKER ARM
ROCKER ARM
B1565-A
B1737-A
B1736-A
F I G . 1 54Fuel Pump
Diaphragm Removal
72
GROUP 3
OIL SEAL
Tool 9 3 5 0 - C OR
Tool-T56L-9350-A, Detail 1
FILTER HOUSING
FILTER
DIAPHRAGM RETURN SPRING
FILTER HOUSING
GASKET
B1738-A
FIG. 1 57Diaphragm
Installation
1B1741-A
GASKET-
cr*" GASKET
FUEL PUMP
BODY
B1732-A
GROUP 3
Tests. For fuel pump tests and
diagnosis procedures, refer to the
pertinent Galaxie or Monterey Shop
Manual.
73
ROCKER ARM PIN.
ROCKER
ARM PIN
/
x
ROCKER
ARM
Removal
1. Disconnect the fuel lines at the
pump.
2. Remove the pump retaining
bolts, then remove the pump and
gasket. Discard the gasket.
Installation
1. Remove all the gasket material
from the pump mounting pad and
pump flange Apply sealer to both
sides of a new gasket.
2. Position the gasket on the
pump flange, and hold the pump in
position against the mounting pad.
Make sure the rocker arm is riding
on the camshaft eccentric.
3. Press the pump tight against
the pad. Install the retaining screws,
and alternately torque them to specifications. Connect the fuel lines.
4. Operate the engine and check
for leaks.
Disassembly
1. Remove the filter housing, gasket, and filter element. Discard the
filter element.
2. Scribe marks on the fuel pump
body, valve housing, and valve housing cover so that these parts can be
assembled in their original position.
3. Remove the valve housing assembly. Separate the valve housing
from the cover and note the position
of the pulsator diaphragm so that it
can be assembled in its proper position. Do not remove the fuel valves
from the valve housing. The valve
housing is replaced as an assembly.
4. Remove the rocker arm return
spring.
5. Scrape away the staking mark
Screwdriver
B1233-B
ROCKER ARM
PIN PLUG
DIAPHRAGM AND
SPRING ASSEMBLY
B1344-B
PULSATOR
DIAPHRAGM
VALVEHOUSING
COVER
czx
FILTER HOUSING
GASKET
FILTER
FILTER HOUSING
B1733-A
F I G . 161Fuel Pump
Assembly
ROCKER ARM
B1234-B
F I G . 160Fuel Pump
Diaphragm Removal or Installation
8. Remove the fuel pump diaphragm assembly. Do not disassemble as the diaphragm and spring are
serviced as an assembly.
Cleaning and Inspection. Clean
the fuel pump body, valve housing,
cover, and filter housing in solvent.
Blow out all body, housing, and
cover passages. Inspect the pump
body, valve housing, and cover for
cracks or damage and replace them
if necessary. The fuel valves are not
serviceable. Therefore, if replacement
is necessary, replace the valve housing
and valves as an assembly. Inspect
the mounting flange for distortion.
Replace the pump body or lap the
distorted flange if necessary.
74
GROUP 3
7. Place a new filter element over
the spout in the valve housing cover.
Lightly lubricate and position the
gasket, then screw the filter housing
on the pump. Hand tighten the filter
housing until the gasket contacts the
pump, then advance it Vs turn.
PULSAT
DIAPHRAGM
ToolT56L-9350-A,Detail 1
or 9350-C
B1735-A
FIG. 162Pulsator
Diaphragm Installation
evenly around the edge of the cover.
Install and tighten the two retaining
screws and lock washers inside the
valve housing.
6. Align the scribe line on the
valve housing and the line on the
fuel pump body. Hold the valve
housing assembly tight against the
fuel pump body and install the six
screws and lock washers. Be sure
the fuel pump diaphragm extends
evenly around the edge of the valve
housing before tightening the retaining screws.
DIAPHRAGM
LINK'
PIN
DIAPHRAGM
SPRING
DIAPHRAGM
FUEL PUMP
BODY SCREW
GASKETS
VALVE BODY
COVER SCREW
AND LOCK WASHER
B1742-A
ToolT56L-9350-A,
Detail 3
B1468-A
B1472-B
75
GROUPS 3-4
ToolT56L-9350-A, Detail 4
B1470- A
9350-D or
T56L-9350-A,Detail 2
B1743-A
COOLING SYSTEM
MAINTENANCE 260 V-8
ENGINE
The cooling system of the 260
V-8 engine consists of the down flow
radiator and cap, water pump, pulley,
spacer, thermostat, fan assembly, and
the fan drive belt.
GENERAL MAINTENANCE
The cylinder block of the 260 V-8
engine is drained by removing the
drain plugs, located on both sides of
the block.
To fill the cooling system, install
the drain plugs in the block and close
the radiator drain cock. Fill the system to just below the filler neck of
the radiator supply tank. Operate the
engine until normal operating temperatures have been reached and add
more coolant to fill the radiator.
After the initial fill, the coolant
level will drop approximately 1 quart
after the engine has been operated
about 20 minutes at 2000 rpm. This
is due to the displacement of entrapped air.
RADIATOR, HOSES AND
THERMOSTAT
A1584-B
RADIATOR REPLACEMENT
260 V-8
Removal
1. Drain the cooling system. Disconnect the upper and lower hoses
76
at the radiator.
On a car with an automatic transmission, disconnect the automatic
transmission fluid cooler inlet and
outlet lines at the radiator.
2. Remove the radiator retaining
bolts and remove the radiator.
On a car equipped with an air conditioner, remove the bolts retaining
the fan shroud to the radiator. Remove the radiator retaining bolts and
remove the radiator. Lift the shroud
from the engine compartment.
Installation
1. If a new radiator is to be installed, remove the drain cock from
the old radiator and install it on the
new radiator.
On a car with an automatic transmission, transfer the transmission
fluid cooler line fittings to the new
radiator.
On a car with an air conditioner,
position the fan shroud in the engine
compartment.
2. Position the radiator assembly
and install (but do not tighten on
cars with an automatic transmission)
the radiator support bolts.
On a car with an automatic transmission, connect the automatic transmission fluid cooler lines; then,
tighten the radiator support bolts.
On a car with an air conditioner,
install the fan shroud bolts.
3. Connect the radiator upper and
lower hoses. Close the drain cock,
then, fill and bleed the cooling system.
4. Operate the engine and check
for leaks at the hose connections and
the automatic transmission fluid
cooler lines. Check the automatic
transmission fluid level.
RADIATOR HOSES260 V-8
Radiator hoses should be replaced
whenever they become cracked or
deteriorated.
GROUP 4
minutes; then check the hoses and
connections for leaks.
3. Check for proper coolant level
after the engine has reached normal
operating temperature.
THERMOSTAT260 V-8
The engine is equipped with a
poppet-type thermostat that is
mounted inside the coolant outlet
elbow.
The high temperature thermostat
used in production is for use with
water or permanent-type anti-freeze.
A low temperature thermostat is also
available for use with non-permanent-type anti-freeze and water.
Removal
1. Drain the cooling system to below the level of the coolant outlet
elbow.
2. Remove the coolant outlet elbow retaining bolts and slide the
elbow and attached hose to one side.
3. Remove the thermostat and
gasket.
Installation
1. Clean the coolant outlet elbow
and intake manifold surfaces. Coat
a new coolant outlet elbow gasket
with sealer. Position the gasket on
the intake manifold. The gasket must
be positioned on the intake manifold
before the thermostat is installed.
2. Coat the edge of the thermostat
with grease for thermostat adhesion.
Position the poppet-type thermostat
in the recess of the coolant outlet
elbow so that the copper pellet or
heat element will be within the in-
GASKET
PUMP BODY
Installation
1. Position the clamps on each end
of the hose. Slide the hose onto the
connections; then, tighten the clamps
firmly. Make sure the clamps are installed beyond the bead on the connections.
2. Fill the radiator with coolant.
Operate the engine for several
HUB
B1647-A
GROUP 4
77
Drift
SMALLER
DIAMETER
THAN SHAFT
Tool
T52L-8501-DAD
Installation
1. Remove all the gasket material
from the mounting surfaces of the
cylinder front cover and the water
pump.
B1648-A
Assembly
1. Install the new slinger on the
new bearing and shaft assembly furnished in the repair kit (Fig. 172).
Press the slinger on until the tool bottoms.
2. Apply a light film of waterproof
sealer on a new seal and press the
seal into the housing (Fig. 173).
Removal
1. Drain the cooling system. Dis-
PRESS UNTIL
BEARING IS
FLUSH WITH
THIS SURFACE
B165O-A
-A
B1652-A
GROUPS 4-5
78
B1654-A
SYNCHRO-SMOOTH
DRIVE TRANSMISSION
chronizer sleeve
Bent or worn shift fork, lever
and/or shaft
End play in input shaft (bearing
retainer loose or broken, loose or
worn bearings on input and output
shafts)
Clutch teeth not engaging completely
Not enough over-shift travel in
column
Lack of lubrication
Improper lubrication
Corroded transmission levers (shaft)
Defective (tight) input shaft pilot
bearing
79
GROUP 5
TROUBLE SYMPTOMS AND POSSIBLE CAUSESContinued
JUMPING OUT OF
SECOND GEAR
STICKING IN
SECOND GEAR
Lack of lubrication
Improper lubrication
Corroded transmission levers (shaft)
Second speed gear seizure on shaft
will give same effect as gears stuck
in second gear
JUMPING OUT OF
LOW GEAR
Lack of lubrication
Improper lubrication
Corroded transmission levers (shaft)
Low gear seizure on shaft will give
same effect as gears stuck in first gear
GEAR NOISE
80
GROUP 5
SCORED OR BROKEN
GEAR TEETH
NOISY IN FIRST
THROUGH THIRD GEARS
NOISY IN REVERSE
HARD SHIFTING
OPERATION
The 3-speed transmission (Fig.
177) is of the fully synchronized
type, with all gears except the reverse
gear and sleeve being in constant
mesh. All forward-speed changes are
accomplished with synchronizer
sleeves (Fig. 178) instead of sliding
gears. The synchronizers will enable
quicker shifts, eliminate gear clash
and permit down-shifting, high to
intermediate between 40-20 mph and
from intermediate to low below 20
mph.
C1422-A
F I G . 1773-Speed Transmission
81
GROUP 5
ing ring and engage external clutch
teeth on the constant mesh first gear.
Since first gear is now locked to the
output shaft and is always meshed
with the countershaft (cluster) gear,
the power flow is from the input
gear, through the countershaft gear,
to the constant mesh first gear,
through the reverse gear and sleeve
to the output shaft and out the rear
of the transmission.
Engagement of second and third
gears is the same as first except for
ratio. In third gear, the input gear
and shaft is locked directly to the
output shaft by the second and third
speed synchronizer to provide a ratio
of 1:1.
Spur teeth are cut on the outside
of the reverse gear and sleeve. The
reverse gear and sleeve like the hub
are always locked to the output shaft.
Reverse gear is engaged by sliding
the reverse gear and sleeve into mesh
with the spur gear at the rear of the
idler gear. The drive is then from the
input gear, through the countershaft
COVER
FRONT
BEARING RETAINER
GASKET
SERIAL NUMBER PLATE
C1434-A
PLUGS
SECOND A N D HIGH
SYNCHRONIZER
ROLL PIN
NOTE:
ALL FORWARD SPEED
GEARS IN CONSTANT
MESH WITH
COUNTERSHAFT GEAR
C1408-A
C1433-A
F I G . 180Removing
Countershaft Roll Pin
GROUP 5
82
Dummy
Shaft
Tool-T63P-7111-A
Tool-T63P-7in-B
Tool-T63P-7111-C
C1427-A
SET SCREW
MACHINED SURFACE
2ND A N D 3RD SHIFT FORK
EXPANSION PLUG
C1410-A
REVERSE IDLER
GEAR SHAFT
C1411-A
GROUP 5
83
BEARING
RETAINER
C1414-A
ROLL PIN
REMOVAL
INSTALLATION
C1025-B
INSERT SPRING
SHIFT
LEVER
SLEEVE AND
REVERSE GEAR
LOCK WASHER
C1412-A
C1416-A
BLOCKING
SNAP
RING
RING
SNAP
OUTPUT SHAFT
RING
2 N D
GEAR
SYNCHRONIZER
THRUST
WASHER
SPEEDOMETER
REAR DRIVE GEAR
BEARING
\
REVERSE GEAR
A N D SLEEVE
SNAP RINGS
C1431-A
BLOCKING RING
SNAP RINGS
C1415-A
CLEANING
1. Clean all parts except the ball
bearings in cleaning solvent and dry
them with compressed air.
GROUP 5
84
INSERT
SPRING
BLOCKING
RING
BLOCKING RING
INSERTS
HUB
""
INSERT SPRING
SLEEVE
C1417-A
worn or broken. If the needle bearing surface in the bore of the gear
is worn or rough, or if the cone
surface is damaged, replace the gear
and the gear rollers.
11. Replace all other gears that
are chipped, broken or worn.
12. Check the synchronizer sleeves
for free movement on their hubs.
Make sure that the alignment marks
(etched marks) are properly indexed
as shown in Figs. 190 and 191.
13. Check the blocking rings for
the grooves being worn smooth or
for the teeth being damaged.
14. Replace the speedometer drive
gear if the teeth are stripped or
damaged. Make certain to install the
correct size replacement gear.
15. Replace the output shaft if
there is any evidence of wear or if
any of the splines are damaged.
16. Inspect the bushing and the
seal in the extension housing. Replace them if they are worn or
damaged. The bushing and/or seal
should be replaced after the extension housing has been installed on
the transmission.
17. Replace the seal in the input
shaft bearing retainer if it is damaged.
TRANSMISSION ASSEMBLY
COUNTERSHAFT GEAR
C1418-A
FIG. 192-Checking
Countershaft Gear End Play
9. Replace the reverse idler gear
if the teeth are chipped, worn or
broken. If the bushings are worn or
damaged, replace the gear assembly.
Replace the idler gear shaft if worn
or scored. Install the idler gear,
thrust washers and shaft in the case.
Make sure that the thrust washer
with the flat side, is at the web end
and that the spur gear is toward the
rear of the case. Check the reverse
idler gear end play as detailed in
step 8. If the end play is within specifications (0.004-0.018 inch), leave
the gear installed in the case.
10. Replace the input shaft and
gear (Fig. 188) if the splines are
damaged or if the teeth are chipped,
GROUP 5
of the retaining spring and push the
assembly together. Install the remaining insert spring, so that the spring
ends cover the same slots as does the
other spring. Do not stagger the
springs. Place a synchronizer blocking ring in each end of the synchronizer sleeve.
4. Lubricate the output shaft
splines and machined surfaces with
transmission lubricant.
5. Slide the first and reverse synchronizer (Fig. 187) onto the output
shaft with the teeth end of the gear
facing toward the rear of the shaft.
Secure it in place with the snap ring.
6. Coat the tapered machined surface on the first gear with grease.
Place the blocking ring on the
greased surface.
7. Slide the first gear onto the output shaft with the blocking ring toward the rear of the shaft. Rotate the
gear as necessary to engage the three
notches in the blocking ring with the
synchronizer inserts. Secure the first
gear with the thrust washer and snap
ring.
8. Coat the tapered machined surface of the second gear with grease
and slide the blocking ring onto it.
Slide the second gear with blocking
ring and the second and third gear
synchronizer onto the mainshaft. The
tapered machined surface of the
second gear must be toward the front
of shaft. Make sure that the notches
in the blocking ring engage the synchronizer inserts. Secure the synchronizer with a snap ring.
9. Install a new O-ring on each of
the two shift lever shafts (Fig. 186).
Lubricate the shafts with transmission fluid and install them in the
case. Secure each shift lever on its
respective shaft with a flat washer,
lock washer and nut.
10. Coat the bore of the input
shaft and gear with a thick coat of
grease. Install the 15 needle bearings
(Fig. 188) in the bore.
11. Install the input shaft gear and
blocking ring through the opening in
the top of the case. Working through
the output shaft opening, carefully
tap the input gear and shaft into the
case with a long brass drift until the
gear contacts the case. Make sure
that none of the roller bearings drop
out of place.
12. Position the output shaft assembly in the case.
13. Place a detent plug spring and
a plug in the case (Fig. 183). Place
85
C1428-A
F I G . 193Installing Output
Shaft Rear Bearing
GROUP 5
86
EXTENSION HOUSING
EXTENSION
HOUSING
EXTENSION HOUSING
Tool7775-A8
ToolT57P-7697-B
or 7657 G
\
BUSHING
SEAL
C1O28-C
FIG. 194Removing
Extension Housing Bushing and
Seal
ft-lbs. If the extension housing seal
bushing and seal is to be replaced,
remove it with the tool shown in Fig.
194.
30. If just the seal is to be replaced, remove it with the tool shown
in Fig. 195.
C1O27-A
C1O29-D
FIG. 196Installing
Extension Housing Bushing
REAR OIL SEAL
ToolT57L-7657-A
or 7657-0
EXTENSION HOUSING
C1O3O-D
NOISY IN REVERSE
HARD SHIFTING
LUBRICANT LEAKS
Excessive lubricant
Incorrect lubricant
Vent plugged
Input shaft bearing retainer loose,
cracked or gasket damaged
GROUP 5
87
C1367-B
finger operated release lever is provided on the shift lever (Fig. 200) to
prevent the transmission from being
accidentally shifted into reverse gear.
All forward gears in the transmission
are helical-type gears. The reverse
front idler is also the helical-type,
however, the reverse sliding gear and
the reverse rear idler gears located
in the extension housing are spurtype gears.
In first speed, the first-and-second
speed synchronizer sleeve is moved
rearward by the shift fork. The sleeve
engages the first speed blocking ring,
which acts as a cone clutch applied
to the free-wheeling first speed gear.
This action speeds up or slows down
the first speed gear to match the speed
of the output shaft. Further movement of the sleeve locks the first-andsecond speed synchronizer hub to the
first-speed gear by means of internal
splines. On engagement of the clutch,
88
GROUP 5
C1368-A
1 AND 2 LEVER
ELONGATED HOLE
3 AND 4 LEVER
C1372-A
/
C1370-A
GROUP 5
89
BALL
RETAINER
BOOT
RETURN SPRING
COVER PLATE
.LOCKOUT WIRE
SUPPORT
GASKET
ROD-RETAINING
LOCK NUTS
3-4 FORK
C1371-A
C1O3O-C
90
GROUP 5
INSTALLATION
REVERSE CAM
AND SHAFT
RETAINING PIN
C1373-A
F I G . 204Removing Reverse
Cam and Shaft Retaining Pin
REVERSE SHIFTER
LOCK PIN
GASKET
BUSHING
SEAL
EXTENSION
HOUSING
GASKET
SPEEDOMETER
DRIVEN GEAR
BEARING
RETAINER
THRUST
BEARING
SLEEVE
INSERTS
BLOCKING
RING
3RD
SPEED
REVERSE
IDLER
LOCK PIN
2ND. SPEED
GEAR
SPR.NG
A HUB
INPUT
BEARING
SHAFT
SPEEDOMETER
DRIVE GEAR
REVERSE
11
SLIDING GEAR
. . . .-_
1ST. SPEED
GEAR
THRUST
WASHER
^ * ^ ^ \
\
THRUST
WASHER
REVERSE
IDLER SHAFT
REVERSE
IDLER GEAR
FRONT REVERSE
IDLER GEAR
COUNTERSHAFT
ROLLERS
C1369-A
GROUP 5
extension housing retaining bolts.
Torque to specifications.
91
REVERSE IDLER
GEAR SHAFT
DETENT BALL
(SPRING LOADED)
THRUST WASHER
C1374-A
the shaft out of the extension housing about Vs inch. This operation
frees the reverse shifter fork from
the reverse sliding gear located in the
extension housing.
5. Remove the extension-to-case
retaining bolts (Fig. 205). Tap the
extension housing with a soft hammer to free it from the case. Slide
the extension housing rearward until
the reverse idler shaft (Fig. 206) is
clear of the reverse rear idler gear.
Rotate the extension housing to the
left to clear the reverse shifter and
remove the extension housing.
REVERSE
SLIDING
GEAR
C1375-A
C1376- A
GROUP 5
92
COUNTERSHAFT
GEAR
COUNTERSHAFT
REVERSE
IDLER GEAR
THRUST WASHER (STEEL)
C1377-A
SPACER
COUNTERSHAFT
Tool-T 57 L-7 111-A
OR 71??
C1378-B
TOOL PILOTS IN
THIS DIAMETER
Tool-T57P-77047-A
OR 70256-6B
Too/-T50T-?00-A
OR 7600-E
C1O31-C
FIG. 210Countershaft
Removal
C1144-B
11. Remove the input shaft bearing retainer and discard the gasket.
Remove the input shaft bearing retaining snap ring and push the input
shaft and bearing assembly inward
and out of the bearing bore. Remove
the input shaft assembly from inside
the case.
12. Remove the cluster gear assembly from the case (including dummy
shaft and thrust washers). Note the
arrangement of the spacers.
13. Disassemble the cluster gear
as shown in Fig. 211. The six steel
spacer washers are interchangeable.
14. Remove the input shaft bearing retainer oil seal as shown in Fig.
212.
GROUP 5
REMOVAL
93
INSTALLATION
C1O25-A
SNAP RING
AND FOURTH-SPEED
SLIDING CLUTCH SLEEVE
A N D HUB
C1379- A
:'
THIRD-SPEED GEAR
SYNCHRONIZER
C138O-A
94
GROUP 5
' " *
Tool-SNAP-ON-CJ-95
OR 4621-K
C1382-B
FIRST- A N D
SECOND-SPEED
CLUTCH HUB
C1383-B
GROUP 5
95
Tool-1175-AB
OR II75-AE
Tool-T50T-100-A
C1174-C
EXTENSION HOUSING
ToolT52L-7000-GAE
OR 7000-G
C1O28-B
Dial Indicator
C1385-B
GROUPS 5-6
96
25. Position a new gasket on the
adapter, using sealer to hold the gasket in place.
26. Move the reverse shifter lever
to bring the shift fork to the extreme
forward position (Fig. 206). Pull the
lever outward so that the reverse fork
will clear the reverse gear on assembly. Slide the reverse gear forward
on the output shaft until it engages
the reverse idler gear.
27. Position the extension housing over the output shaft and carefully push the housing forward. Insert the reverse idler shaft into the
reverse idler gears. When the reverse
shifter fork seats in the reverse gear
shift collar groove (Fig. 224), push
the reverse snifter shaft into position.
Move the reverse gear rearward with
the shift lever, and seat the extension
housing against the adapter plate.
EXTENSION HOUSING
Tool-T52L-7000-HAE
OR 7000-HF
BUSHING
C1O29-C
IDENTIFICATION TAG
A new improved pump seal is being used in the 1963 models. The new
seal is Vs -inch narrower than the seal
previously used. The seal is removed
GROUP 6
TRANSMISSION MODEL
97
DETAIL CHANGES
D1252-C
PRY BETWEEN
GOVERNOR COUNTERWEIGHT AND
OIL DISTRIBUTOR SLEEVE
-GOVERNOR
COUNTERWEIGHT
D1284-A
D1285-A
The 1963 converter has been modified to replace the sprag-type clutch
with a roller-type clutch. Also, the
bronze and aluminum thrust washers
have been replaced with aluminum
coated stamped thrust washers and
flat steel retainers.
REAR PUMP-
D1289-A
98
GROUP 6
To replace the toggle lever shaft,
press it out of the case after all of
the parking pawl linkage has been
removed. Press a new shaft into the
case, until the end of the shaft is
flush with the case. With the shaft in
position, the toggle lift lever (Fig.
232) should be centered on the toggle
link pin, when in the applied position.
ACCUMULATOR TUBE
PISTON
SEALS
SPRING
SEAL
RETAINER
SNAP RING
D1287-A
TOGGLE
LIFT
LEVER
FRONT SERVO
D1290- A
IRAL GROOVE
PATTERN
(METALLIC)
(5 REQ'D.)
2 ADJACENT TEETH
REMOVED 180 APAR
REAR CLUTCH
EXTERNAL
SPLINE PLATES
WAFFLE GRID
PATTERN
(RESILIENT)
PARKING LINKAGE
Figure 232 illustrates the new type
parking pawl linkage in the transmission. The control rod incorporates a
compression spring to drive the tog-
(3 REQ'D.)
3/32"
NOMINAL - FLAT
'(3 REQ'D.)
D 1296 A
GROUP 6
CENTER SUPPORT
99
PLANETARY CLUTCH
CHAMFER ON PRODUCTION
PART, ONLY-SERVICE PART NOT CHAMFERED
PLANET CARRIER
D1288-A
INSTALLATION CENTER
SUPPORT WITH SQUARE EDGE
1. Install the center support and
the rear band in the case.
2. Install the primary sun gear
thrust bearing race and the bearing
in the planet carrier using petroleum
jelly to retain them in place.
3. Lubricate the bearing surface
on the center support, the rollers of
the planetary clutch and the cam
race in the carrier with vaseline.
4. Install the planetary clutch on
the center support with the "saw
teeth?' of the clutch cage pointing in
the clockwise direction as viewed
from the rear (Fig. 236). Make sure
that all rollers are in the cage.
5. Position the planet carrier on
the support so that the cams in the
carrier engage the "saw teeth" on the
clutch cage.
6. Push the planet carrier forward
until the rollers are felt to contact
the surface of the cam race.
7. While applying forward pressure on the carrier, rotate it counterclockwise as viewed from the rear.
This will cause the rollers to roll
toward the large opening end of the
cams in the race, compressing the
springs slightly, so that the rollers
will enter the cams.
8. Some rollers may become
cocked preventing their entry into
the outer race. These rollers must be
positioned individually with a small
INSTALLATION CENTER
SUPPORT WITH CHAMFERED
EDGE
1. Install the center support and
the rear band in the case.
2. Install the primary sun gear
rear thrust bearing race and the bearing in the planet carrier using petroleum jelly to retain them in place.
3. Lubricate the bearing surface
on the center support, the rollers of
the planetary clutch and the cam
race in the carrier with petroleum
jelly.
4. Install the planetary clutch in
the carrier (Fig. 235).
5. Carefully position the planet
carrier on the center support. Move
the carrier forward until the clutch
rollers are felt to contact the bearing
surface of the center support.
6. While applying forward pressure on the planet carrier, rotate it
ROTATE CARRIER
COUNTER CLOCKWISE
D1292-A
100
GROUPS 6-7
ROTATE
CARRIER
COUNTER
CLOCKWISE
CENTER
SUPPORT
F I G . 237Transmission Control
Lever for Use with Floor Shift
Models
SAWTEETH IN
CLOCKWISE
DIRECTION
MOVE ROLLER
TOWARD CENTER
D1291-A
MODEL APPLICATION
TRANS.
MODEL
USAGE
ENGINE
PCH-B
PCP-C
PCP-D
Galaxie
Galaxie (Column Shift)
Galaxie (Floor Shift)
GROUP 7
101
COVER PLATE
THROTTLE PRESSURE
REDUCING VALVE ^
COVER PLATE
12 SHIFT VALVE
SPRINGS
COMPENSATOR-
VALVE SPACER
ORIFICE CONTROL VALVE,
PLUG, AND SPRING
REAR PUMP
CHECK VALVE
DOWNSHIFT VALVE,
SPRING, AND STOP PLATE
1 2 SHIFT VALVE
GOVERNOR PLUG AND
COVER PLATE
MANUAL VALVE
SCREW
COMPENSATOR CUT-BACK VALVE,
SPRING, AND COVER PLATE
CONTROL PRESSURE
REGULATOR VALVE SPRING
REAR SERVO
CHECK BALL
SPRING RETAINER
D1185-D
Fig. 239.
GROUPS 7-8
102
5. After the valve body bolts have
been installed and torqued to specifications, the two separator plate attaching screws may be removed to
install the hold-down and throttle
valve stop plates.
REAR SERVO
APPLY PASSAGE
CHECK BALL POCKET
SEPARATOR PLATE
UPPER VALVE
BODY
FRONT PUMP
CHECK VALVE
D1293-A
NEW HUB
NEW ROTOR
DRIVE LUGS
OLD HUB
OLD ROTOR
D1294A
ice procedures outlined in the previous shop manuals apply to the 1963
Galaxie and Monterey. Refer to
Group 8 of the 1962 Galaxie Shop
GROUP 9
103
GROUP 9-STEERING
The 1963 maintenance recommendations covered in Group 14, and the
1963 specifications are in Group 15
of this manual.
All the service procedures outlined
in Group 9 of the 1962 Galaxie Shop
Manual and in Section 5 of the 1961
Mercury Maintenance Manual remain the same with the following exceptions.
MOVABLE STEERING
COLUMN
A movable steering column is
available as a factory installed option
on 1963 Galaxie and Monterey cars.
It will be available only in conjunction with an automatic transmission
and power steering.
When the transmission selector
POSSIBLE CAUSES
Lack of lubrication.
Nylon wedges bound up.
Nylon shipping guide not removed
at assembly.
Mounting bracket rubbing on
track.
LATERAL LOOSENESS IN
COLUMN WHEN LOCKED
VERTICAL LOOSENESS IN
COLUMN WHEN LOCKED
BINDING, ROUGH, OR
RASPING COLUMN
MOVEMENT
HARD COLUMN
MOVEMENT
GROUP 9
104
TOP VIEW
PIVOT BOLT
BOTTOM VIEW
STEERING COLUMN
LATCH
LATCH
SET SCREW
SET SCREW
LATCH CAM
LATCH CAM
STARTER NEUTRAL
SWITCH OPENING
G1169-A
PIVOT BRACKET
1. On a car with a movable steering column, remove the pivot bracketto-steering column pivot bolt nut and
washers, then the three bracket-tosteering gear housing bolts (Fig. 243).
Remove the pivot bracket from the
gear housing and column pivot bolt.
STEERING GEAR
HOUSING
G1168-A
STEERING GEAR
INSTALLATION
TOP VIEW
UPPER STEERING
SHAFT
BOTTOM VIEW
NYLON INSERT
LATCH SPRING
INCH
CLEARANCE LIMIT
PARK
POSITION
STOP
HOUSING
TO FRAME
G1167-A
G1164-A
105
GROUPS 9-10
3. Lower the car and install the
clamp bolt that locks the flex joint to
the steering gear worm shaft (Fig.
244).
4. After turning the steering wheel
to the left to move the ball nut below
the filler hole, remove the filler plug
and fill the steering gear with specified lubricant. Fill the gear until lubricant comes out of the housing
cover lower bolt hole. Install the filler
plug and the cover bolt. Torque the
bolt to specifications.
5. On cars with a movable steering
column, position the pivot bracket on
the pivot bolt and the steering gear
housing (Fig 243). Install the washers
and retaining nut on the pivot bolt
and torque to specifications. Install
the three bracket-to-steering gear
housing bolts and torque to specifications.
FRONT SPRING
REPLACEMENT
Follow the procedure in the 1962
Galaxie Shop Manual and the 1961
Mercury Maintenance Manual with
the following exceptions:
Removal. After disconnecting the
lower ball joint stud from the spindle,
break loose but do not remove the
following: the threaded bushing that
retains the suspension lower arm and
anti-harsh crank to the frame; the nut
that retains the front end of the arm
ADJUSTING
NUT
GREASE
CAP
OUTER
BEARING
CONE AND
ROLLER
INNER BEARING
CONE AND
ROLLER
WHEEL
ASSEMBLY
COTTER
PIN
HUB BOLT
F1O56-C
106
GROUP 10
F1138-A
Removal
1. Disconnect the lower ball joint
from the wheel spindle, and remove
the front spring as outlined in the
1962 Galaxie and the 1961 Mercury
Manuals.
2. Remove the bolt, nut, and
washers that retain the rear end of
the lower arm to the frame (Fig. 247).
Remove the threaded retainer bushing and shims from the frame and
anti-harsh crank, then remove the
suspension lower arm from the car
(Figs. 247 and 248).
3. Remove the crank retaining
nut, and remove the anti-harsh crank
and washer from the suspension lower
arm.
Installation. The replacement lowTHREADED RETAINER BUSHING
LOWER SUSPENSION A R M ,
SERRATED WASHER
FRONT
I
BUSHING
WASHER
CRANK
RETAININ
NUT
REAR RETAINING
BOLT NUT
REAR RETAINING BOLT
SHIMS
CRANK
THROW
Fl 173-A
LOWER SUSPENSION
ARM REPLACEMENT
SHIMS
^ *
ANTI-HARSH
CRANK
THREADED
RETAINER BUSHING
F1172-A
GROUPS 10-11
Tool-T63P-3044-A
107
HYDRAULIC SYSTEM
BLEEDING
CONTROL VALVE
PLUNGER
CONTROL VALVE HUB
O-RING
^RETURN SPRING
'RETAINER
H1235-B
F I G . 2 5 1 -Assembly of Control
Valve Components to Valve Hub
POWER BRAKES
BATTERY TERMINAL
OF STARTER RELAY
ACCESSORY
TERMINAL
CHARGE
INDICATOR
LIGHT
ALTERNATOR
OUTPUT TERMINAL
FORD ALTERNATOR
ALTERNATOR TESTS
(GALAXIE)
Figure 252 shows the alternator
charging circuit schematic. Figure
253 shows the alternator output connector block.
Alternator Output Test. When an
alternator output test is conducted
off the car, a test bench must be used.
Follow the procedure given by the
test bench manufacturer.
SLIP RINGS
REGULATOR
J1210-A
GROUP 11
108
CONNECTOR
BLOCK
ji221-A
ALTERNATOR
J122O-A
GROUP 11
Good diodes will be indicated as
on the meter in Figs. 255 and 256 (2
amps or more and readings alike
within 2 scale divisions).
CONTACT
EACH
DIODE PAIR
WITH SHARP
Probe
J1211-A
109
FIELD TERMINAL
J1213-A
J1212-A
GROUP 11
110
ALTERNATOR TESTS
(MONTEREY)
Figure 252 shows the alternator
charging circuit schematic. Figure
253 shows the alternator output connector block.
Alternator Output Test. When an
alternator output test is conducted
off the car, a test bench must be used.
Follow the procedure given by the
test bench equipment manufacturer.
When the alternator is removed from
the car for this purpose, always disconnect a battery cable, as the alternator output connector is connected
to the battery at all times.
To test the output of the alternator
on the car, proceed as follows:
1. Charge the battery if necessary.
Make the connections as shown in
Fig. 257A. Be sure that the Generator
Field Control is in the OPEN posi-
VAT-20-B OR
EQUIVALENT
\
GENERATOR FIELD
CONTROL SET AT
OPEN POSITION
(MAXIMUM
COUNTER
CLOCKWISE)
VAT-20-B OR EQUIVALENT
INSERT
SPADE LUGS
IN THE A + AND
F OPENINGS
BATTERY
ALTERNATOR
BATTERY
J1233-A
J1224-A
GROUP 11
Add 5 amperes to this reading to
obtain total alternator output.
8. Stop the engine, return the Generator Field Control to the OPEN
position and disconnect the test
equipment.
An output of two to five amperes
below specifications indicates an open
diode rectifier. An output of approximately ten amperes below specifications indicates a shorted diode rectifier. An alternator with a shorted
diode will usually whine, which will
be most noticeable at idle speed.
A shorted positive diode may sometimes be accompanied by alternate
flashing of the oil pressure and charge
indicator lights when the ignition
switch is off. The field relay contacts
will also be closed and the battery
will be discharging through the field
to ground.
Under this condition, the instrument constant voltage regulator will
receive power through the charge indicator light. The operating of the
constant voltage regulator through
the charge indicator light causes the
alternate flashing of the lights. When
the regulator contacts close, the oil
pressure light becomes dim and the
charge indicator light becomes bright.
When the contacts open the oil pressure light becomes bright and the
charge indicator light becomes dim.
Diode Test. To test the positive
diodes, make the connections shown
in Fig. 255. Contact the probe to
each diode lead. Make sure that the
tip of the probe is sharp and that it
penetrates the varnish at the diode
terminal.
To test the negative diodes, make
the connections shown in Fig. 256.
Follow the same procedure as for the
positive diodes.
Good diodes will be indicated as
on the meter in Figs. 255 and 256 (2
amps or more and readings alike
within 2 scale divisions).
Field Open or Short Circuit Test.
Make the connections as shown in
Fig. 257B. The normal current draw,
as indicated by the ammeter, should
be 2.9-3.1 amperes at 12 volts. If
there is little or no current flow, the
field has a high resistance or is open,
or the brushes are not making proper
contact with the slip rings. A current
flow considerably higher than that
specified above, indicates shorted or
grounded turns. If the test shows that
the field is shorted and thefieldbrush
assembly is not at fault, the entire
rotor must be replaced.
111
ALTERNATOR REPLACEMENT
SHIELD
SPACER
INSTALLED
Removal
1. Disconnect the battery ground
cable.
2. Loosen the shield front mounting bolt (Fig. 258).
3. Remove the cable b r a c k e t
mounting screw from the air deflector, and position the cables out of
the way.
4. Remove the remaining shield
mounting bolt and remove the shield.
5. Loosen the alternator mounting
bolt and remove the adjustment arm
to alternator bolt.
6. Disengage the alternator belt.
Remove the alternator mounting bolt
and spacer, disconnect the alternator
cable and remove the alternator.
Installation
1. Attach the alternator cable. Position the alternator to the engine,
and install the spacer and alternator
mounting bolt finger-tight (Fig. 258).
2. Install the adjustment arm to
alternator bolt.
3. Adjust the belt tension using
tool T63L-8620-A. Apply pressure
on the alternator front housing only.
Tighten the adjusting bracket bolt
and the mounting bolt.
4. Position the shield over the alternator and install the mounting
bolts.
5. Position the cables and cable
mounting brackets to the shield and
install the mounting screw.
6. Connect the battery ground
cable.
ALTERNATOR OVERHAUL
Figure 259 shows a disassembled
view of the Ford alternator.
Disassembly
1. Mark both end housings with
SHIELD REMOVED
J1209-A
112
GROUP 11
BEARING RETAINER
THROUGH BOLTS
BEARING
BRUSH AND
DIODE END HOUSING
J1166-A
Rubber Band
J12O3-A
J1162-A
J1167-A
GROUP 11
Tool-T63L-10300-A
J1163-A
113
Dial Indicator
ROTATE ROTOR
SHAFTS O N
BEARING SURFACES
.4
j
/
"V" Block
J12O8-A
J1165-A
114
GROUP 11
J1206-A
'
He<
"
Sink a n d T e f m i
'
L; I ! l \ , t h e
J1207-A
resist
<* to supply a d e
ent ? V
alterna
tor builds
field c u
recti
REGULATOR AND
CIRCUrr TESTS (G4LAXIE)
T
n 1
are closed
field Z,'
REGULATOR
fl atS b e t w e e n
CUrrent is reduc
'he c
e d by
m ter
'
' W e r c o n t e cts
U r r e n t flows
to the
>
and
ll s
serves
necessary,
CHARGE INDICATOR
LIGHT TERMINAL
' h
/oltage b
.4uild-up.
charge indicator light is shunted
char
FIELD
TERMINAL
FIELD RELAY
TERMINAL
MINAL FOR
FOR
SUPPLY VOLTAGE
j12l4.A
GROUP 11
closes immediately, even with the
field resistance close to the OFF position, use a 6-volt battery for this test.
If the closing voltage is not to specifications, adjust the relay (Fig. 274).
Voltage Limiter Test. For test
purposes, the lower stage (armature
vibrating on the lower contact) regulation is used. Voltage limiter calibration tests must be made with the
regulator cover in place and the
regulator at normal operating temperature (equivalent to the temperature after 20 minutes of operation on
the car with a 10-ampere load).
Make the test connections as shown
in Fig. 271. Turn all accessories off,
including door operated dome lights.
Close the battery adapter switch,
start the engine, then open the adapter switch. Attach the voltage regulation thermometer to the regulator
cover. Operate the engine at 2000
rpm for 5 minutes. Turn the master
control to the cutout relay position.
If the ammeter indicates more than
10 amperes, stop the engine, remove
the battery cables and charge the
battery.
When the battery is charged, and
the voltage regulator has been tem-
115
Ambient Air
Temperature F.
50
75
100
125
150
175
Voltage Regulation
Setting (Volts)
14.3-15.1
14.1-14.9
13.9-14.7
13.8-14.6
13.6-14.4
13.5-14.3
Yellow
J1215-A
ALTERNATOR
Green
J1216-A
116
equipment will not show on the ammeter and will have to be taken into
account when making this test.
ALTERNATOR TO BATTERY
GROUND TERMINAL. To check
the alternator to battery ground terminal voltage drop, make the connections as shown in Fig. 273. Close
the battery adapter switch, start the
engine and open the adapter switch.
Slowly increase the engine speed
until the ammeter reads 20 amperes.
The voltage indicated on the voltmeter should be less than 0.1 volt.
REGULATOR AND CIRCUIT
TESTS (MONTEREY)
The tests presented are outlined
for on the car operation. Be sure
that the regulator is at "normal" operating temperature (equivalent to
the temperature after 20 minutes of
operation on the car with 10 ampere
load).
Field Relay Test. Disconnect the
regulator terminal plug, and remove
GROUP 11
the regulator cover. Make the connections as shown in Fig. 273A.
Slowly rotate the field resistance control clockwise from the OPEN position until thefieldrelay contacts close.
Observe the voltmeter reading at the
moment that the relay closes. This is
the relay closing voltage. If the relay
closes immediately, even with the
field resistance close to the OPEN
position, use a 6-volt battery for this
test. If the closing voltage is not to
specifications, adjust the relay.
Voltage Limiter Test. For test
purposes, the lower stage (armature
vibrating on the lower contact) regulation is used. Voltage limiter calibration tests must be made with the
regulator cover in place and the regulator at "normal" operating temperature (equivalent to the temperature after 20 minutes of operation
on the car with a 10 ampere load).
Make the test connections as
shown in Fig. 273B. Turn all accessories off, including door operated
dome lights. Close the battery adapter switch, start the engine, then open
the adapter switch. Attach the voltage regulation thermometer to the
regulator cover. Operate the engine
at 2000 rpm for 5 minutes. Turn the
master control to the DIRECT position. If the ammeter indicates more
than 10 amperes, stop the engine, remove the battery cables and charge
the battery.
When the battery is charged, and
the voltage regulator has been temperature stabilized, rotate the master
control to the XA OHM position, the
ammeter should indicate less than 2
amperes.
Cycle the regulator as follows:
Stop the engine, close the adapter
switch, start the engine, and open
the adapter switch. Allow the battery
to normalize for a short time, then
read the voltmeter. Read the thermometer, and compare the voltmeter
reading with the voltage given in
Table 1A for the ambient temperature
Yellow
J1219-A
J1218-A
GROUP 11
indicated on the thermometer. If the
regulated voltage is not within specifications, make a voltage limiter adjustment. After each adjustment, be
sure to cycle the regulator before
each reading. The readings must be
made with the cover in place.
Circuit Resistance Tests. For the
purpose of this test, the resistance
values of the circuits have been converted to voltage drop readings for
a current flow of 20 amperes. If the
battery is fully charged disconnect
the regulator and run a jumper from
the A+ terminal to the F terminal of
the cable connector, before making
the test.
ALTERNATOR TO BATTERY
POSITIVE TERMINAL. Make the
connections as shown in Fig. 273C.
Turn off all electrical accessories, and
lights. Close the battery adapter
switch, start the engine, then open
the battery adapter switch. Slowly
Voltage
Regulation
Setting (Volts)
50
75
100
125
150
175
14.3-15.1
14.1-14.9
13.9-14.7
13.8-14.6
13.6-14.4
13.5-14.3
117
the engine and open the adapter
switch. Slowly increase the engine
speed until the ammeter reads 20
amperes. The voltage indicated on
the voltmeter should be less than 0.1
volt.
REGULATOR ADJUSTMENTS
Erratic operation of the regulator,
indicated by erratic movement of the
voltmeter during a voltage limiter
test, may be caused by dirty or pitted
regulator contacts. Use a very fine
abrasive paper such as silicon carbide, 400 grade, to clean the field relay and the voltage limiter contacts.
Wear off the sharp edges of the abrasive by rubbing it against another
piece of abrasive paper. Fold the
abrasive paper over and pull the
paper through the contacts to clean
them. Keep all oil or grease from contacting the points. Do not use compressed air to clean the regulator.
When adjusting the gap spacing use
VAT-20-B OR EQUIVALENT
BATTERY
J1225-A
J1229-A
118
only hospital clean feeler gauges.
Regulator Gap Adjustments. The
difference between the upper stage
and lower stage regulation (0.3 volt),
is determined by the voltage limiter
point and core gaps. Make the gap
adjustments with the regulator removed from the car.
Adjust the point gap first. Loosen
the left side lock screw VA turn. Use
a screw driver blade in the adjustment slot above the lock screw. Adjust the upper contact until there is
0.010 to 0.015-inch gap between the
lower contacts. Tighten the lock
screw and recheck the contact gap.
Adjust the core gap with the upper
contacts closed. Loosen the center
lock screw VA turn. Use a screwdriver blade in the adjustment slot under
the lock screw. Adjust the core gap
for 0.045 to 0.052-inch clearance between the armature and the core at
GROUP 11
the edge of the core closest to the
contact points. Tighten the lock
screw and recheck the core gap.
Regulator Voltage Adjustments.
Final adjustment of the regulator
must be made with the regulator at
normal operating temperature.
The field relay closing voltage is
adjusted by bending the spring arm
(Fig. 274). To increase the closing
voltage, bend the spring arm down.
To decrease the closing voltage, bend
the spring arm up.
The voltage limit is adjusted by
bending the voltage limiter spring
arm (Fig. 274). To increase the voltage setting, bend the adjusting arm
downward. To decrease the voltage
setting, bend the adjusting arm upward.
Before setting the voltage and before making a final voltage test, the
alternator speed must be reduced to
VAT-20-B OR
EQUIVALENT
AUTOLITE 40-AMPERE
GENERATOR
ALTERNATOR
J1227-A
GROUP 11
GAP ADJUSTMENTS
VOLTAGE LIMITER
VOLTAGE ADJUSTMENTS
CONTACT GAP
ADJUSTING
SLOTS
VOLTAGE
LIMITER
CORE GAP
ADJUSTING SLOTS
119
VOLTAGE LIMIT
"^SS**^
BND
ADJUST
|NG
A R M
DO
WN
TO INCREASE CLOSING
VOLTAGE. BEND ARM UP TO
DECREASE CLOSING VOLTAGE
J1217-A
FIELD TERMINAL
FLD
100 OHMS
H u n
V^^
4H
I CURRENT
LIMITER
CUT OUT
BAT
REGULATOR
BATTERY
BATTERY TERMINAL
OF STARTER RELAY
J1234-A
120
GROUP 11
BEARING AND
OIL FELT
COVER
OIL FELT
INNER OIL FELT RETAINER
OUTER OIL FELT RETAINER
SHAFT
OIL FELT
OILER
OILER
BEARING
COVER
GASKET
BEARING
OIL FELT
BEARING
&
PULLEY SPACER
THROUGH BOLTS
PULLEY
BRUSH ASSEMBLY
J1230-A
J1085-A
GROUP 11
121
AMMETER
BATTERY
POSITIVE LEAD
DO NOT CONNECT
LEAD TO BEARING
SURFACE
TO GENERATOR REGULATOR
STARTER RELAY
BATTERY
M)
J1O87-C
TC
IGNIT irw
COIL
Red-Blue Stripe
000
STARTER
AUTOMATIC
TRANSMISSION ONLY
STARTER NEUTRAL SWITCH
CLOSED WITH SELECTOR IN
N OR P POSITION
~ / ^ Red-Blue Stripe
JSTARTER SWITCH
T (ON IGNITION SWITCH)
TO BATTERY TERMINAL OF
GENERATOR REGULATOR
J1O83-C
test will determine if the winding insulation has failed, permitting a conductor to touch the frame or armature core.
To determine if the armature
windings are grounded, make the
connections as shown in Fig. 282. If
the voltmeter indicates any voltage,
the windings are grounded.
Grounded field windings can be
detected by making the connections
as shown in Fig. 283. If the voltmeter
indicates any voltage, the field windings are grounded.
Starter Circuit Test. Excessive re-
VOLTMETER POSITIVE L E A D - ^
TOUCH TO COMMUTATOR J 1 O 8 8 - B
F I G . 282-Armature Grounded
Circuit Test
JUMPER LEAD
JUMPER LEAD
DISCONNECT
HOLDING COIL
GROUND LEAD
STARTER
AUTOMATIC
TRANSMISSION ONLY
STARTER NEUTRAL SWITCH
CONNECT TO
INSULATED BRUSH,
THEN TO
HOLDING COIL
GROUND LEAD.
STARTER SWITCH
(ON IGNITION SWITCH)
VOLTMETER
NEGATIVE LEAD
TO BATTERY TERMINAL OF
GENERATOR REGULATOR
DISCONNECT
HOLDING COIL
GROUND LEAD
STARTER
TERMINAL
VOLTMETER
POSITIVE LEAD
J1O95-B
J1O84-D
INSERT INSULATOR
BETWEEN CONTACTS
VOLTMETER
VOLTMETER
POSITIVE
NEGATIVE
LEAD
LEAD
J1094-A
GROUP 11
122
TO
IGNITION
SWITCH
STARTER
TO
COIL
J1O73-B
Tool-10044-A
STARTER
FRAME
" V " Block
BE SURE TO SEAT DRIVE HEAD
IN SCREW SOCKET
J1O59-B
STARTER DRIVE
ACTUATING LEVER
ACTUATING LEVER
RETURN SPRING
COVER-
SNAP
RING
SNAP RING
RETAINER
"V" Blocks
J1O89-B
GROUP 11
GROUND BRUSH
STARTER DRIVE
ACTUATING COIL
AND HOLDING
COIL
TERMINAL
SCREW
*>'
GROUND BRUSH
J1O92-C
123
the through bolts. Be sure that the
snap ring retainer is seated properly
in the drive gear housing.
9. Place the brushes in their holders, and center the brush springs on
the brushes.
10. Position the actuating lever
cover and brush cover band, with
gasket, and then tighten the retaining
screw.
Commutator Turning. Check the
commutator runout as shown in Fig.
287. If the surface of the commutator is rough or more than 0.002
inch out-of-round, turn it down.
Brush Replacement. Replace the
starter brushes when they are worn
to half size. Always install a complete
set of new brushes.
1. Loosen and remove the brush
cover band and starter drive actuating lever cover. Remove the brushes
from their holders.
2. Remove the two through bolts
from the starter frame.
3. Remove the drive gear housing,
and the actuating lever return spring.
4. Remove the starter drive actuating lever pivot retaining pin and
lever, and remove the armature.
5. Remove the brush end plate.
6. Remove the ground brush retaining screws from the frame and
remove the brushes (cut the ground
brush nearest the starter terminal)
from the terminal block.
7. Unsolder (or cut) the brush
leads from the field coils.
8. Clean and inspect the starter
motor.
9. Replace the brush end plate if
the insulator between the field holder
brush and the end plate is cracked or
broken.
10. Solder the new field brushes
to the field coils using rosin core
solder (Fig. 288). Use a 300 watt
iron.
11. Install the ground brush leads
to the frame with the retaining
screws.
12. Clean the commutator with
#00 or #000 sandpaper.
13. Position the brush end plate
to the starter frame, with the end
plate boss in the frame slot.
14. Position the fiber washer on
the commutator end of the armature
shaft and install the armature in the
starter frame.
15. Install the starter drive gear
actuating lever to the frame and starter drive assembly, and install the
pivot pin.
124
GROUPS 11-12
J1093-A
12 VOLTS
FROM A TO C
WITH IGNITION
SWITCH ON
AND WIPER
SWITCH
OFF
K1408-A
GROUP 12
125
grease to the output gear teeth and
shaft bearing surface. Place the thrust
washer on the shaft and insert the
shaft in the bearing. Make certain
that the parking switch lever is clear
of the cam and gear assembly.
3. Place the spacer 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.
MOTOR
CAM ACTUATED PUSH ROD
PARK POSITION
BEGINNING OF
PARK POSITION
OFF
POSITION
ON
POSITION
BATTERY
O N A N D OFF SWITCH
K1406-A
OUTPUT ARM
SWITCH TERMINAL
INSULATOR SLEEVE
SWITCH TO PARKING
LEVER PIN
THRUST WASHER
GEAR HOUSING
GEAR COVER
K1405-A
GROUP 12
126
in the gear housing and remove the
brush retracting wires.
7. Holding the armature in position, install the terminal insulating
sleeve, motor housing and magnet assembly, and through bolts. Seal the
area where the terminal insulator
sleeve seats against the motor and
gear housings.
8. Apply Sun Prestige grease to the
worm gear and idler gear, and install
the idler gear, thrust washer and retainer.
9. Install the armature shaft end
play adjusting screw and adjust the
end play to 0.003-inch.
10. Apply a generous amount of
Sun Prestige grease to the area around
the end of the armature shaft. Install
the gear housing cover and ground
terminal.
Two-Speed Electric Motor Disassembly. The two-speed electric motor
may be disassembled for service of
the drive mechanism parts.
1. Remove the gear housing cover
plate and gasket (Fig. 293).
2. Remove the output shaft retainer and spacer washer.
3. Remove the crankpin bearing
retainer and remove the spacer washer and cam return spring assembly.
4. Remove the arm and link assembly.
5. Remove the crankpin bearing
cam.
6. Remove the input gear retainer
and outer spacer shim, and remove
the input gear and inner spacer shim.
7. Remove the wiper arm lever nut
and lock washer.
8. Remove the wiper arm lever
and spacer, and remove the output
shaft and gear assembly from the
housing.
9. The output gear may be removed from its shaft by tapping with
a fiber hammer. Be careful not to
damage the end of the shaft.
The worm drive gear and armature assembly is not serviced.
Two-Speed Electric Motor
Assembly and Adjustment
1. Tighten the motor cover. Adjust the motor shaft end play to 0.0000.005 inch by turning the shaft stop
screw. Measure with a feeler gauge
between the stop screw and the motor
shaft.
2. Install the input gear shim or
the input gear shaft and install the
RETAINER
OUTPUT GEAR
SPACER WASHER
GEAR
HOUSING COVER
OUTPUT SHAFT
GASKET
SPACER
ER
TERMINAL
C
TERMINAL
B
RING GEAR
RETAINER
MOTOR SHAFT
STOP SCREW
WORM
TESTING
TO PARK
B TERMINAL
C TERMINAL
Yellow TO
CONNECTIONS
CRANKPIN
RETAINER
BEARING CAM
CAM RETURN
SPRING ASSEMBLY
TO VOLTAGE SOURCE
TO Blue AND Red
White Black TO GROUND
GROUP 13
127
GROUP 13-BODY
The 1963 maintenance recommendations are in Group 14, and the 1963
specifications are in Group 15 of this
manual.
All the service procedures outlined
in Group 13 of the 1962 Galaxie
Shop Manual remain the same for
1963 except as described herein. All
the service procedures in Section 11
of the 1961 Mercury Maintenance
Manual and the 1962 portion of this
manual are the same except as described herein.
HOOD LOCK ADJUSTMENT
GALAXIE
HOOD LOCK
SAFETY CATCH
HOOD LOCK
LOCK DOWEL
LOCK NUT
N1241-A
LOCK NUT
GALAXIE
N1240-A
REMOVAL
1. Remove the two bolts that at-
GROUP 13
128
RADIATOR
SUPPORT BRACE
N1242-A
INSTALLATION
6. Remove the two bolts that secure the skirt of the fender to the
fender apron.
REMOVAL
1. Working from the underside of
the fender, remove the 3 sheet metal
screws that attach the splash shield
GROUP 13
129
BRACKET
V I E W BB
N1243-A
9. Remove the two bolts that attach the skirt of the fender to the
apron.
10. Remove the bolt that attaches
the lower end of the skirt to the
rocker panel.
11. Carefully lift the fender off the
fender apron and cowl.
M1095-A
INSTALLATION
1. Apply a bead of sealer to the
apron, grille and the radiator support
as shown in Fig. 297.
2. When installing the fender,
make sure that all bolts are installed
before tightening any of them. Carefully position the fender over the
apron and on the cowl. Make sure
that the lip on the fender skirt is on
the outside of the apron. Install the
two fender skirt-to-apron bolts.
3. Install the two bolts that attach
the fender to the upper end of the
cowl. Working from the inside of the
car, install the nut that secures the
fender to the cowl.
4. Install the bolts that attach the
fender to the upper end of the apron
and to the radiator support brace.
5. Install the nut that secures the
fender to the end of the grille.
6. Install the bolt that attaches the
fender to the stone shield.
7. Install the two bolts that secure
the fender to the radiator support.
130
GROUP 13
4. Working from the underside of
the front fenders, remove the three
metal screws that attach each splash
shield to the fender and remove the
shields.
5. Remove the two nuts that secure each outer headlamp housing to
the fender.
HEADLAMP
DOOR
N124 7- A
REMOVAL
1. Remove the four sheet metal
screws from each headlamp door
(Fig. 299). Remove the doors from
the headlamp housings.
2. Remove the four nuts that attach the lower end of the grille to the
stone deflector.
3. Remove the four attaching
screws from the upper end of the
grille.
4. Remove the two ornament at-
taching screws and remove the ornament from the hood latch handle.
5. Lift the grille from the car.
INSTALLATION
1. Position the grille on the mounting brackets and install the four upper attaching screws.
2. Secure the grille to the stone
deflector with the four attaching nuts.
3. Secure each headlamp door to
the housings with four sheet metal
screws.
4. Secure the ornament to the
hood latch handle with two screws.
GRILLE REPLACEMENT
MONTEREY
REMOVAL
1. Remove the battery.
2. Remove the two nuts that attach each inner headlamp to the radiator support.
3. Disconnect the headlamp wires
at the connectors.
N1248-A
131
GROUP 13
ECCENTRIC BOLT
RUBBER
BUMPER
LICENSE PLATE
BOLT
NUT
N-1277-A
INNER ARM
-~\l
REINFORCEMENT
BAR
ECCENTRIC BOLT
BOLT
END BRACE
ABSORBER
RUBBER BUMPER
GROUP 13
132
the headlamp housings to the fenders
and radiator support.
7. Tighten all grille attaching bolts
and nuts at this time.
8. Secure each splash shield to the
fenders with three sheet metal screws.
9. Connect the headlamp wires to
their respective terminals.
10. Install the battery.
FRONT BUMPER REPLACEMENT
GALAXIE
REMOVAL
1. Disconnect the parking lamp
wires from their terminals.
2. Support the bumper with a jack
or stands.
3. Remove the four bolts, flat
washers and lock washers that secure
the two bumper arms to each frame
side rail (Fig. 301).
4. Carefully remove the bumper
and arms from the car.
5. Remove the parking light attaching nuts and retainers. Remove
the parking lights.
LOCK ACTIVATING
ROD OUTER
DOOR
LOCK
REMOTE
CONTROL
REMOTE CONTROL
ROD
DOOR
LOCK
N1249-A
REMOVAL
1. Disconnect the parking lamp
wires from their terminals.
2. Support the bumper with a jack
or stands.
3. Remove the four bolts, and lock
washers that secure the three bumper
arms to each frame side rail (Fig.
302).
4. Carefully remove the bumper
and arms from the car.
5. Remove the parking light attaching nuts and retainers. Remove
the parking lights from the bumper
bar.
6. Remove all bumper arm bolts
and spacer washers from the bumper.
Keep all washers (shims) with their
respective arms to permit proper
alignment of the new bumper.
INSTALLATION
1. Assemble all arms to the
bumper bar (Fig. 302) making sure
that all washers (shims) are in their
original location. Do not tighten the
bumper bolts at this time.
GROUP 13
2. Secure the parking lights to the
bumper bar with retainers.
3. Secure the bumper arms to the
car frame with four bolts and lock
washers. Make certain that the two
eccentric bolts are in the forward
holes of the frame side rails.
4. Tighten all bumper arm-tobumper bar bolts to 17-23 ft.-lbs.
5. Turn each eccentric bolt (forward bolts) as required to align the
bumper. Tighten the bumper arm attaching bolts to 60-80 ft.-lbs. when
the bumper is in proper alignment.
6. Connect the parking lamp wires
to their respective terminals.
133
REMOVAL
INSTALLATION
1. Apply a film of sealer to the
door lock mounting surface.
2. Working through the access
hole in the door inner panel, hold the
lock in position and secure it in place
with three screws and lock washers.
3. Using two new sleeve nuts, connect the lock control rod to the bellcrank and lock. Insert the rod in the
FINISH PLATE
REMOVAL
1. Remove the door trim panel.
2. Remove the water shield from
the door inner panel.
3. Disconnect the remote control
link from the remote control and
from the lock.
4. Disconnect the door lock actuating rods (Fig. 303) from the door
lock.
5. Remove the three screws and
lock washers that attach the door
lock to the inner panel.
6. Remove the lock through the
access hole in the inner panel.
INSTALLATION
1. Apply a film of sealer to the
door lock mounting surface.
2. Working through the access
hole in the door inner panel, hold the
lock in position and secure it in place
with three screws and lock washers.
3. Using two new sleeve nuts, connect the two door lock actuating rods
to the lock.
4. Using two new sleeve nuts, connect the remote control rod to the
door lock and to the remote control.
5. Check the door locking and
window mechanism to make sure that
they function properly.
6. Cement the water shield to the
door inner panel.
7. Install the trim panel and hardware.
N1250-A
134
GROUP 13
N O . 1 B O W REAR
WEATHERSTRIP
WEATHERSTRIP
WEATHERSTRIP
VIEW AA
N1251-A
VIEW AA
VIEW BB
N1252-A
8. Starting at one end of the compartment, carefully pull the trim retainer out of the channel. Fold the
trim over the seat area and quarter
panel trim.
9. Remove the tip (Fig. 307) from
each end of the moulding on the rear
bow. Carefully pull the moulding out
of the retainer. Pry the moulding retainer off the bow.
' H / HEADER
TO N O . 1 BOW
HORIZONTAL
CLEARANCE.
Yi6" HEADER
TO NO. 1 BOW
VERTICAL
NO. 3
BOW
NO. 1
BOW
NO. 4
BOW
TACKING STRIP
ATTACHING BOLT
TACKING STRIP
W SIDE RAIL TO
QUARTER PANEL
AT BELT LINE.
STAY PADS HAVE BEEN OMITTED FROM ILLUSTRATION. STAY PADS
ARE NOT AS A RULE REPLACED WITH THE TOP AND ARE NOT
FURNISHED WITH A SERVICE TOP ASSEMBLY.
NO. 1 BOW
WEATHERSTRIP
N1255-A
136
10. Remove the bolts that attach
the top and back curtain tacking
strips to the body.
11. Remove the staples that secure the top material to the rear bow.
12. Carefully pull the top material
free from the underside of each side
rail.
13. Remove the staples that secure the top material to the underside
of the front bow.
14. Carefully separate the top from
the listings on No. 2 and 3 bows.
15. Remove the staples that secure the upper end of the back curtain to the rear bow. Remove the
curtain.
GROUP 13
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 curtain 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. Fit the new top on the roof
bows.
5. Working from the center outward, staple the top deck to the rear
bow. Make sure that the rear section
of the slits is stapled to the bow before drawing and stapling the front
portion of the slits (Fig. 307).
6. Secure, and tighten the quarter
deck tacking strips to the body as
required to align the listings with
the No. 2 and 3 bows.
7. Center the top material and
pull it forward over the front bow
to remove the wrinkles from the top
deck and quarters. While the material is pulled over the front bow, make
a reference mark on the material 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
DIVISION BAR
MOULDING
VIEW CC
N1256-A
GROUP 13
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.
10. Install the weatherstrip and
the three retainers on the No. 1 bow.
11. Secure the flaps to the underside of the side rail with trim cement.
Trim the excess material from the
flaps.
12. Install the rear, center and the
front weatherstrips on the side rails
so that the end of the weatherstrips
are in alignment of the side rail
joints.
13. Tighten the quarter deck tacking strips as required to remove
wrinkles from the material and obtain a tight seal at the mouldings.
14. Install a piece of tape across
the rear bow to cover the staples.
15. Install the moulding retainer,
moulding and the two tips on the
rear bow.
16. Secure the back curtain to the
upper part of the zipper.
17. Secure the back curtain tacking strip in place with the attaching
bolts. Tighten the bolts as required
working from the center outward to
remove all wrinkles.
18. Starting at one end of the folding top compartment, force the trim
retainer into the channel.
19. Secure each end of the trim to
the pivot bracket supports with a
metal screw and washer.
20. Install the rear seat back and
cushion.
21. Cement the top material to the
listings on the No. 2 and 3 bows.
22. Remove the protective covers
from the deck and the hood.
23. Clean all chalk reference
marks from the top material.
STATIONARY BACK W I N D O W
OR SIDE GLASS REPLACEMENTMONTEREY
REMOVAL
1. Remove the upper outside
137
9. Working from the inside of the
car, carefully press the glass outward
to remove it from the flange.
10. Remove the weatherstrip from
the glass.
11. Clean all of the sealer from
the weatherstrip.
INSTALLATION
1. Apply a film of sealer around
the edge of glass and in the glass
channel of the weatherstrip.
2. Install a piece of chalk line cord
in the flange groove of the weatherstrip. Make sure that the ends of the
cord overlap each other.
3. Apply a film of sealer around
the window opening as shown in Fig.
309.
7. Remove the two moulding lower corners, attaching screws and remove the corners.
5. If working on a retractable
window, install the division bar outside mouldings and secure them with
two cap screws.
BACK WINDOW
WEATHERSTRIP
BACK
WINDOW
VIEW AA
VIEW CC
N1258-A
GROUP 13
138
RUBBER TIP
UPPER
MOULDING
N1257-A
RETRACTABLE REAR W I N D O W
OR MOTOR REPLACEMENTMONTEREY
REMOVAL
1. Remove the seat cushion and
the seat back.
2. Remove the two screws from
each division bar moulding and remove the two mouldings.
3. Remove the six screws from the
lower garnish moulding and remove
the moulding.
4. Remove the six cap screws that
secure the seat back support (Fig.
311) to the body and remove the
support.
5. Remove the five screws that
secure the inner weatherstrip to the
cover and remove the weatherstrip.
UPPER
SEAL
INNER
WEATHERSTRIP
DIVISION
WINDOW
BAR
SEAT BACK
SUPPORT
COVER
MOTOR
HOUSING
DRAIN
N1259-A
GROUP 13
GLASS CHANNEL
139
ATTACHING
BOLTS
D O W N STOP
INSTALLATION
1. Rotate the vent regulator handle shaft until the flat on the regulator
shaft is at a 90 angle to the handle
shaft.
2. Hold the regulator in place on
the door inner panel and install but
do not tighten the two attaching
screws.
3. Secure the regulator shaft to
the vent window pivot with a cap
screw and lock washer.
4. Tighten the regulator-to-panel
attaching screws.
5. Install the door trim panel and
hardware.
LOCK STRIKER ADJUSTMENT
GALAXIE AND MONTEREY
REGULATOR
GROMMET
MOTOR
DRAIN TABS
N1260-A
REMOVAL
LOCK
R1146-A
REGULATOR
ATTACHING
SCREWS
N1261-A
STRIKER
UPPER
PIVOT
HANDLE
SHAFT
STRIKER
140
GROUP 13
LOCK ASSEMBLY
LOCK STRIKER
N1246-A
ward to decrease the clearance between the deck lid and lower panel
or downward to increase the clearance.
GALAXIE
REAR VERTICAL
SOLENOID
Blue
N1245-A
GROUP 13
141
REAR TILT SWITCH
FRONT TILT SWITCH
HORIZONTAL AND
VERTICAL SWITCH
BEZEL
HORIZONTAL ACTUATOR
REAR VERTICAL
ACTUATOR TUBE
UPPER SUPPORT
REAR VERTICAL
ACTUATOR TUBE
FRONT VERTICAL
ACTUATOR TUBE
COUPLING
VERTICAL
DRIVE GEARS
N132O-A
center solenoid operates the front vertical drive assemblies. The horizontal
seat screw jacks are operated by the
rear solenoid.
Both the control and power circuits are protected by a common 30ampere circuit breaker mounted on
the starting motor relay (Fig. 318).
TROUBLE SHOOTING
Motor Operates, But There Is No
Seat Movement
1. Defective shaft or coupling between motor and transmission.
2. Solenoid not engaging transmission.
3. Solenoid relay not energizing
the solenoid.
(30-amp) circuit
142
GROUP 13
2. Remove the two sheet metal
screws that secure both relays to the
mounting bracket and remove the relays.
3. Secure both relays to the mounting bracket with two sheet metal
screws. Make sure that the motor control relay (four-prong connector) is
toward the driver's side of the seat.
4. Connect each connector to its
respective relay.
SWITCH
CONNECTORS
SEAT SIDE
SHIELD
SWITCH MOUNTING
PAD
INSTALLATION FOR ALL "B" MODELS
N1244-A
MOTOR REPLACEMENT
1. Disconnect the motor leads
from the four connectors (Fig. 319).
2. Remove the two nuts and lockwashers that secure the motor to the
mounting bracket.
3. Slide the motor out of the shaft
coupling and off the mounting
bracket.
4. Slide the motor shaft into the
coupling and the studs into the
mounting bracket.
5. Secure the motor to the mounting bracket with two lockwashers and
nuts.
6. Connect the green, red, yellow
and the black motor leads to their
respective connectors.
RELAY REPLACEMENT
1. Disconnect the connector from
the seat regulator relay and from the
motor control relay (Fig. 319).
TRANSMISSION
REPLACEMENT
1. Disconnect the three leads from
the three solenoids on the transmission (Fig. 319).
2. Remove the cable housing retainer from each end of the transmission. Separate the six cables and
housings from the transmission.
3. Remove the two cap screws and
lock washers that secure the transmission to the mounting bracket.
Separate the transmission from the
mounting bracket.
4. Secure the transmission to the
mounting bracket with two lock
washers and cap screws.
5. Slip the six cables and housings
into their respective ports. Install the
two cable housing retainers.
6. Connect the brown lead to the
front solenoid, the green lead to the
center solenoid and the blue lead to
the rear solenoid.
SWITCH REPLACEMENT
1. Remove the left seat side shield
attaching screws. If working on an
"A" model, remove the two switch
attaching screws (Fig. 320). Separate
the side shield from the seat.
2. Remove the wiring shield that
encloses the seat switch wires.
3. Disconnect the switch from the
four connectors.
4. Remove the two switch attaching screws and remove the switch,
mounting pad and the mounting
bracket ("B" models only).
5. Secure the switch, mounting
pad and the mounting bracket to the
left seat side shield with the two
attaching screws ("B" models only)
as shown in Fig. 320.
6. Connect the four connectors at
the switch leads.
7. Install the wiring shield to enclose the wiring and seat switch connectors.
GROUP 13
SHIFT LEVER BOOT RETAINER
SHIFT LEVER
143
STORAGE COMPARTMENT
MOUNTING PLATE
CARPET
P1088-A
CONSOLEGALAXIE AND
MONTEREY
REPLACEMENT
1. Raise the car on a hoist. Disconnect the gear shift linkage from
the control levers. Lower the car to
the floor.
2. Remove the screw that attaches
the release button and knob to the
transmission shift lever. Lift the release button and the knob off the
lever (Fig. 321).
3. Remove the four center panel
attaching screws. Loosen the two
screws at the forward end of the
glove box. Lift the center panel from
the console (Fig. 321).
Two drain and dust valves are provided in the bottom of the door, two
in the rocker panel, and one in the
quarter panel. These valves are located in the lowest point in the panel.
The weight of the water will open
the valve and allow the water to
escape from the panel. After the
water has drained, the valve will close
and prevent the entry of dust. If for
any reason the door trim panel, rocker panel scuff plate or luggage compartment trim panel has been removed, the drain holes in the metal
should be inspected to make sure that
they are not obstructed.
EXTERIOR MOULDINGS
GALAXIE AND MONTEREY
The following illustrations will assist in replacing any exterior moulding. They also show the various types
of retainers and sealer that is used.
GROUP 13
144
N1272-A
FIG. 322-Exterior Side Mouldings-Galaxie Models 54A, 62Ar 65A, 65B, 75A, 76A and 76B
GROUP 13
145
MODEL C3AB-62B
Jffi
S2
Si
S)
82
182
MODEL C3AB-54B
TYPICAL
N1275-A
146
GROUP 13
MODELS C3AB-71A-71E
N1274-A
GROUP 13
147
MODELS C3AB-54A-62A-65A-65B
75A-76A-76B
MODELS C3AB-54B-62B
N1273-A
148
GROUP 13
a.
N1271-A
FIG. 326-Exterior Side Mouldings-Monterey Models 54B, 65B, 65C, 7SB, 76A and 76B
GROUP 13
149
N1270-A
150
GROUP 13
MODELS C3MB-54-62-65-75-76
MODEL C3MB-71
N1269-A
GROUP 14
151
Operation
Lubricant
Check Air Conditioner State of Refrigerant Charge, and Add Refrigerant as Required
Adjust Accelerator Pump Lever
AS REQUIRED
Check Convertible Top Pump Reservoir Fluid Level, and Add Fluid as
Required
Use Rotunda Automatic Transmission Fluid, Ford Part No. C1AZ19582-B (Ford Spec. M2C33-D)
for adding or for complete refill. If
Rotunda fluid is not available, automatic transmission fluid marked
"Type A, Suffix A" may be used to
"add to" the factory fill to maintain
fluid level
6000
Operation
Lubricant
152
GROUP 14
(continued)
Operation
Lubricant
Use Rotunda Automatic Transmission Fluid, Ford Part No. C1AZ19582-B (Ford Spec. M2C33-D)
for adding or for complete refill. If
Rotunda fluid is not available, automatic transmission fluid marked
"Type A, Suffix A" may be used to
"add to" the factory fill to maintain
fluid level
Check Power Steering Pump Reservoir Fluid Level, and Add Fluid
as Required
Use Rotunda Automatic Transmission Fluid, Ford Part No. C1AZ19582-B (Ford Spec. M2C33-D)
for adding or for complete refill. If
Rotunda fluid is not available, automatic transmission fluid marked
"Type A, Suffix A" may be used to
"add to" the factory fill to maintain
fluid level
M-2C28-B C2AZ-19580-A
352 2-V
Power
Option M-2C28-B C2AZ-19580-A
390 4-V M-2C50-B C1AZ-19580-E
orF
406 4-V
High
Performance
M-2C57-A C2AZ-19580-D
406 6-V
High
Performance
M-2C57-A C2AZ-19580-D
If other specified lubricants are unavailable, M-2C50-B may be used
for "adding to," not exceeding one
pint in quantity, in all except EquaLock axles
CONTINUED ON NEXT PAGE
GROUP 14
153
6000
(continued)
Operation
Lubricant
154
GROUP 14
Operation
Lubricant
Use Rotunda Automatic Transmission Fluid, Ford Part No. C1AZ19582-B (Ford Spec. M2C33-D)
for adding or for complete refill. If
Rotunda fluid is not available, automatic transmission fluid marked
"Type A, Suffix A" may be used to
"add to" the factory fill to maintain
fluid level
Check Power Steering Pump Reservoir Fluid Level, and Add Fluid
as Required
Use Rotunda Automatic Transmission Fluid, Ford Part No. C1AZ19582-B (Ford Spec. M2C33-D)
for adding or for complete refill. If
Rotunda fluid is not available, automatic transmission fluid marked
"Type A, Suffix A" may be used to
"add to" the factory fill to maintain
fluid level
GROUP 14
155
12,000
(continued)
Operation
Lubricant
I Cllll /
1 8,000
Use Rotunda Automatic Transmission Fluid, Ford Part No. C1AZ19582-B (Ford Spec. M2C33-D)
for adding or for complete refill. If
Rotunda fluid is not available, automatic transmission fluid marked
"Type A, Suffix A" may be used to
"add to" the factory fill to maintain
fluid level
Check Power Steering Pump Reservoir Fluid Level, and Add Fluid
as Required
GROUP 14
156
MAINTENANCE SCHEDULE (Continued)
Odometer Reading (Miles)
1 8,000
(continued)
Operation
Lubricant
M-2C28-B C2AZ-19580-A
352 2-V
Power
Option M-2C28-B C2AZ-19580-A
390 4-V M-2C50-B C1AZ-19580-E
orF
406 4-V
High
Performance
M-2C57-A C2AZ-19580-D
406 6-V
High
Performance
M-2C57-A C2AZ-19580-D
If other specified lubricants are unavailable, M-2C50-B may be used
for "adding to," not exceeding one
pint in quantity, in all except EquaLock axles
For all cars equipped with EquaLock axles, regardless of engine
size, use M-2C50-B, plus one (1)
ounce of M-2C58 additive per pint
of M-2C50-B (4 oz. for complete
refill)
SAE 90 grade lubricants are recommended for all temperatures above
25 F. For temperatures below
25 F, the same type of lubricant, but of a SAE 80 grade, should
be used
Check Clutch Linkage and Adjust if
Necessary (Std. and O/D)
Check Tension of Engine Accessory
Drive Belts and Adjust if Necessary
Clean Carburetor Air Cleaner Filter
Element
Clean Crankcase Breather Cap and
Filter
Clean Positive Crankcase Ventilation
System Valve
Lubricate Exhaust Control Valve
(223 6-Cylinder or 406 8-Cylinder
only)
GROUP 14
157
1 8,000
(continued)
Operation
Lubricant
24,000
Use Rotunda Automatic Transmission Fluid, Ford Part No. C1AZ19582-B (Ford Spec. M2C33-D)
for adding or for complete refill. If
Rotunda fluid is not available, automatic transmission fluid marked
"Type A, Suffix A" may be used to
"add to" the factory fill to maintain
fluid level
Check Power Steering Pump Reservoir Fluid Level, and Add Fluid
as Required
Use Rotunda Automatic Transmission Fluid, Ford Part No. C1AZ19582-B (Ford Spec. M2C33-D)
for adding or for complete refill. If
Rotunda fluid is not available, automatic transmission fluid marked
"Type A, Suffix A" may be used to
"add to" the factory fill to maintain
fluid level
158
GROUP 14
24,000
(continued)
Operatioi
Lubricant
Ford
Part No.
C2AZ-19580-A
C2AZ-19580-A
C2AZ-19580-A
C1AZ-19580-E
orF
406 4-V
High
Performance
M-2C57-A C2AZ-19580-D
406 6-V
High
Performance
M-2C57-A C2AZ-19580-D
If other specified lubricants are unavailable, M-2C50-B may be used
for "adding to," not exceeding one
pint in quantity, in all except EquaLock axles
For all cars equipped with EquaLock axles, regardless of engine
size, use M-2C50-B, plus one (1)
ounce of M-2C58 additive per pint
of M-2C50-B (4 oz. for complete
refill)
SAE 90 grade lubricants are recommended for all temperatures above
25 F. For temperatures below
25 F, the same type of lubricant, but of a SAE 80 grade, should
be used
Check Clutch Linkage and Adjust if
Necessary (Std. and O/D)
Check Parking Brake and Adjust if
Necessary
Check Front End Alignment and
Correct if Necessary
Check Valve Tappets and Adjust if
Necessary (Conventional Mechanical)
Check Ignition Timing and Adjust if
Necessary
Clean Positive Crankcase Ventilation
System Valve, Tubes, Filter and/or
Separator
Clean Carburetor Air Cleaner Filter
Element
CONTINUED ON NEXT PAGE
GROUP 14
159
24,000
(continued)
Operation
Lubricant
Use Rotunda Automatic Transmission Fluid, Ford Part No. C1AZ19582-B (Ford Spec. M2C33-D)
for adding or for complete refill. If
Rotunda fluid is not available, automatic transmission fluid marked
"Type A, Suffix A" may be used to
"add to" the factory fill to maintain
fluid level
CONTINUED ON NEXT PAGE
160
GROUP 14
Operation
Lubricant
Check Power Steering Pump Reservoir Fluid Level, and Add Fluid
as Required
Use Rotunda Automatic Transmission Fluid, Ford Part No. C1AZ19582-B (Ford Spec. M2C33-D)
for adding or for complete refill. If
Rotunda fluid is not available, automatic transmission fluid marked
"Type A, Suffix A" may be used to
"add to" the factory fill to maintain
fluid level
Ford
Part No.
C2AZ-19580-A
C2AZ-19580-A
C2AZ-19580-A
C1AZ-19580-E
orF
406 4-V
High
Performance
M-2C57-A C2AZ-19580-D
406 6-V
High
Performance
M-2C57-A C2AZ-19580-D
If other specified lubricants are unavailable, M-2C50-B may be used
for "adding to," not exceeding one
pint in quantity, in all except EquaLock axles
For all cars equipped with EquaLock axles, regardless of engine
size, use M-2C50-B, plus one (1)
ounce of M-2C58 additive per pint
of M-2C50-B (4 oz. for complete
refill)
SAE 90 grade lubricants are recommended for all temperatures above
25 F. For temperatures below
25 F, the same type of lubricant, but of a SAE 80 grade, should
be used
CONTINUED ON NEXT PAGE
GROUP 14
161
30,000
(continued)
Operation
Lubricant
Use Rotunda Automatic Transmission Fluid, Ford Part No. C1AZ19582-B (Ford Spec. M2C33-D)
for adding or for complete refill. If
Rotunda fluid is not available, automatic transmission fluid marked
"Type A, Suffix A" may be used to
"add to" the factory fill to maintain
fluid level
Use "Rotunda" Manual Transmission
Lubricant, Ford Part No. C3RZ19C547-A (Ford Spec. M-568-D)
for "adding" or for complete refill.
If Rotunda lubricant is not available, a reputable SAE 80 grade mild
extreme pressure type lubricant
may be used to "add to" the factory
fill to maintain the lubricant level
CONTINUED ON NEXT PAGE
162
GROUP 14
36,000
(continued)
Operatioi
Lubricant
Check Power Steering Pump Reservoir Fluid Level, and Add Fluid
as Required
Use Rotunda Automatic Transmission Fluid, Ford Part No. C1AZ19582-B (Ford Spec. M2C33-D)
for adding or for complete refill. If
Rotunda fluid is not available, automatic transmission fluid marked
"Type A, Suffix A" may be used to
"add to" the factory fill to maintain
fluid level
GROUP 14
163
36,000
(continued)
Operation
Lubricant
Lubricate
Joints
Drive
Shaft
Universal
Lubricate
Joints
Front
Suspension Ball
164
GROUP 14
MAINTENANCE OPERATIONS (PART 14-2)
MAINTENANCE OPERATIONS
CHECK AUTOMATIC
TRANSMISSION FLUID
LEVEL
CHECK MANUAL-SHIFT
TRANSMISSION LUBRICANT
LEVEL
The fluid level should be maintained s inch below the top of the
filler opening.
CHECK TENSION OF
ENGINE ACCESSORY DRIVE
BELTS AND ADJUST IF
NECESSARY
BELT TENSION
SPECIFICATIONS:
Air conditioning Drive
Power Steering
Water Pump and Fan
CLEAN CRANKCASE
BREATHER CAP AND
POSITIVE CRANKCASE
VENTILATION SYSTEM
LUBRICATE FRONT
SUSPENSION BALL
JOINTS
Remove plugs.
Apply the recommended lubricant
to each ball joint fitting with a pressure gun and replace the plugs.
LUBRICATE STEERING
LINKAGE
Remove plugs.
Apply the recommended lubricant
Galaxie
Shop Manual
Part 12-3
Part 9-2
Part 4-1
Mercury
Shop Manual
Section 8C
Section 5B
Section 6E
GROUP 14
165
LUBRICATE DECK
LID LATCH
LUBRICATE D O O R
LOCKS
REPLACE FUEL
FILTER
Complete procedures for replacing the fuel filter are given in Part
3-1 of the 1962 Ford Galaxie Shop
CROSS-SWITCH WHEELS
AND TIRES
PERFORM AIR
CONDITIONER SEASONAL
SERVICES
166
GROUP 14
GROUP 15
167
GROUP 15SPECIFICATIONS
NOTE: All specifications are given in inches unless otherwise noted.
ENGINES
GENERAL (Continued)
GENERAL SPECIFICATIONS
ENGINE MODELS AND PISTON DISPLACEMENT Cubic Inches
Mileage Maker Six
223
260
260 V-8
352
352 V-8
390
390 Special V-8
390
390 Police Interceptor V-8
406
406 High Performance V-8 (4-V)
406
406 High Performance V-8 (6-V)
COMPRESSION RATIO
Mileage Maker Six
8.4:1
260 V-8
352 V-8
390 Special V-8
8.7:1
8.9:1
10.5:1
10.5:1
11.5:1
11.5:1
138 4200
164 4400
220 4300
300 4600
330 5000
385 5800
405 5800
203 2200
258 2200
336 2600
427 2800
427 3200
444 3400
448 3500
3.62x3.60
3.80x2.87
4.00x3.50
4.05x3.78
4.13x3.78
...675-700
500-525
U.S.
MEASURE
4 quarts
5 quarts
IMPERIAL
MEASURE
3.5 quarts
4
quarts
. . . 4 5 - 7 0 psi
406
. . . 4 0 - 5 5 psi
Other Engines
. . . 3 5 - 5 5 psi
CYLINDER HEAD
GASKET SURFACE FLATNESS
0.003 inch in any 6 inches or 0.006 inch overall
VALVE GUIDE BORE DIAMETERStandard
Intake and Exhaust
223
260
352, 390 and 406
...0.3433-0.3440
...0.3115-0.3125
. ...0.3728-0.3735
0.060-0.080
Other Engines
0.070-0.090
30
Other Engines
45
Exhaust
TAXABLE HORSEPOWER
223
260
352
390
406
All Engines
31 54
46.20
5120
52 49
54.56
1-5-3-6-2-4
..1-5-4-2-6-3-7-8
0.0015
0.002
VALVE MECHANISM
FIRING ORDER
223
45
E-l-l-E-l-E-E-l-E-l-l-E
...Right I-E-I-E-I-E-I-E
Left
E-l-E-l-E-l-E-l
E-l-E-l-l-E-l-E
VALVE LASH
Cold
INTAKE AND EXHAUST
406 with Mechanical Lifters
0.028
Hot
INTAKE AND EXHAUST
406 with Mechanical Lifters
0.025
GROUP 15
168
VALVE MECHANISM (Continued)
VALVE CLEARANCE
223*
260**
352 and 390**
...0.3416-0.3423
...0.3100-0.3107
...0.3711-0.3718
EXHAUST
223
260
352 and 390
406
...0.3398-0.3405
...0.3090-0.3097
...0.3693-0.3700
...0.3701-0.3708
0.003 Oversize
INTAKE
223
260
352, 390 and 406
.0.3446-0.3453
...0.3130-0.3137
...0.3741-0.3748
EXHAUST
223
260
352,390
406
...0.3428-0.3435
...0.3120-0.3127
...0.3723-0.3730
...0.3731-0.3738
0.015 Oversize
INTAKE
223
260
352, 390 and 406
...0.3566-0.3573
...0.3250-0.3257
...0.3861-0.3868
EXHAUST
223
260
352 and 390
406
.0.3548-0.3555
...0.3240-0.3247
...0.3843-0.3850
...0.3851-0.3858
0.030 Oversize
INTAKE
223
260
352,390 and 406
.0.3716-0.3723
...0.3400-0.3407
0.4011-0.4018
EXHAUST
223
0.3698-0.3705
.0.3390-0.3397
...0.3993-0.4000
0.4001-0.4008
260
352 and 390
406
VALVE FACE ANGLE
406
Other Engines
29
44
1.775-1.785
1.582-1.597
2.022-2.037
Exhaust
223
260
352 and 390
406
1.505-1.520
1.381-1.396
1.551-1.566
1.645-1.660
0.002
Exhaust
260,352, 390 and 4 0 6 . . .
223
0.002
0.0015
2.33
2.15
2.26
2.15
2.06
0.072
P/4-l25/32
l 13 /l6-l 27 /32
l51/64"l53/64
0.015
0.025
406
Other Engines
223
260, 352, 390 and 406
0.4983-0.4989
0.8740-0.8745
. . . .0.0018-0.0035
0.0020-0.0034
0.0028-0.0042-Wear Limit 0.0055
223
260, 352, 390 and 406
10-100 Seconds
GROUP 15
169
CRANKSHAFT (Continued)
...0.780-0.781
.0.8385-0.8395
..0.783-0.784
..0.843-0.844
1.9255-1.9265
2.0805-2.0815
2.0655-2.0665
2.0505-2.0515
2.0355-2.0365
2.0205-2.0215
2.1238-2.1248
0.0005
0.001
0.5
223
260
352
390
406
Exhaust
223
260
352
390
406
.1.359-1.361
1.137-1.139
.1.124-1.126
0.001
2.2984-2.2988
2.2980-2.2984
2.1236-2.1240
2.1232-2.1236
2.4384-2.4388
2.4380-2.4384
.0.004-0.008-Wear Limit 0.012
0.007
.0.006
MAIN BEARINGS
JOURNAL CLEARANCE
223
260
352 and 390
406
0.0009-0.0033
0.0006-0.0026
0.0006-0.0031
No. 1-0.001-0.002
Nos. 2, 3, 4, 5-0.0010-0.0031
CAMSHAFT BEARINGS
INSIDE DIAMETER
223
260 #1
260/2
260 #3
260 #4
260 #5
352, 390 and 406.
CONNECTING ROD
.1.9275 1.9285
.2.0825 2.0835
.2.0675 2.0685
.2.0525 2.0535
.2.0375 2.0385
.2.0225 2.0235
.2.1258 2.1268
No. 1 bearing is installed with the front edge 0.005 to 0.020 inch toward
the rear from the front face of the cylinder block on all engines.
CRANKSHAFT
MAIN BEARING JOURNAL DIAMETER
Standard
223 Coded Red
Coded Blue
260 Coded Red
Coded Blue . . . .
352, 390 and 406 Coded Red
Coded Blue
2.4984-2.4988
2.4980-2.4984
2.2486-2.2490
2.2482-2.2486
2.7488-2.7492
2.7484-2.7488
260
352, 390 and 406
0.9122-0.9125
0.9107-0.9112
0.9752-0.9755
2.4230-2.4234
2.4234-2.4238
2.2390-2.2394
2.2394-2.2398
2.5907-2.5911
2.5911-2.5915
GROUP 15
170
223
260
352
6 258-6.262
5.154-5.156
6.538-6.542
6.486-6.490
0.012
0.004
.0.0006-0.0028
.0.0009-0.0025
.0.0007-0.0028
.0.0009-0.0029
PISTON
PISTON DIAMETER
Color Coded Red
223
260
352
390
406
Color Coded Blue
223
260
352
390
406
0.003 Oversize
223
260
352
390
3.156-3.170
3.202-3.212
PISTON RINGS
3.010-3.030
CONNECTING ROD
Side Clearance
223
260,352, and 390
406
3 6236-3 6242
3 7976-3 7982
3.9982-3 9988
4.0477-4.0483
4.1258-4.1264
RING WIDTH
Compression Ring
UPPER
223
Other Engines
0.0929-0.0936
0.0774-0.0781
LOWER
All Engines
0.0930-0.0940
SIDE CLEARANCE
Compression Ring
UPPER
223 and 260
352,390 and 406
LOWER
223
260
352, 390 and 406
Oil Ring
All Engines
Snug
0.010-0.020
0.015-0.025
0.015-0.055
CYLINDER BLOCK
CYLINDER BORE DIAMETERStandard Spreads for 8 Grades
260
352
390
406
0.0008-0 0026Wear
0.0021-0 0039Wear
0.0012-0.003-Wear
0.0017-0.0035-Wear
0.0043-0 0049Wear
Limit
Limit
Limit
Limit
Limit
0 006
0 006
0.006
0.006
0 006
223
260
352
390
406
3.6250-3.6274
3.8003-3.8027
4.0000-4.0024
4.0500-4.0524
4.1300-4.1336
PISTON PIN
CYLINDER BORE TAPER
All Engines
223
260
0.9120-0.9123
0.9118-0.9124
0.9750-0.9753
0.001 Oversize
223
0.9130-0.9133
0.9760-0.9763
0.002 Oversize
223
352, 390 and 406
0.9140-0.9143
0.9770-0.9773
GROUP 15
OIL PUMPRotor Type (Continued)
RELIEF VALVE CLEARANCE
All Engines
0.0015-0.0029
223
171
0.0025-0.0039
260
223,352,390 and 406
12-15
23-28
..30-35
..35-45
70-90
0.006-0.012
CONNECTING ROD NUTS
260
223, 352 and 390
406
TORQUE LIMITSFt-Lbs
MAIN BEARING CAP BOLTS-Olled Threads
260
223, 352, 390, and 406
.60-70
95-105
19-24
40-45
53-58
.3-5
.4-7
105-115
65-70
80-90
100-110
...7-9 !/4-20
.9-11 Vie18
9-13
Intake
223
260
352 and 390
406
23-28
12-15
32-35
25-28
Exhaust
223
260
352, 390 and 406
23-28
.13-18
12-18
FLYWHEEL TO CRANKSHAFT
75-85
30-35
23-28
12-15
223
260
OIL FILTER TO ADAPTER OR CYLINDER BLOCK
All Engines
6-9
12-15
30-35
.4.5-10
.2.0-2.5
12-15
223
260
FUEL PUMP TO CYLINDER BLOCK OR CYLINDER FRONT
COVER
223
All V-8 Engines
3-4
6-9
12-15
23-28
6-9
50-60
40-45
All Engines
..23-28
12-15
.40-45
Bracket to Engine
223
.35-40
Bracket to Crossmember
All Engines
.45-50
Insulator to Frame
All Engines
.45-55
Insulator to Engine
All V-8 Engines
.35-40
.40-45
.12-15
GROUP 15
172
TORQUE LIMITS-Ft-Lbs (Continued)
T O R Q U E LIMITS FOR V A R I O U S SIZE BOLTS
C A U T I O N : If any of the torque limits listed in this table disagree with any of those listed in the preceding tables, the limits listed in the preceding tables prevail.
Size (Inches)
1/4-28
1/4-20
6-9
Torque (Ft-lbs)
7
Size (Inches)
/ie-14
45-50
Torque (Ft-lbs)
/ie-18
/ie-24
6-9
12-15
15-18
/i6-20
1/2-13
1/2-2O
60-70
70-80
50-60
3/8-16
23-28
30-35
/ie-18
85-95
/8-24
/ 8 -18
130-145
IGNITION SYSTEM
IGNITION TIMING*
DISTRIBUTOR
Recommended Setting
ENGINE
Manual-Shift
Transmission
Automatic
Transmission
4
6
3
6
10
8
10
10
6
6
10
8
*The initial ignition timing may be advanced 5 over the recommended setting. T o d o t h i s , advance the timing progressively until engine detonation
(spark knock) is evident under actual road test acceleration. Retard the
timing until the detonation is eliminated. If the individual requirements
of the car a n d / o r if sub-standard fuels are used, the initial timing may
be retarded from the recommended setting not to exceed 2 BTC.
17-20
0.024-0.026
35-38
260 Y-8
Breaker Arm Spring Tension (Ounces)
Contact Spacing (Inches)
Dwell Angle at Idle Speed
17-20
0.015-0.018
26-28
17-20
0.014-0.016
26 o -28i/ 2
17-20
0.014-0.018
26-28
27-32
0.019-0.021
Not Applicable
406 V-8
Breaker A r m Spring Tension (Ounces)
Contact Spacing (Inches)
27-32
0.015-0.018
DIMENSION
0.005-0.008
V-8
Distance from bottom of mounting flange to bottom of gear (Inches)
260 V-8
4.031-4.038
3.071-3.077
CLEARANCEInches
(Continued)
500
800
Advance
(Degrees)
0.30
6-714
0.45
1400
8 3 / 4 -10
nm-12
Advance Limit.
Vacuum (Inches
of Mercury)
1M-2V4
2000
2.30
4.30
13V*
...10
Distributor
(rpm)
GENERAL
(Continued)
CHARACTERISTICS
DISTRIBUTOR
GEAR L O C A T I O N
ADVANCE
.0.005-0.008
.0.024-0.035
.0.022-0.030
CHARACTERISTICS
500
800
1400
2000
Advance L i m i t .
Advance
(Degrees)
Vacuum (Inches
of Mercury)
1-2
0.45
41/4-51/4
1.07
7-8
7-8
3.30
10V4
8.50
6.00
Vacuum (Inches
of Mercury)
500
800
VA-lVi
1200
Wi-VA
0
0
0
0
0
Distributor
(rpm)
1600
81/2-10
2000
103/4-12V4
Vacuum (Inches
of Mercury)
1000
1-4
1000
1000
5 ^ -81/2
71/2-IO1/2
1000
8-11
8
12
16
20
Distributor
(rpm)
11
Advance Limit
C3AF-12127-II
500
600
900
Advance
(Degrees)
Vacuum (Inches
of Mercury)
V4-1V*
P/4-21/4
0
0
0
0
0
3-4
1500
5 3 / 4 -7
2000
8!/4-93/4
GROUP 15
DISTRIBUTOR
(Continued)
ADVANCE CHARACTERISTICS
DISTRIBUTOR
(Continued)
0
1-2
0
0
0
0
5-61/4
1250
2000
111/2-13
18
Advance Limit.
VACUUM ADVANCE. Refer to Distributor No. COAF-12127-D.
352 V-8 (Distributor No. COAF-12127-D
Used With Automatic Transmission)
CENTRIFUGAL ADVANCE. Disconnect the vacuum line. Set test stand
to 0 @ 200 rpm.
Distributor
Advance
Vacuum (Inches
(rpm)
(Degrees)
of Mercury)
300
500
0
3/4-13/4
0
0
0
0
1100
5-61/4
2000
III/2-I3
18
Advance Limit.
VACUUM ADVANCE. Set test stand to 0@1000 rpm and 0 inches of vacuum.
Distributor
Advance
Vacuum (Inches
(rpm)
(Degrees)
of Mercury)
1000
0-1
5
1000
5-8
10
1000
8-11
I31/2
9H-121/2
1000
17
Advance Limit.
121/2
390 V-8 (Distributor No. C2AF-12127-A)
CENTRIFUGAL ADVANCE. Set test stand to 0c @ 250 rpm and 0 inches
of vacuum.
Distributor
Advance
Vacuum (Inches
(rpm)
(Degrees)
of Mercury)
325
400
500
600
H-W
31/2-41/2
5-6
0
0
0
0
0
2000
103/4-121/4
VACUUM ADVANCE. Set test stand to 0 @ 1000 rpm and 0 inches
of vacuum.
Distributor
Advance
Vacuum (Inches
(rpm)
(Degrees)
of Mercury)
O-21/2
1000
6
1000
4-7
10
1000
51/2-81/2
15
Advance Limit @ 20" HG
8i/ 2
390 V-8 Engine (Distributor No. C3MF-12127-A)
CENTRIFUGAL ADVANCE. Set test stand to 0 @ 250 rpm and 0 inches
of vacuum.
Distributor
Advance
Vacuum (Inches
(rpm)
500
700
1000
1500
2000
(Degrees)
I-21/4
51/4-61/4
81/4-91/4
103/4-121/4
13i/2-15
(Continued)
ADVANCE CHARACTERISTICS
500
775
173
of Mercury)
0
0
0
0
0
(Continued)
Advance
(Degrees)
Vacuum (Inches
of Mercury)
1-4
7
10
12
17
31/2-6!/ 2
5-8
7-10
10
325
400
525
700
2000
VACUUM ADVANCE. Set test
of vacuum.
0
Vi-VA
0
0
0
0
0
41/2 -51/2
7-8
151/4-163/4
s t a n d t o 0 <c% 1000
Advance
Distributor
Vacuum (Inches
(rpm)
of Mercury)
(Degrees)
0-1
5
1000
7
1-4
1000
10
1000
4-7
15
51/2-81/2
1000
8i/ 2
Advance Limit 20" HG
406 V-8 Engine (Distributor No. COAF- 12127-K Dual Points)
Set test stand to 0 @ 250 rpm and 0 inches of vacuum.
Distributor
(rpm)
650
800
Advance
(Degrees)
Vacuum (Inches
of Mercury)
0
0
0
0
21/4-33/4
5-61/2
73/4-9
1125
Hi/2-13
2000
Advance Limit @ 2500 r p m . . .
14
CONDENSER
All Engines
.0.21-0.25
5
1
Capacity (Microfarads)
Minimum Leakage (Megohms)
Maximum Series Resistance (Ohms).
COIL
All Engines
1.40-1.54 (75F.)
8000-8800 (75F.)
4.5
2.5
1.30-1.40 (75F.)
6.5-5.3
SPARK PLUGS
Mileage Maker Six
260 V-8
352 and 390 V-8
390 and 406 High Performance.
Autolite BTF-6
Autolite BF-82*
..Autolite BF-42
BF-32
All Plugs
Size
Gap (Inches)
Torque (Ft-lbs)
18 mm
....0.032-0.036
15-20**
GROUP 15
174
FUEL SYSTEM
CARBURETOR (Continued)
FUEL PUMP
FUEL PUMP STATIC PRESSURE-Psl a t 5 0 0 Engine rpm
223
3.5-5.5
260
4-5
352,390, and 406
4.5-6.5
MINIMUM FUEL PUMP VOLUMEFlow
223
All V-8 Engines
0.290-0.310 inch
0.340-0.360 inch
0.690-0.710 inch
Vie inch
/32 inch
Vs inch
7
/64 inch
406-4-V
Vie inch
406-6-V
y64 inch
CARBURETOR
FORD SINGLE-BARREL CARBURETORS
C3AF-9510-A
Manual-Shift Transmission
C3AF-9510-B
Automatic Transmission
C3AF-9510-C (Economy)
Manual-Shift Transmission
C3AF-9510-D (Economy)
Automatic Transmission
Main Metering Jet Identification No.
0-5,000 feet
C3AF-9510-A
C3AF-9510-B
C3AF-9510-C
C3AF-9510-D
63F
63F
62F
62F
5,000-10,000 feet
C3AF-9510-A....
C3AF-9510-B....
C3AF-9510-C...
C3AF-9510-D....
.61F
61F
61F
.61F
10,000-15,000 feet
C3AF-9510-A
C3AF-9510-B
C3AF-9510-C
C3AF-9510-D
59F
59F
59F
59F
None
Venturi Size
Economy
All Except Economy
l /64 inches
l /64 inches
13
C3AF-9510-A and B
55
54
58
56
10,000-15,000 feet
C3AF-9510-E
C3AF-9510-F
C3MF-9510-A
C3MF-9510-B
53
52
56
54
Red
Red
Red
Red
5,000-10,000 feet
C3AF-9510-E
C3AF-9510-F
C3MF-9510-A
C3MF-9510-B
10,000-15,000 feet
C3AF-9510-E
C3AF-9510-F
C3MF-9510-A
C3MF-9510-B
65
65
65
65
55
55
55
55
.. .
390
\V% inches
l15/64 inches
0.060-0.090
Me inch
/ i 6 inch
/32 inch
5
/32 inch
3
57
56
60
58
...
1" from bottom of float to air horn with air horn inverted.
manual-shift transmission.
automatic transmission.
manual-shift transmission.
automatic transmission.
Final choke setting may be varied + two (2) digits from the initial setting
to suit specific operating conditions.
GROUP 15
CARBURETOR (Continued)
CARBURETOR (Continued)
46
45
5,000-10,000 feet
C30F-9510-E
C30F-9510-F
44
43
10,000-15,000 feet
C30F-9510-E
C30F-9510-F
42
41
Black
Black
55
lVfo inches
% inch
7
/64 inch
4 digits lean
0.060-0.090
l-P/2 turns open
Final choke setting may be varied + two (2) digits from the initial
setting to suit specific operating conditions.
Fast (Cold) Idle Adjustment
Bench
0.020 inch clearance between throttle plate and bore (opposite idle
port)with fast idle screw on kickdown step of cam.
In-Chassis
With fast idle screw on the kickdown step of the cam (hot engine).
C1AE-9510-AV
1600 rpm
Power Valve Opens at
C3AF-9510-R and T
Secondary
0-5,000 feet
C3AF-9510-N, S and T
C3AF-9510-R
10,000-15,000 feet
C3AF-9510-N, S and T
C3AF-9510-R
Power Valve Identification No.
0- 5,000 feet
5,000-10,000 feet
10,000-15,000 feet
...61
...60
...59
...58
Plain
...65
...55
Yenturi Size
Primary...
Secondary.
\V% inches
l 3 /ie inches
Index
2 digits lean
0.060-0.090
66
64
62
0.078 inch orifice
0.078 inch orifice
0.078 inch orifice
65
65
65
56
Venturi Size
54
Primary
Secondary
54
52
10,000-15,000 feet
C3AF-9510-N and S
175
52
50
At Index
Vie inch
l-P/2 turns open
63
62
\XA inches
l3/i6 inches
Final choke setting may be varied + two (2) digits from the initial
setting to suit specific operating conditions.
176
CARBURETOR
GROUP 15
(Continued)
CARBURETOR
(Continued)
Primary
Secondary
Wi inches
l3/ie inches
1-114 turns
%-WA turns
FUEL TANK
Venturi Size
Primary
Secondary
At Index
Capacity-Cars
Station Wagons.
U.S.
MEASURE
IMPERIAL
MEASURE
20 gallons
. 21 gallons
16.5 gallons
17.5 gallons
COOLING SYSTEM
WATER PUMP, DRIVE BELTS, AND
THERMOSTATS
223
260
352, 390 and 406
0.95:1
1.05:1
0.90:1
223
260
352, 390 and 406
Low Temperature
Opens FAll Engines..
Fully OpenAll Engines.
155-162 C
182C
High Temperature
Opens F - A l l Engines..
Fully OpenAll Engines.
185-192 C
212C
0.015-0.025 inch
0.030-0.050 inch
0.070-0.080 inch
STANDARD
120-150
Used* 90-120
New
Used*
New
Used*
90-120
60-120
110-140
80-110
223
260 V-8
Other V-8 Engines
U.S.
MEASURE
Quarts
15*
14*
19*
IMPERIAL
MEASURE
Quarts
12.5
11.5
16
Inches
Clutch Pedal Free Travel (Engine Idling)
63/4
10-10%
0.010
0.007
GROUP 15
177
CLUTCH IDENTIFICATION
Pressure Plate
Engine Cubic Inch Displacement
Diameter
(Inches)
Disc
Number of
Springs
Number of
Springs
Spring Color
Spring Color
Aluminum
3 Pink
3 Aluminum
ii*
9*
3 Pea Green*
6 Bronze with
White Stripe*
8*
4 Aluminum*
4 Pink*
10
Bronze
4 Aluminum
4 Plain
n*
n
n
9*
Pea Green*
12*
Blue*
Pea Green
12
Blue
4 Pea Green
5 Aluminum
Gray
223
260 V-8
352 V-8
390 V-8
K
Heavy-Duty Clutch
Engine
1st Gear
2nd Gear
3rd Gear
Reverse Gear
Conventional Drive
Conventional Drive
Conventional Drive
Conventional Drive
3.26
1.84
1.00
3.35
2.79
1.70
1.00
2.87
2.42
1.61
1.00
2.33
2nd Gear
3rd Gear
Reverse Gear
Drive
Overdrive
Conventional
Drive
Overdrive
Drive
Overdrive
Conventional
Drive
3.20
2.80
1.86
1.69
1.00
0.70
3.83
3.80
2.49
1.51
1.59
1.00
0.72
2.81
3.15
Conventional
2.37
Conventional
TORQUE SPECIFICATIONS
Foot
Foot
Pounds* Pounds!
Lower Access Clutch Cover Plate to Flywheel
Housing Bolts
17-20
14-19
40-50
40-50
Pints
(Approximate)
Manual Shift Transmission
Overdrive
23-28
23-28
37-42
42-50
25-30
25-30
12-15
19-25
TRANSMISSION ADJUSTMENT
37-42
37-42
37-42
12-15
12-15
12-15
18-23
45-50
40-45
40-45
*Overdrive Transmission
fThree Speed Synchronized Transmission
Overdrive
Inches
Cluster Gear End Play
0.004 - 0.018
GROUP 15
178
Engine
and
Transmission
Model
Manual
Shift
Speeds
(mph)
D1 or D2
D1
D2
2-3
Minimum
Throttle
2-3
Maximum
Throttle
3-1
Minimum
Throttle
3-2
Maximum
Throttle
2-1 or 3-1
Maximum
Throttle
3-2
Minimum
Throttle
2-1
Minimum
Throttle
D1
1-2
Minimum
Throttle
D1 or D2
1-2
Maximum
Throttle
260 V-8
PCT-A
7-9
35-42
10-21
58-67
6-8
54-62
26-36
6-10
17-24
352 V-8
PCD-D
8-10
37-46
14-24
60-70
7-8
56-65
27-36
7-10
19-26
390 V-8
PCE-G
8-10
38-46
14-24
62-71
7-8
57-66
27-37
7-10
19-26
390 V-8
PCE-H Police
Interceptor
6-11
47-56
14-27
79-90
6-8
73-81
37-46
4-11
21-31
TORQUE LIMITS
Selector
Lever
Position
Engine
Speed
(rpm)
450-475
Gauge
Reading
Police
(PSI) All V-8 Interceptor
Except Police
Interceptor
N-D1-D2
57-72
70-95
P-R-L
57-213
70-228
D1-D2
145-170
170-200
R-L
201-213
212-228
Stall
Specification
0.010-0.029 inch
Selective Thrust Washers
Available:
0.063-0.061 inch, 0.069-0.067 inch
0.076-0.074 inch, 0.083-0.081 inch
Item
Foot Pounds
15-28
35-45
17-22
30-35
40-45
20-25
4-6
8-10
17-22
28-38
10-13
7-15
35-40
20-25
35-40
17-20
25-35*
80-90*
25-35*
50-60*
0.002-0.009 inch
15-28
45-50
7-12
50-60*
20-30*
20-30*
20-30*
20-30*
20-30
Flat
*lnch-Pounds
GROUP 15
179
FORDOMATIC TRANSMISSION
CONTROL PRESSURE AT
ZERO OUTPUT SHAFT SPEED
EngineSpeed
Throttle
Position
Shift
Selector
Levr.r Position
Control
(Line)
Pressure
Closed
All
46-63
15 to 12.5
Inches of
Mercury
As
Required
Drive
Low
Reverse
Pressure
Starts
Rising
Stall Below
1.5 Inches
of Mercury
Through
Detent
(Wide Open)
Drive
Low
Reverse
175-200
Manifold Vacuum
Idle Above
15 Inches
of Mercury
Specifications
0.020-0.039 inch
Selective Thrust Washers
Available:
0.069-0.067 inch, 0.076-0.074 inch
0.085-0.083 inch, 0.094-0.092 inch
Transmission
Model
Free
Height
(inches)
PCH-B 223
PCP-B-C-D 260
Quarts
Total
Coils
Wire
Diameter
(inches)
3.29
9%
.207
3.11
103/4
.187
Selector Lever at D
Engine
VI w HOI
1-2
Minimum
Throttle
1-2
Thru
Detent
2-1
Thru
Detent
2-1
Closed
Throttle
260 V-8
13-17
46-54
45-52
10-14
223 Six
13-17
46-54
45-52
10-14
260 V-8
12-16
41-48
40-47
9-13
223 Six
12-16
41-48
40-47
9-13
3.50 to 1
3.89 to 1
TORQUE SPECIFICATIONS
Name
Thread
Foot-Poundi
Inch-Pounds
10-24 x /4
20-30
10-32 X Vie
20-30
%-20x%
10-24 x %
50-60
Screws
tf-20x
%-20xltt
10-24 x IK
20-30
70-85
Screw-Downshift Valve
tt-20xl%
10-24 x Vi
20-30
tf-20xltf
70-85
Screw-Plate to Body
10-24 x Me
20-30
Control
Valve
Body
20-30
70-85
8-10
180
GROUP 15
Foot-Pounds
/l6-18 X 5/8
10-13
Name
Oil Pan to Case
12-15
/l6-18 X 5/8
5
/l6-18 X /8
12-15
/ie-18 x %
12-17
18-22
/l6-18 X l f t
/ie-18xl%
Inch-Pounds
12-15
/8-16 X l f t
28-38
NUTS
Manual Control Shift Lever Shaft
/i6-24
15-18
/i6-24
15-18
/ 8 -24
15-18
ft-16
35-40
lVie-16
45-55
/2-20
5-8
PLUGS
Pressure Gauge Connection
ft-27 Taper
10-15
ft-27 Taper
10-15
ft-27 Taper
9-12
ft-27 Taper
20-28
ft-20
15-18*
0.003
0.003
Drive Gear
Pinion
3.00:1
39
13
3.25:1
39
25
3.56:1
32
3.89:1
35
4.11:1
37
0.004-0.009
Thickness
Differential Side Gear Thrust Washers
Differential Pinion Gear Thrust Washers
Number of Teeth
Ratio
0.030-0.032
0.030-0.032
0.020
0.008-0.029
GROUP 15
181
-4
-3
-2
-1
+4
+0.008
+0.007
+0.006
+0.005
+3
+0.007
+0.006
+0.005
+2
+0.006
+0.005
+1
+0.005
+1
+2
+3
+4
+0.004
+0.003
+0.002
+0.001
+0.004
+0.003
+0.002
+0.001
-0.001
+0.004
+0.003
+0.002
+0.001
-0.001
-0.002
+0.004
+0.003
+0.002
+0.001
-0.001
-0.002
-0.003
+0.004
+0.003
+0.002
+0.001
-0.001
-0.002
-0.003
-0.004
-1
+0.003
+0.002
+0.001
-0.001
-0.002
-0.003
-0.004
-0.005
-2
+0.002
+0.001
-0.001
-0.002
-0.003
-0.004
-0.005
-0.006
-3
+0.001
-0.001
-0.002
-0.003
-0.004
-0.005
-0.006
-0.007
-4
-0.001
-0.002
-0.003
-0.004
-0.005
-0.006
-0.007
-0.008
TORQUE LIMITS
TORQUE LIMITS-Continued
Foot
Pounds
Foot
Pounds
55-65
15-20
12-20
30-45
30-40
30-40
65-75
New Bearings
175*
17-27 inch-pounds
15-25
30-40**
8-12 inch-pounds
Used Bearings
.55-65
Standard
3-8 inch-pounds
Power
2-6 inch-pounds
Standard
10-16 inch-pounds
Power
*4-10 inch-pounds
No Perceptible Backlash
GROUP 15
182
TORQUE LIMIT
Part Name
Foot-Pounds
Part Name
Foot-Pounds
35-47
25-35
35-47
17-25
35-47
11-14*
25-35
60-70
15-20
8-11
110-150
28-43
12-16
8-13
60-80
32-40
3H-5
POWER STEERING
CHECKS AND ADJUSTMENTS
12 pounds
Engine
11-14
New: 120-150
Old: 90-120
FootPounds
Part Name
45-55
3
Mileage
Maker
Six
5-22
20-55
20-25
20-25
12-18
30-40
10-14
50-60
10-14
35-40
15-20
18-22
35-43
18-22
18-24
18-25
6-9
260 V-8
TORQUE LIMITS
Engine
All
Part Name
FootPounds
60-70*
16-21
35-47
15-20
35-43
352,
390
and
406 V-8
10-20
8-10
12-15
23-28
55-65
20-25
20-25
18-24
12-15
30-35
20-25
20-25
30-35
4-61/2
GROUP 15
183
Model
Drum
Maximum
Boring
Limit
(Inches)
Lining Length
Lining Width
(Inches)
(Inches)
Secondary
Primary
Primary
Secondary
IVi
IVi
Front
Sedan
Rear
Station Wagon,
Police Interceptor,
and Taxi
Wheel
Cylinder
Bore
Diameter
(Inches)
l 3 /32
15
11.030
9.34
11.090
12.12
Front
Rear
Master Cylinder
Bore
Diameter (Inches)
/l6*
1.000
l /32
IVi
15
/l6
Specification
Drum Diameter
11.030-11.045 inch
11.045-11.060 inch
Oversize
Power Unit
TORQUE LIMITS
FootPounds
Description
FootPounds
Description
20-25
FRONT BRAKES
12-16
15-19
30-40
12-18
POWIR BRAKES
Vacuum Manifold to Booster Body Mounting Bolt
8-10
10-13
15-25
20-30
80-100
75-110
25-35
Hand
Push Fit
75-110
10-20
30-40*
- V ^ t o + / 2 *
VB inch
61.0 inches
60.0 inches
Wheelbase
119 inches
/2
Toe-In
/4tO + l *
5
VS-VA inch
241/4
/s inch
TORQUE LIMITS
I Connecting Rod Sleeve Clamp Bolts
GROUP 15
184
Name
Lower Arm Ball Joint Assembly to Spindle Nut
70-90
60-80
28-35
28-35
65-85
15-25
15-25
40-60
36-46
15-25
80-100
25-35
8-13
20-35
Front Shock Absorber Pin & Bushing Assembly to Lower Arm Nut
12-20
160-190
160-240
40-60
REAR S U S P E N S I O N T O R Q U E L I M I T S
Name
Foot-Pounds
30-45
15-22
15-25
15-22
15-22
30-45
Width of
Springs
(Inches)
Deflection
Rate (Pounds
Per Inch)
Number of
Leaves
Capacity at
Normal Loaded
Height (Pounds)
2-Door Sedan
906-944
96-110
935-975
96-110
Model Application
2.5
Car-Heavy Duty
992-1038
Station Wagon-Standard
1155-1195
117-135
1280-1320
144-164
Number of
Leaves
Capacity at
Normal Loaded
Height (Pounds)
60.0
126-140
Length of Springs
Under Normal Load
(Inches)
Width of
Springs
(Inches)
Deflection
Rate (Pounds
Per Inch)
60.0
2.5
119-136
971-1009
CarHeavy Duty
1006-1054
Station Wagon
1188-1232
109-126
1223-1277
133-152
95-111
GROUP 15
185
Model Application
Tire Size
and Ply Rating
All except
Station Wagons
7>5
7 xx 114
4t
4"4t
Station Wagons
8.00 x 14-41
Inflation
Pressure
(psi)*
Front
Bolt
Circle
Diameter
(inches)
Rim
Type
Wheel
Number
Nut
of
Torque
Bolts (Foot-Pounds)
Rear
Wheel
Type
24
Disc
Ledge 5.5
4.5
28
Disc
Special 6.0
4.5
Front Wheel
Bearing
End
Play
0.001-0.0006
0.001-0.003 Preferred
75-110
24
*For Sustained High Speed Driving or for Hauling Heavy Loads, add 4 lbs. to recommended pressures.
f8.00 x 14 with Air Conditioning and 390 V-8 Engine.
J8.00 x 1 4 - 6 ply with Air Conditioning and 390 V-8 Engine.
Vendor
Amperes
(@ 15 V)
Watts
(@ 15 V)
Field Current
(Amps. @
12 V 75 F.)
Cut-In Speed
(Generator
rpm)*
Rated Output
Speed
(Generator
rpm)*
Belt
Width
(Inches)
Number
Used
Brushes
Original
Length
(Inches)
Spring
Tension
(Ounces)
0.9
20-26
Ford
30
450
1.2-1.8
1300
2525
Autolite
(Low Cut In)
40
600
1.2-1.8
960
1800
/8
15
Ford
Alternator
30
450
2.3-2.5
950
6500 (Hot)
Vs
0.63
7-12
Ford
Alternator
40
600
2.9-3.1
950
6500 (Hot)
0.63
7-12
/8
34-41
/l6
"To find the equivalent engine rpm, divide the generator pulley diameter by the crankshaft pulley diameter and then multiply by the generator rpm.
REGULATOR
Voltage Limiter
Current
Rating
Cut-Out
Voltage
Reverse
Amperage
To Open
Voltage
Regulation
75 F
Ford
30
12.0-12.8
6-9
Autolite
40
12.5-13.8
30
and
40
14.1-14.9
Manufacturer
Ford
Alternator
Field Relay
Current
Limiter
(Amperes)
Air
Gap
Contact
Gap
Air
Gap
Contact
Gap
14.6-15.4
28-32
14.3-15.1
32-48
0.045-0.052
0.010-0.015
0.022-0.030
0.015-0.022
GENERATOR DATA
Generator Commutator Maximum Runout
Generator Brushes Maximum Wear Limits
Alternator Brushes Maximum Wear Limits
0.002 inch
5
/8 inch
V22 inch
GROUP 15
186
VOLTAGE REGULATION SETTING
Ambient
Temperature
F.
Standard Ford
Generator
Regulator
Ambient
Temperature
F.
Standard Ford
Alternator
Regulator
25
15.1-15.9
25
14.4-15.0
95
14.3-15.1
35
15.0-15.8
50
14.3-14.9
105
14.2-15.0
45
14.9-15.7
75
14.1-14.7
115
14.1-14.9
55
14.8-15.6
100
13.9-14.5
65
14.7-15.5
125
13.8-14.4
125
13.9-14.7
75
14.6-15.4
150
13.6-14.2
135
13.8-14.6
85
14.5-15.3
175
13.5-14.1
145
13.6-14.4
Ambient
Temperature
F.
Standard Ford
Generator
Regulator
Ambient
Temperature
F.
Standard Ford
Alternator
Regulator
STARTER MOTOR
Engine
Current Draw
Under Normal
Load
(Amperes)
Normal Engine
Cranking
Speed
(rpm)
Minimum Stall
Torque @ 5
Volts
(Foot-Pounds)
Maximum
Load
(Amperes)
No Load
Amperage
155-210
150-180
14.8
580
80-110
260 V-8
250-290
15.5
670
70
STARTER BRUSHES
Minimum
Mfg. Length
(Inches)
7
Wear
Limit
(Inches)
5
/l6
/l6
SPECIFIC GRAVITY
Brush
Spring Tension
(Ounces)
No.
Used
48
Amp.
Battery
Engine
and Transmission
Plain
Red
Yellow
66
54
55
55
Dry Charge
Red
Gray
Green
78
66
65
70
OPTION
Freezing Temp.
1.280
1.250
1.200
1.150
1.100
-90F.
-62F.
-16F.
+ 5F.
+19F.
All Engines
Yellow
66
70
Gray
78
65
(Domestic Only)
Specific
Gravity
1.150 or less..
1.150 to 1.175.
1.175 to 1.200.
1.200 to 1.225.
Above 1.225..
Maximum
Fast Charge Time
1 hour
% hour
Vz hour
VA hour
Slow Charge Only
Ground
Hours
Negative
GROUP 15
187
Unit
Candle Power
or Wattage
Trade No.
2 c.p.
1895
Cluster Illumination
2c.p.
1895
Heater Control
2 c.p.
1895
Clock
2 c.p.
1895
Hi Beam Indicator
2c.p.
1895
2 c.p.
1895
Generator Indicator
2 c.p.
1895
Radio Dial
2 c.p.
1891
Trade No.
EXTERIOR LIGHTS
Unit
INSTRUMENT PANEL INDICATORS
37.5 w
4001
50/37.5 w
4002
32/4 c.p.
1157
32/4 c.p.
1157
32 c.p.
1156
Spot Light
30 w
4405
License Plate
4 c.p.
1155
Back-Up Light
INTERIOR ILLUMINATION
Dome Light
15 c.p.
1003
Courtesy LightConvertible
4 c.p.
1155
Courtesy LightTaxi
2 c.p.
1895
Location
Protective Device
Spotlight
Clock
Cigar Lighter
Reset C.B.
Overdrive
3AG-15 Fuse
SFE-14 Fuse
Headlight
3AG-15 Fuse
Radio
Heater Blower
SFE 14 Fuse
Air Conditioning
Power Circuit
Ground Circuit
Front Doors
Circuit Breaker
Rear Doors
Circuit Breaker
Rear Quarters
Circuit Breaker
Tail Gate
Electric Seat
SFE 14 Fuse
188
GROUP 15
INSTRUMENT VOLTAGE
5 Volts |
0.7 0.3
Ford Two-Speed
Low
High
3.0 + 0.3
2.0 + 0.3
I Operating Pressure
psi
Model No.
Manufacturer
3TMF
Motorola
3TBM
Bendix
F-3TBF
Bendix (AM-FM)
F-3TBM
Bendix (AM-FM)
At Medium Speed
At High Speed
Unit
SelectAire Blower
HI
12-14
Ford Blower
HI
6-8
Magnetic Clutch
SEDANS
Gauge
Reading
2.65
TURN INDICATOR
Current Draw at 12 Volts
0-4 Amperes
STATION WAGONS
Approximate
Gallons in Tank
Gauge
Reading
Approximate
Gallons in Tank
1.5-4
2-4.5
4-7.5
5.5-9
Vz
7.5-11
Vz
9.5-13
%
F
12-15.5
/4
13.5-17
15.5-19
16-19.5
8.00 x 14
7.50 x 14
Teeth in
Drive Gear
Teeth in
Driven Gear
Color
Teeth in
Drive Gear
Teeth in
Driven Gear
2-Sp. Auto.
18
Purple
18
Purple
3-Sp. Auto.
18
Natural
18
Natural
Manual-Shift
19
Red
18
Natural
Overdrive
19
Red
18
Natural
2-Sp. Auto.
21
Yellow
21
Yellow
3-Sp. Auto.
21
Green
21
Green
Manual-Shift
20
Orange
20
Orange
Overdrive
20
Orange
20
Orange
Transmission
Color
3.00:1
3.50:1
3.89:1
Screw Size
3
Head Type
Torque (in-lbs)
Base Plate
Cylinder Head
Hex Head
144-192
!/4-20x5/8 UNC2A
Hex Head
66-120
Service Valve
/i6-18xl% UNC2A
Allen Socket
120-144
Mounting Bolt
/8-16UNC2A
Hex Head
164-200
/i6-18x / 4 UNC2B
Hex Head
120-192
Flat Head
60-120