Ford 1956, Thunderbird 1956 Shop Manual

19

5

6

FORD

DIVISION

M

O

T

O

COMPANY

Copyright © 2009, Forel Publishing Company, LLC, Woodbridge, Virginia

All Rights Reserved. No part of this book may be used or reproduced in any manner whatsoever

without written permission of Forel Publishing Company, LLC. For information write to Forel

Publishing Company, LLC, 3999 Peregrine Ridge Ct., Woodbridge, VA 22192

1956 Ford Car Shop Manual

EAN: 978-1-60371-006-0

ISBN: 1-60371-006-X

Forel Publishing Company, LLC

3999 Peregrine Ridge Ct.

Woodbridge, VA 22192

Email address: [e-mail]

Website: http://www.ForelPublishing.com

This publication contains material that is reproduced and distributed under a license from Ford

Motor Company. No further reproduction or distribution of the Ford Motor Company material is

allowed without the express written permission of Ford Motor Company.

NNoottee ffrroomm tthhee EEddiittoorr

This product was created from the original Ford Motor Company’s publication. Every effort has
been made to use the original scanned images, however, due to the condition of the material;
some pages have been modified to remove imperfections.

Although every effort was made to ensure the accuracy of this book, no representations or
warranties of any kind are made concerning the accuracy, completeness or suitability of the
information, either expressed or implied. As a result, the information contained within this book
should be used as general information only. The author and Forel Publishing Company, LLC
shall have neither liability nor responsibility to any person or entity with respect to any loss or
damage caused, or alleged to be caused, directly or indirectly by the information contained in
this book. Further, the publisher and author are not engaged in rendering legal or other
professional services. If legal, mechanical, electrical, or other expert assistance is required, the
services of a competent professional should be sought.

Disclaimer

19

5

6

Copyright

1955

FORD

MOTOR

COMPANY

DEARBORN,

MICHIGAN

All

rights

reserved

'Reproduced

under

License

#5008

trom

Ford

Motor

Company-February

2002.

September,

1955

FORD

DIVISION

FORD

MOTOR

COMPANY

FOREWORD

This

manual

has

been

prepared

to

provide

information

for

the

proper

servicing

of

1956

Ford

Cars

and

the

1956

Ford

Thunderbird.

The

manual

should

be

kept

where

it

will

be

readily

available

for

reference

at

all

times.

The

service

procedures

are

accompanied

by

illustrations

of

many

of

the

service

operations.

Disassembled

views

of

some

of

the

car

units

are

also

given.

The

manual

is

divided

into

five

main

parts

as

listed

in

the

Table

of

Contents

on

the

following

pages.

Part

ONE

POWER

PLANT

is

composed

of

the

various

engines

and

their

related

systems,

which

are

ignition,

fuel,

and

cooling.

Part

TWO

-CHASSIS

-includes

information

on

the

entire

power

train

(clutch,

conventional

transmission,

Overdrive,

drive

line,

rear

axle,

etc.)

and

the

running

gear

(frames,

springs,

suspen

sion,

brakes,

wheels,

tires,

steering

gear,

steering

linkages,

etc.).

Service

procedures

for

the

Fordomatic

transmission

are

published

in

a

separate

manual.

Part

THREE

-

ELECTRICAL

AND

ACCESSORIES

-

covers

all

of

the

electrical

systems

and

units

(except

the

ignition

system)

and

all

of

the

accessories

(except

the

Overdrive

and

Fordomatic).

Part

FOUR

BODIES

contains

information

on

the

mainte

nance

and

repair

of

all

body

components,

including

adjustment

and

alignment

of

doors,

hoods,

and

fenders.

Window

glass

adjustments

are

also

included

in

this

part.

Part

FIVE

-MAINTENANCE

AND

SPECIFICATIONS

-

includes

complete

maintenance

and

lubrication

information,

and

contains

all

the

specifications

necessary

for

properly

servicing

Ford

cars.

The

page

headings,

throughout

the

manual,

designate

the

subject

matter

covered.

The

heading

on

each

left-hand

or

even-numbered

page

indicates

the

name

of

the

chapter

and

the

heading

on

each

right-hand

or

odd-numbered

page

indicates

the

section

covered.

The

descriptions

and

specifications

contained

in

this

manual

were

in

effect

at

the

time

the

book

was

approved

for

printing.

The

Ford

Division

of

Ford

Motor

Company

reserves

the

right

to

dis

continue

models

at

any

time,

or change specifications

or

design,

without

notice

and

without

incurring

obligation.

SERVICE

DEPARTMENT

FORD

DIVISION

FORD

MOTOR

COMPANY

TABLE

OF

CONTENTS

Foreword

.

.

Section

1

2

3

4

5

Section

Section

1

2

3

4

5

6

Section

1

2

3

4

5

6

Section

1

2

3

4

Section

1

2

3

Section

1

2

3

4

5

Section

1

2

3

Section

1

2

3

4

Part

TWO-CHASSIS

CHAPTER

I

CLUTCH,

TRANSMISSION,

AND

GEAR

SHIFT

LINKAGE

Section

5

Conventional

3-Speed

Transmission.

6

Overdrive

Transmission

.

7

Gear

Shift

Linkage

.

CHAPTER

II

REAR

AXLES

AND

DRIVE

LINES

Trouble

Shooting

.

Clutch

.

Flywheel

Housing

Alignment.

Transmission

Cleaning

and

Inspection

117

119

123

124

Trouble

Shooting.

Cleaning

and

Inspection.

.

.

Banjo

Housing

Hypoid

Rear

Axle

Trouble

Shooting

Wheel

Alignment.

Frames.

Front

Suspension

.

Rear

Suspension.

.

.

141

.

.

142

143

CHAPTER

III

159

.

.

161

163

164

168

Section

4

Integral

Housing

Hypoid

Rear

Axle.

5

Drive

Lines.

RUNNING

GEAR

Section

6

Shock

Absorbers.

7

Steering

Gear

...

8

Steering

Linkage

.

9

Wheels

and

Tires.

10

Hubs

and

Bearings

CHAPTER

IV

POWER

STEERING

Troubleshooting

183

Inspection

and

Maintenance

186

Power

Steering

System

Operation.

.

.

187

CHAPTER

V

Section

4

5

6

7

Pump

and

Fluid

Reservoir

Assembly

Control

Valve

Assembly.

Power

Cylinder

Assembly

.

.

Steering

Linkage

.

Troubleshooting.

206

Adjustments.

207

Hydraulic

System

.

208

Brake

Assemblies.

212

Brake

Drums

Vacuum

Booster

Page

2

Part

ONE-POWER

PLANT

CHAPTER

I

GENERAL

ENGINE

OVERHAUL,

INSPECTION,

AND

REPAIR

Page

^age

Troubleshooting.

5

Section

6

Timing

Chain,

Sprockets

and

Camshaft

20

Tune-Up

8

7

Flywheeel,

Crankshaft

and

Main

Bearings.

22

Engine

Removal

and

Installation

10

8

Cylinder

Block,

Pistons,

Piston

Rings,

and

Intake

and

Exhaust

Manifolds

...

14

Connecting

Rods

and

Bearings

.

...

25

Rocker

Mechanism,

Cylinder

Head,

Valves,

9

Oil

Pan

and

Oil

Pump

29

Valve

Lash

Adjustment,

and

Valve

Timing.

.15

10

Exhaust

System

30

CHAPTER

II

6-CYLINDER

ENGINE

Engine

Steady

Rest.

31

Section

7

Flywheel,

Crankshaft,

and

Main

Bearings

39

Manifolds

....

32

Cylinder

Head

and

Valves.

33

8

Connecting

Rods

and

Bearings,

Pistons,

Pins,

Crankshaft

Damper.

.

....

36

and

Rings

42

Cylinder

Front

Cover

and

Crankshaft

Oil

Seal

36

g

Qil

p

Qil

pilter

and

oil

p

44

sprocket

and

Timing

Chain,

Camshaft

and

Bearings,

and

Tappets

.

37

10

Exhaust

System

.

45

CHAPTER

III

8-CYLINDER

ENGINES

General

Information.

47

Section

7

Sprockets

and

Timing

Chain,

Camshaft

and

Engine

Steady

Rest.

.

49

Bearings,

and

Tappets

56

Manifolds

49

8

Flywheel,

Crankshaft,

and

Main

Bearings

.

60

-

..

,

'.''..,

,

9

Connecting

Rods

and

Bearings,

Pistons,

Pins,

Cylinder

Heads

and

Valves

51

and

Rings

62

Crankshaft

Damper...

54

io

Oil

Pan,

Oil

Filter,

and

Oil

Pump.

.

.

64

Cylinder

Front

Cover

and

Crankshaft

Oil

Seal

.

55

11

Exhaust

System

..

.

...

66

CHAPTER

IV

IGNITION,

FUEL,

AND

COOLING

SYSTEMS

Ignition

System

....

69

Section

7

Four-Barrel Carburetor

Operation,

Distributor

Minor

Repair

and

Adjustments.

.

74

Adjustments,

and

Overhaul

95

Distributor

Overhaul

.

....

78

8

Fuel

Pumps,

Vacuum

Booster,

and

Fuel

Filter

.

108

Carburetor

Operation

and

Adjustments

9

Fuel

Tanks

and

Lines.

110

Single

and

Dual

Carburetors.

.

84

10

Fans

and

Belts.

.

.

Ill

Single

Barrel

Carburetor

Overhaul.

.89

11

Water

Pumps

112

Dual

Carburetor

Overhaul

92

12

Radiator,

Hose,

and

Thermostat

115

125

129

138

152

158

169

170

175

178

181

190

194

200

202

BRAKES

Section

5

6

7

Parking

Brakes.

216

213

214

Part

THREE-ELECTRICAL

AND

ACCESSORIES

CHAPTER

I-GENERATING

SYSTEM

AND

BATTERY

Section

1

Trouble

Shooting

. .

2

Generator

Page

217

221

Section

3

Generator

Regulator

4

Battery

Page

.

226

.

232

CHAPTER

II

STARTING

SYSTEM

Section

1

Trouble

Shooting

235

2

Starter

and

Circuit

238

Section

3

Starter

Drive

244

CHAPTER

III

LIGHTING

SYSTEM,

HORNS,

AND

INSTRUMENTS

Section

1

Trouble

Shooting

245

2

Lighting

System

247

Section

3

Horns

252

4

Instruments

253

CHAPTER

IV

ACCESSORIES

Section

1

Trouble

Shooting

257

Section

4

Windshield

Wiper

268

2

Radio

260

5

Miscellaneous

Accessories

269

3

Heater

265

Part

FOUR

BODIES

CHAPTER

I

BODY

CONSTRUCTION

AND

MAINTENANCE

Section

1

Construction

Details

and

Sealer

Application.

.

.

271

Section

4

2

Body

Alignment

278

5

3

Quarter

Panel

Repair

279

6

Fibre

Glass

Repair

Thunderbird

Hardtop

....

281

General

Body

Maintenance

282

Paint

Refinishing

284

CHAPTER

II-

Section

1

Door

and

Quarter

Trim

Panels.

...

2

Headlining

Replacement

3

Ventilator

and

Division

Bar

TRIM,

UPHOLSTERY,

AND

WINDOW

GLASS

289

292

294

Section

4

5

6

7

Door

Glass

and

Regulator

Replacement

296

Door

Glass

Adjustments

299

Quarter

Glass

303

Windshield

and

Rear

Window

307

Section

1

2

3

CHAPTER

III

REMOVABLE

SHEET

METAL

ASSEMBLIES

Section

5

6

7

8

Door

Replacement

and

Alignment

313

Door

Locking

Mechanism

317

Luggage

Compartment

Door

Replacement

and

Alignment

320

Luggage

Compartment

Door

Locking

Mechanism

323

Grille

and

Hood

324

Hood Alignment

and

Lock

Adjustment

326

Thunderbird

Grille

and

Hood

328

Front

Fenders

329

CHAPTER

IV

POWER

INSTALLATIONS

AND

SPECIAL

ITEMS

Section

1

Power

Windows

331

Section

4

2

Power

Seats

337

5

3

Convertible

Top

342

6

Thunderbird

Top

Adjustments

347

Care

of

Country

Squire

Paneling

349

Crown

Victoria

Transparent

Top

350

Part

FIVE-MAINTENANCE

AND

SPECIFICATIONS

CHAPTER

I-MAINTENANCE

Section

1

Preventive

Maintenance

353

Section

2

Lubrication

355

CHAPTER

II

SPECIFICATIONS

Section

1

Wheels

and

Tires

357

2

Brakes

357

3

Wheel

Alignment

and

Steering

358

4

Rear

Axles

358

5

Frame

and

Springs

359

6

Engines

360

7

Clutch

and

Transmission

362

Section

8

Cooling

353

9

Fuel

System

353

10

Generating

System

354

1

1

Starting

System

354

1

2

Ignition

354

13

Fuse

and

Bulb

Chart

365

14

Paint

365

15

Tools

and

Equipment

355

Part

ONE

POWER

PLANT

Chapter

i

Genera/

Engine

Overhaul,

Inspection,

and

Repair

Section

Page

1

Trouble

Shooting

5

2

Tune-Up

8

3

Engine

Removal

and

Installation

10

4

Intake

and

Exhaust

Manifolds

14

5

Rocker

Mechanism,

Cylinder

Head,

Valves,

Valve

Lash

Adjustment,

and

Valve

Timing

15

6

Timing

Chain,

Sprockets,

and

Camshaft

20

7

Flywheel,

Crankshaft,

and

Main

Bearings

22

8

Cylinder

Block,

Pistons,

Piston

Rings,

and

Connecting

Rods

and

Bearings

25

9

Oil

Pan

and

Oil

Pump

29

10

Exhaust

System

30

Trouble

shooting;

tune-up;

the

cleaning,

inspection,

after

the

engine

has

been

disassembled.

and

repair

of

component

parts;

and

overhaul

instruc-

To

completely

disassemble

or

assemble

an

engine,

tions

are

covered

in

this

chapter.

follow

all

the

removal

or

installation

instructions

con-

The

cleaning,

inspection,

repair,

and

overhaul

instruc-

tained

in

the

applicable

engine

chapter.

If

it

is

only

tions

apply

only

after

the

parts

have

been

removed

desired

to

remove

or

install

an

individual

part,

refer

to

from

the

engine,

or

in

the

case

of

a

complete

overhaul

the

applicable

section.

1.

TROUBLE

SHOOTING

Trouble

shooting

is

the

application

of

a

definite

pro

cedure,

in

a

logical

sequence,

to

locate

and

eliminate

the

cause

of

trouble

in

a

particular

system

or

unit.

When

trouble

shooting,

first

look

for

the

obvious

causes

of

trouble,

such

as;

an

empty

gas

tank,

a

wet

or

cold

en

gine,

loose

or

disconnected

wiring,

or

any

other

item

that

may

cause

a

temporary

defect.

The

various

factors

that

affect

power

plant

operation

are

outlined

in

this

section.

a.

Engine.

Poor

engine

performance

can

be

attributed

to

the

engine

or

to

forces

on

the

car

that

tend

to

retard

its

motion.

For

example,

dragging

brakes

can

cause

the

engine

to

work

harder

which

will

result

in

poor

performance.

Engine

performance

depends

on

proper

fuel

distribu

tion,

correctly

timed

ignition,

normal

and

uniform

com

pression,

and

an

unobstructed

flow

of

exhaust

gases.

Engine

troubles,

their

causes,

and

remedies

are

dis

cussed

under

appropriate

headings.

(1)

ENGINE

WILL

NOT

CRAISK.

If

the

starter

does

not

turn

the

engine

over,

or

turns

it

over

too

slowly

to

start,

the

most

probable

causes

are

a

defective

bat

tery

or

starter.

Perform

the

following

checks

in

the

order

listed,

until

the

trouble

is

located.

(a)

Check

the

Battery.

Try

the

horn

or

lights.

If

they

do

not

operate

properly,

test

the

battery.

Recharge

or

replace

the

battery

as

necessary.

(b)

Check

the

Battery

Cables.

Check

for

loose

or

corroded

connections

at

the

starter,

relay,

battery,

and

ground.

Clean,

tighten

or

replace

them

as

necessary.

(c)

Check

the

Starter

Relay

Circuit.

The

relay

contact

surfaces

seldom

become

so

badly

burned

that

they

will

prevent

the

starter

from

cranking

the

engine.

However,

other

wiring

may

be

at

fault.

Repair

as

nec

essary.

Refer

to

Part

THREE,

"Electrical

and

Ac

cessories."

(d)

Check

the

Starter

or

Starter

Drive.

If

the

above

components

are

not

at

fault,

the

trouble

is

prob

ably

in

the

starter

or

starter

drive.

If

the

starter

is

run

ning,

but

not

engaging

the

flywheel,

remove

the

starter

and

make

the

necessary

repairs

to

the

starter

drive.

In

rare

cases,

the

starter

drive

may

lock

up

with

the

fly

wheel.

This

can

be

corrected

by

loosening

the

starter

and

releasing

the

starter

drive.

If

the

starter

does

not

operate,

remove

it

and

make

the

necessary

repairs.

(2)

ENGINE

CRANKS.

BUT

WILL

NOT

START.

The

trouble

probably

lies

in

either

the

ignition

system

or

the

fuel

system.

The

following

test

will

determine

which

system

is

at

fault:

Remove

the

ignition

wire

from

one

spark

plug,

and

Chapter

1

General

Engine

Overhaul,

Inspection,

and

Repair

insert

a

piece

of

proper

sized

metal

rod

so

it

protrudes

from

the

insulator.

With

the

ignition

on

and

the

starter

turning

the

engine

over,

hold

the

end

of

the

rod

approximately

3/16

inch

from

the

block.

CAUTION:

On

Fordomatic

equipped

cars,

make

sure

the

selector

lever

is

in

"N."

Ii

there

is

no

spark,

or

if

there

is

a

weak

spark,

follow

steps

"a"

or

"b"

whichever

is

applicable.

If

there

is

a

good

spark,

proceed

with

step

"c."

(a)

No

Spark.

Follow

the

steps

below

to

determine

the

cause,

and

make

the

necessary

repairs

or

replace

ments.

(

1

)

Pull

the

coil

wire

from

the

top

of

the

distributor.

Hold

the

wire

316

inch

from

the

cylinder

head,

and

with

the

ignition

on

and

the

engine

turning

over,

check

for

a

spark.

CAUTION:

On

Fordomatic

equipped

cars,

make

sure

the

selector

lever

is

in

"/V."

If

a

good

spark

is

obtained,

the

trouble

lies

in

either

the

distributor

cap,

rotor,

or

spark

plug

wires.

Make

sure

these

components

are

clean,

dry,

and

not

defective.

Make

repairs

or

replacements

as

necessary.

(2)

If

there

was

no

spark

in

(1),

clean

the

coil

tower

socket,

or

replace

the

high

tension

wire

between

the

coil

and

distributor,

then

repeat

the

check.

If

a

weak

spark

exists,

the

points

are

probably

arcing.

Test

the

condenser

and

replace

it

if

necessary.

Adjust

the

points.

If

a

weak

spark

persists,

test

the

coil,

and

replace

it

if

necessary.

(3)

If

there

was

no

spark

in

(2),

remove

the

dis

tributor

cap,

and

see

if

the

points

are

"breaking"

and

if

an

electrical

spark

occurs

at

the

points.

Adjust

or

replace

the

points

as

necessary.

If

there

is

a

spark

at

the

points;

install

a

"jumper"

between

the

"DIST"

terminal

of

the

coil

and

the

distributor,

then

check

for

a

spark

at

the

points.

If

there

is

a

spark,

replace

the

coil

to

distributor

primary

wire.

If

there

is

no

spark,

crank

the

engine

until

the

points

are

closed,

then

install

a

"jumper"

on

one

of

the

primary

coil

terminals

and

check

for

a

spark

at

the

other

terminal.

Replace

the

coil

if

there

is

now

a

spark.

If

there

is

no

spark,

install

a

"jumper"

between

the

battery

and

the

battery

terminal

of

the

coil,

then

check

for

a

spark

at

the

points.

If

a

spark

exists,

the

ignition

switch

or

switch

to

coil

wiring

is

defective

and

must

be

repaired

or

replaced.

(b)

Weak

Spark.

Perform

the

following

checks

in

the

order

listed:

(

1

)

The

battery

may

be

weak.

Test

the

battery,

then

charge,

or

replace

it

if

necessary.

(2)

Remove

the

distributor

cap,

and

adjust,

clean,

or

replace

the

points

as

necessary.

Severely

pitted

points

usually

indicate

that

the

voltage

regulator

is

improperly

set

or

the

condenser

is

faulty.

(3)

Check

the

condition

of

the

rotor,

distributor

cap,

and

plug

wires.

The

wires

must

be

clean,

dry,

and

fully

seated

in

the

terminals.

Replace

any

damaged

or

cor

roded

wires.

(4)

If

the

weak

spark

persists,

test

the

coil,

and

re

place

it

if

necessary.

(c)

Good

Spark.

If

there

is

a

good

spark,

perform

the

following

fuel

system

checks

in

the

order

given.

(1)

Check

the

fuel

supply

at

the

fuel

tank.

(2)

Check

to

see

if

fuel

is

reaching

the

carburetor.

Remove

the

air

cleaner,

and

look

down

the

carburetor

throat

while

working

the

throttle

by

hand

several

times.

Each

time

the

throttle

is

actuated,

fuel

should

spurt

from

the

accelerator

pump

discharge

nozzle.

If

there

is

fuel

at

this

point,

the

engine

is

probably

flooded

or

there

is

water

in

the

fuel

system.

If

no

fuel

is

observed

at

this

point,

disconnect

the

carburetor

inlet

line

at

the

carburetor.

Using

a

suitable

container

to

catch

the

fuel,

crank

the

engine

to

see

if

fuel

is

reaching

the

inlet

fitting.

If

fuel

is

reaching

the

inlet

fitting,

the

trouble

is

in

the

carburetor.

Repair

the

carburetor

as

necessary.

If

no

fuel

is

reaching

the

inlet

fitting,

the

trouble

is

in

the

fuel

pump

or

the

fuel

pump

inlet

line

is

clogged.

NOTE:

Check

the

flexible

fuel

pump

inlet

line

for

a

collapsed

condition.

Remove

the

fuel

tank

filler

cap,

then

disconnect

the

fuel

pump

inlet

line

at

the

pump.

Blow

air

into

the

line

to

remove

any

obstructions.

Connect

the

line

and

try

to

start

the

engine.

If

the

engine

does

not

start,

check

the

fuel

pump

pressure,

then

repair

or

replace

the

pump

as

necessary.

(3)

ENGINE

STARTS

BUT

FAILS

TO

KEEP

RUN

NING.

Check

the

fuel

system

first.

The

ignition

system

sometimes

can

cause

trouble,

but

it

is

usually

after

the

engine

has

run

for

some

time

and

is

at

operating

temperature.

(a)

Check

the

fuel

supply

at

the

tank.

(b)

Try

to

start

the

engine.

If

the

engine

will

oper

ate

with

constant

foot

throttle,

adjust

the

idle

speed

and

check

the

choke

adjustment.

If

it

will

not

operate

with

constant

foot

throttle,

check

the

fuel

system

as

outlined

in

(2)

(c).

(c)

If

the

fuel

system

is

operating

correctly

and

the

engine

still

stalls,

it

may

be

due

to

the

coil

or

condenser

breaking

down

under

operating

temperature.

Check

these

components,

and

replace

them

as

necessary.

(4)

ENGINE

CONTINUALLY

MISSES

AT

IDLE.

When

the

engine

continually

misses

on

the

same

cylin

ders,

the

fault

generally

lies

in

the

ignition

system.

(a)

Isolate

the

miss

by

pulling

one

spark

plug

cable

at

a

time

from

the

plugs.

Remove

the

plugs,

then

clean,

inspect,

and

adjust

them.

Replace

those

that

are

badly

fouled

or

burned.

(b)

Check

the

spark

plug

wires

for

signs

of

deteriora

tion

and

corrosion

and

replace

them

as

necessary.

(c)

Remove

the

distributor

cap

and

rotor,

then

clean,

inspect,

and

replace

them

as

necessary.

Section

1

Trouble

Shooting

(d)

If

the

above

steps

do

not

correct

the

condition,

check

the

compression

to

determine

if

it

is

satisfactory

and

check

the

intake

manifold

passages

for

obstructions.

(5)

ENGINE

MISSES

ERRATICALLY

AT

IDLE.

A

miss

of

this

type

may

be

caused

by

a

combination

of

things.

Check

the

following

in

sequence:

(a)

Carburetor,

including

choke

operation,

idle

mix

ture

setting,

and

fuel

level.

(b)

The

ignition

system,

starting

with

the

spark

plugs.

Make

the

necessary

repairs.

(c)

The

vacuum

lines

and

fittings

for

leaks.

Make

any

necessary

repairs.

(d)

Valve

operation.

Perform

a

compression

test

if

the

miss

persists.

Repair

the

engine

as

necessary.

(6)

ENGINE

MISFIRES

OR

HESITATES

ON

AC

CELERATION.

This

malfunction

is

usually

a

combina

tion

of

faults

in

the

ignition

and

fuel

system,

but

also

can

be

caused

by

the

exhaust

system.

Check

the

follow

ing

in

sequence.

(a)

Check

the

operation

of

the

exhaust

gas

control

valve.

If

it

is

sticking,

free

it

up

or

replace

it

as

necessary.

(b)

Check

the

paint

on

the

intake

manifold

heat

riser

passage.

If

the

paint

is

not

burned

off,

the

passage

may

be

obstructed

preventing

the

carburetor

from

properly

vaporizing

the

fuel.

(c)

Remove

the

spark

plugs.

Inspect,

clean,

and

adjust

the

gap.

Replace

any

plugs

that

are

defective

or

lead-fouled.

(d)

Remove

the

distributor

cap,

and

check

the

point

gap,

distributor

shaft

clearance,

condition

of

the

cam

lobes,

and

the

points.

Make

the

necessary

repairs

or

replacements.

Check

the

high

tension

wiring

for

signs

of

deterioration,

and

make

replacements

or

repairs

as

necessary.

(e)

Check

the

coil

and

condenser.

Replace

them

if

they

are

defective.

(f)

Check

the

fuel

pump

pressure

and

adjust

the

carburetor

fuel

level.

Check

the

accelerator

pump

action

and

linkage.

(g)

If

the

problem

still

persists,

perform

a

compres

sion

test,

and

check

the

valve

lash.

Check

the

valve

spring

rates

and

assembled

height.

Make

repairs

or

replacements

as

necessary.

(7)

ENGINE

DOES

NOT

DEVELOP

FULL

POWER.

Lack

of

power

is

usually

caused

by

poor

compression.

However,

some

preliminary

checks

should

be

made.

Make

sure

the

throttle

opens

all

the

way,

and

the

choke

remains

open.

After

preliminary

checks

are

made,

perform

the

following

operations

if

the

trouble

has

not

been

located:

(a)

Check

the

compression.

This

will

indicate

whether

the

internal

components

are

operating

properly.

(b)

If

the

compression

checks

within

limits,

check

the

ignition

system,

including

initial

timing

and

distri

butor

operation.

(c)

If

the

compression

and

the

ignition

system

are

satisfactory,

check

the

fuel

system,

including

carburetion

and

fuel

pump

pressure.

(d)

If

the

problem

still

exists,

a

check

of

mechanical

components

must

be

made.

Check

the

valve

lash,

cam

lobe

lift,

and

valve

timing.

Make

the

necessary

repairs.

b.

Fuel

System.

The

fuel

system

consists

of

the

fuel

tank,

fuel

pump,

carburetor,

and

connecting

lines.

Dirt

and

other

foreign

material

are

a

major

source

of

fuel

system

problems.

Keep

all

components

as

clean

as

possible.

(1)

EXCESSIVE

FUEL

CONSUMPTION.

Faulty

carburetion

is

usually

responsible

for

excessive

fuel

consumption.

However,

the

following

preliminary

checks

should

be

made:

Check

for

fuel

leaks

in

the

system.

Check

choke

oper

ation

and

adjustment,

and

make

certain

the

accelerator

linkage

is

free.

Check

to

see

if

the

brakes

are

dragging.

Adjust

the

carburetor.

(a)

Verify

the

complaint

with

test

equipment

in

stalled

in

the

car.

Show

the

customer

how

improper

operation

of

the

car

will

affect

fuel

consumption.

(b)

If

the

test

shows

fuel

consumption

to

be

exces

sive,

rebuild

the

carburetor.

Since

poor

carburetion

is

usually

a

combination

of

internal

malfunctions,

it

is

usually

not

advisable

to

try

to

repair

only

one

system

in

the

carburetor.

Time

will

be

saved

by

a

complete

carburetor

overhaul.

(2)

CARURETOR

FLOODS.

Make

a

visual

inspec

tion

of

the

carburetor

for

leaking

gaskets

or

casting

defects.

Tap

the

carburetor

bowl.

If

the

flooding

stops,

the

inlet

needle

was

held

open

by

foreign

material.

If

the

flooding

persists,

follow

the

steps

below:

(a)

Remove

the

air

cleaner

and

check

the

choke

operation.

(b)

Check

the

fuel

level,

the

condition

of

the

car

buretor

float,

and

the

fuel

inlet

needle

and

seat.

Replace

any

defective

parts.

(c)

Check

fuel

pump

pressure.

If

the

pressure

is

excessive,

the

pump

was

forcing

fuel

past

the

inlet

needle

and

the

pump

should

be

rebuilt

or

replaced.

c.

Cooling

System.

The

cooling

system

is

thermostatically

controlled

to

regulate

engine

operating

temperature

and

provide

for

a

short

engine

warm-up

period.

(1)

ENGINE

OVERHEATS.

Usually,

engine

over

heating

is

the

result

of

insufficient

coolant

supply.

Check

the

coolant

level

first.

Make

certain

that

the

cause

of

trouble

is

not

anti-freeze

evaporation.

(a)

If

the

supply

is

low,

check

for

leaks

in

the

cooling

system,

then

make

the

necessary

repairs.

(b)

Check

the

water

pump

belt

for

proper

tension

and

adjust

it

if

it

is

loose.

8

Chapter

1

General

Engine

Overhaul,

Inspection,

and

Repair

(c)

Inspect

the

radiator

fins

for

obstructions

(bugs,

dirt,

etc.).

Clean

it

if

it

is

clogged.

(d)

Using

a

thermometer

in

the

radiator,

check

the

gauge

reading

for

accuracy.

NOTE:

Inaccurate

readings

are

sometimes

caused

by

insufficient

clearance

between

the

head

casting

and

the

temperature

sending

unit

element.

Make

repairs

or

replacements

as

necessary.

(e)

Check

the

thermostat

for

proper

operation

and

heat

range.

If

it

is

defective

or

of

the

wrong

heat

range,

replace

it.

Make

sure

the

thermostat

is

correctly

installed.

(f

)

Check

the

ignition

timing

and

adjust

it

if

necessary.

(g)

Check

the

radiator

for

proper

flow.

Flush

it

if

necessary.

(h)

Remove

the

water

pump

and

check

for

a

defec

tive

impeller

or

a

water

passage

obstruction.

Make

repairs

or

replacements

as

necessary.

(i)

Check

the

cylinder

head(s)

for

water

passage

obstructions.

Clean

out

the

passages

or

replace

the

head(s)

if

necessary.

(j)

Check

the

cylinder

block

for

water

passage

obstructions.

Clean

out

the

passages

or

replace

the

block

if

necessary.

(2)

ENGINE

FAILS

TO

REACH

NORMAL

OPER

ATING

TEMPERATURE.

Generally

this

is

caused

by

the

thermostat

sticking

or

being

of

the

wrong

heat

range.

Check

the

thermostat

first.

If

the

engine

still

does

not

reach

operating

temperature,

check

the

gauge

and

send

ing

unit

with

a

thermometer

installed

in

the

radiator.

Replace

any

defective

parts.

2.

TUNE-UP

Regular

maintenance

and

inspection

services

are

necessary

for

proper

car

operation.

In

addition,

to

main

tain

satisfactory

performance,

a

periodic

engine

tune-up

should

be

made.

A

reliable

type

of

engine

test

equipment

should

be

used

to

perform

the

tests.

As

the

checks

and

tests

are

made,

make

a

visual

inspection

of

the

wiring,

vacuum

hoses,

cooling

system

hoses,

heater

hoses,

etc.

a.

Minor

Tune-Up.

Perform

the

following

operations

in

the

order

given.

(1)

INSPECT

IGNITION

WIRES,

BATTERY

CABLES,

AND

CHECK

THE

CONDITION

OF

THE

BATTERY.

Inspect

all

ignition

wires

for

worn

or

dam

aged

insulation.

Make

sure

the

wires

are

firmly

seated

in

the

distributor

cap

and

that

the

terminals

and

terminal

sockets

are

free

from

corrosion.

Inspect

the

battery

case

for

cracks

and

leaks.

Make

a

battery

capacity

test.

If

unsatisfactory,

make

a

battery

charge

test.

If

the

charge

is

low,

recharge

the

battery.

Inspect

the

battery

cable

connections

for

corrosion,

and

clean.

them

if

necessary.

Brush

the

cable

connectors

with

grease

to

retard

further

corrosion,

then

tighten

the

con

nectors

securely.

(2)

TEST

CYLINDER

COMPRESSION. Be

sure

the

battery

is

good.

Operate

the

engine

until

normal

operat

ing

temperature

is

reached.

Turn

the

ignition

switch

off.

Remove

all

spark

plugs.

Set

the

throttle

in

the

wide

open

position

and

be

sure

the

choke

is

wide

open.

Install

a

compression

gauge

in

number

1

cylinder.

Crank

the

engine

until

the

gauge

registers

a

maximum

reading

and

record

the

reading.

Note

the

number

of

compression

strokes

required

to

obtain

this

reading.

Repeat

the

test

on each

cylinder,

cranking

the

engine

the

same

number

of strokes

as

was

required

to

obtain

a

maximum

reading

on

number

1

cylinder.

A

variation

of

10

pounds

from

specified

pressure

is

satisfactory.

However,

the

compression

of

all

cylinders

should

be

uniform

within

10

pounds.

A

reading

of

more

than

10

pounds

above

normal

indi

cates

carbon

or

lead

deposits

in

the

cylinder.

A

reading

of

more

than

10

pounds

below

normal

indi

cates

leakage

at

the

head

gasket,

rings,

or

valves.

A

low

even

compression

in

two

adjacent

cylinders

indicates

a

head

gasket

leak. This

should

be

checked

before

condemning

the

rings

or

valves.

To

determine

whether

the

rings

or

the

valves

are

at

fault,

put

a

tablespoon

of

heavy

oil

on

the

piston,

and

repeat

the

compression

test.

The

oil

will

temporarily

seal

leakage

past

the

rings.

If

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,

it

indicates

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

indi

cates

a

sticky

or

stuck

valve.

(3)

CLEAN,

ADJUST,

AND

INSTALL

THE

SPARK

PLUGS.

Sandblast

the

spark

plugs,

wipe

the

porcelain

clean,

file

the

electrode

tips

flat,

and

adjust

the

spark

gap.

Test

the

plugs

in

an

approved

spark

plug

tester-

Inspect

the

plugs

for

broken

or chipped

porcelain

and

badly

burned

electrodes.

Replace

all

defective

plugs.

Install

the

spark

plugs

and

tighten

them

to

the

specified

torque.

(4)

CHECK

THE

DISTRIBUTOR.

Remove

the

dis

tributor

cap

and

rotor.

Inspect

the

breaker

points

for

pitting

and

burning.

Replace

defective

points.

Clean

and

install

the

distributor

cap

and

rotor.

(5)

CHECK

IGNITION

TIMING.

Disconnect

the

dis-

Section

2

Engine

Tune-Up

tributor

vacuum

line.

Operate

the

engine

at

idle

speed.

Check

the

timing

with

a

timing

light

and

make

the

necessary

adjustments.

Connect

the

distributor

vacuum

line.

(6)

CHECK

MANIFOLD

VACUUM

AND

ADJUST

CARBURETOR

IDLE.

Check

the

manifold

vacuum

at

the

specified

idle

speed.

If

the

vacuum

is

lower

than

specified,

check

for

leak

age

at

the

vacuum

lines

and

intake

manifold.

Check

the

carburetor

idle

adjustment.

If

the

vacuum

is

still

below

normal

or

is

erratic,

it

is

an

indication

of

bad

rings,

sticky

valves,

weak

valve

springs,

or

a

head

gasket

leak.

Set

the

engine

idle

speed

and

the

carburetor

idle

fuel

adjustment

as

outlined

in

Chapter

IV.

(7)

CLEAN

THE

AIR

CLEANER

AND

THE

FUEL

FILTER.

Clean

the

air

cleaner,

and

oil

the

element.

If

the

air

cleaner

is

the

oil

bath-type,

fill

to

the

indicated

level

with

engine

oil

of

the

specified

viscosity.

On

passenger

cars,

remove

and

clean

the

fuel

pump

bowl.

Install

a

new

filter

element.

On

Thunderbirds,

clean

the

fuel

line

filter.

Install

a

new

filter

element.

(8)

CHECK

THE

DEFLECTION

OF

THE

DRIVE

BELTS.

Check

the

deflection

of

all

drive

belts

(fan,

air

conditioning,

and

power

steering).

Make

the

neces

sary

adjustments.

b.

Major

Tune-Up.

Perform

the

following

operations

in

the

order

given.

(1)

BATTERY.

Remove

the

cables

from

the

battery.

Clean

the

battery

terminals

and

cable

connectors.

In

spect

the

battery

case

for

cracks

and

leaks.

Make

a

battery

capacity

test.

If

unsatisfactory,

make

a

battery

charge

test.

If

the

charge

is

low,

recharge

the

"battery.

Replace

deteriorated

connectors

and

cables

that

have

worn

insulation.

Brush

the

cable

connectors

with

grease

to

retard

further

corrosion.

Connect

the

cables

to

the

battery.

(2)

CHECK

THE

GENERATOR

AND

REGULA

TOR.

Follow

the

procedures

outlined

in

Part

THREE,

"Electrical

and

Accessories."

(3)

TEST

SPARK

INTENSITY.

Determine

if

the

spark

from

each

plug

wire

will

jump

a

3/16

inch

gap,

as

follows:

Remove

one

spark

plug

wire,

and

install

a

terminal

adapter

in

the

wire

terminal.

Hold

the

end

of

the

adapter

approximately

3/16

inch

from

the

cylinder

head.

Run

the

engine

at

idle

speed.

The

spark

should

jump

the

gap

regularly.

Repeat

the

test

on

each

lead.

If

the

spark

is

unsatisfactory

at

all

spark

plugs,

trouble

exists

in

the

coil,

condenser,

rotor

or

cap,

inter

nally

in

the

distributor,

or

in

the

external

primary

circuit.

If

the

spark

is

unsatisfactory

at

some,

but

not

all

of

the

spark

plug

wires,

the

trouble

is

in

the

wire

itself,

the

wire

is

not

seated

in

the

housing

socket,

or

the

distributor

cap

is

corroded.

(4)

TEST

CYLINDER

COMPRESSION.

Follow

the

procedure

under

"a.

Minor

Tune-Up."

(5)

CLEAN,

ADJUST,

AND

INSTALL

SPARK

PLUGS.

Sandblast

the

spark

plugs,

wipe

the

porcelain

clean,

file

the

electrode

tips

flat,

and

adjust

the

gap.

Test

the

plugs

in

an

approved

tester.

Inspect

the

plugs

for

broken

or

chipped

porcelain

and

badly

burned

electrodes.

Replace

all

defective

plugs.

Install

the

plugs

and

tighten

them

to

the

specified

torque.

(6)

CHECK

MANIFOLD

BOLT

TORQUE.

Tighten

the

intake

and

exhaust

manifold

bolts

and

nuts

to

23-28

foot-pounds

torque.

(7)

TEST

COIL

AND

CONDENSER.

If

the

spark

intensity

(3)

is

satisfactory,

it

will

not

be

necessary

to

test

the

coil

and

condenser.

However,

if

the

spark

is

not

satisfactory,

test

these

parts

on

a

test

unit

to

deter

mine

which

one

is

defective.

Follow

the

instructions

of

the test

unit

manufacturer.

(8)

INSPECT

BREAKER

POINTS

AND

TEST

THE DISTRIBUTOR.

Inspect

the

distributor

points

for

pits,

excessive

metal

transfer,

and

burned

spots.

Test

the

vacuum

advance

and

make

adjustments,

repairs,

or

replacements

as

required.

Set

the

point

gap

to

specifications.

After

setting

the

gap,

check

the

point

dwell.

If

the

dwell

angle

is

not

to

specifications,

the

distributor

cam

is

worn

or

the

point

assembly

is

defec

tive.

Replace

all

defective

parts.

Lubricate

the

distribu

tor

cam

lightly

with

distributor

cam

lubricant.

(9)

CLEAN

AND

INSPECT

THE

DISTRIBUTOR

CAP.

Inspect

the

cap

for

cracks

or

other

damage.

Re

move

all

corrosion

from

the

terminal

housing

sockets.

(10)

CHECK

IGNITION

TIMING.

Disconnect

the

vacuum

line

between

the

distributor

and

carburetor

and

operate

the

engine

at

idle

speed.

Check

the

timing

with

a

timing

light

and

make

the

necessary

adjustments.

Connect

the

distributor

vacuum

line

after

completing

the

adjustment

and

check

ignition

advance

as

the

en

gine

is

accelerated.

(11)

CHECK

AND

ADJUST

VALVE

LASH.

Check

and

adjust

the

valve

lash

after

the

engine

is

thoroughly

warmed

up.

(12)

TEST

MANIFOLD

VACUUM.

Check

the

mani

fold

vacuum

at

the

specified

idle

speed.

If

the

vacuum

is

lower

than

specified,

check

for

leak

age

at

the

vacuum

lines

and

intake

manifold.

Check

the

carburetor

idle

adjustment.

If

the

vacuum

is

still

below

normal

or

is

erratic,

it

is

an

indication

of

bad

rings,

sticky

valves,

weak

valve

springs,

or

a

leaking

head

gasket.

If

this

condition

exists,

it

should

be

reported

to

the

customer.

10

Chapter

1

General

Engine

Overhaul,

Inspection,

and

Repair

(13)

TEST

FUEL

PUMP

PRESSURE

AND

CAPAC

ITY.

The

static

pressure

should

be

3.5-5.5

p.s.i.

at

500

r.p.m.

The

capacity

should

be

1

pint

in

30

seconds

at

500

r.p.m.

(14)

TEST

BOOSTER

PUMP

VACUUM.

The

booster

pump

vacuum

should

be

10.0

inches

of

mercury

at

500

r.p.m.

The

vacuum

should

not

drop

rapidly

when

the

engine

is

stopped.

(15)

INSPECT

AND

CLEAN

THE

FUEL

FILTER.

On

passenger

cars,

remove

and

clean

the

fuel

pump

bowl.

Install

a

new

filter

element.

On

Thunderbirds,

clean

the

fuel

line

filter.

Install

a

new

filter

element.

(16)

CLEAN

THE

CARBURETOR.

Disassemble

and

clean

the

carburetor.

Set

the

fuel

level,

and

check

the

accelerator

pump

operation.

(17)

CLEAN

THE

AIR

CLEANER.

Clean

the

air

cleaner

and

the

element.

If

the

air

cleaner

is

the

oil

bath-type,

fill

to

the

indicated

level

with

engine

oil

of

the

specified

viscosity.

(18)

ADJUST

CARBURETOR

IDLE.

Set

the

en

gine

idle

speed

and

the

carburetor

idle

fuel

adjustment

as

outlined

in

Chapter

IV.

(19)

EXHAUST

ANALYSIS.

On

dual

exhaust

equipped

cars,

connect

the

analyzer

tube

to

the

left

muffler

outlet

pipe.

Inasmuch

as

there

are

several

types

of

analyzers,

follow

the

instructions

of

the

manufacturer.

(20)

CHECK

THE

DEFLECTION

OF

THE

DRIVE

BELTS.

Check

the

deflection

of

all

drive

belts

(fan,

air

conditioning,

and

power

steering).

Make

the

necessary

adjustments.

(21)

ROAD

TEST.

Road

test

the

car

as

a

final

check

on

the

work

performed.

Also,

notice

the

performance

of

the

transmission,

axle,

brakes,

and

any

optional

accessories.

Recommend

any

additional

service

required

when

the

car

is

delivered

to

the

owner.

3.

ENGINE

REMOVAL

AND

INSTALLATION

Separate

procedures

are

given

for

the

conventional

passenger

car

and

the

Thunderbird.

a.

Conventional

Passenger

Car.

The

following

procedures

apply

to

all

conventional

passenger

cars.

Differences

in

the

procedures

peculiar

to

cars

equipped

with

an

8

or

6-cylinder

engine

are

noted

when

they

exist.

The

procedures

given

are

for

the

engine

only,

without

the

transmission

attached.

Engine

compartment

toler

ances

make

it

impractical

to

remove

or

install

the

en

gine

with

the

transmission

attached.

(1)

REMOVAL.

If

the

car

is

equipped

with

a

stand

ard

or

overdrive

transmission,

follow

steps

(a)

and

(c).

If

the

car

is

equipped

with

Fordomatic,

follow

steps

(b)

and

(c).

(a)

Steps

Peculiar

To

A

Standard

Or

Overdrive

Transmission.

Disconnect

the

clutch release

spring.

Remove

the

screws

retaining

the

equalizer

bar

support

to

the

flywheel

housing,

then

remove

the

support

and

bushing.

Disconnect

the

accelerator

linkage

at

the

mani

fold bell

crank.

Remove

the

two

flywheel

housing

upper

bolts.

Remove

the

flywheel

housing

cover,

support

the

transmission

with

a

jack,

then

remove

the

remaining

flywheel

housing

bolts.

(b)

Steps

Peculiar

To

Fordomatic

Disconnect

the

transmission

throttle

linkage

at

the

cross

shaft,

and

tie

the

linkage

to

the

dash

panel.

Remove

the

idler

arm

bracket.

Fold

back

the

floor

mat,

remove

the

two

rubber

plugs,

then

remove

the

two

converter

housing

to

engine

upper

bolts.

Jack

up

the

front

of

the

car

and

position

safety

stands.

Support

the

transmission

with

a

jack,

then

remove

the

remaining

converter

housing

to

engine

bolts.

Remove

the

converter

housing

lower

access

cover,

then

turn

the

flywheel

till

the

flywheel

drive

plate

is

in

posi

tion

to

remove

the

three

bolts.

Turn

the

flywheel

180,

then

remove

the

other

three

bolts.

CAUTION:

After

the

bolts

are

removed

from

the

converter

drive

plate,

turn

the

drive

plate

90

so

the

flex

plates

will

not

catch

on

the

converter

housing

when

the

engine

is

removed.

Drain

the

transmission.

Remove

the

bracket

that

secures

the

transmission

oil

level

indicator

tube

to

the

engine.

Disconnect

the

tube

at

the

transmission

oil

pan,

then

remove

the

tube

assembly.

Remove

the

transmis

sion

control

linkage

splash

shield

from

the

cylinder

block,

then

remove

the

oil

filter.

(c)

Engine

Removal.

Remove

the

hood.

Drain

the

cooling

system

and

the

crankcase.

Remove

the

heater

hoses.

Remove

the

heater

inlet

duct

and

the

heater

blower

motor.

Remove

the

radiator

upper

and

lower

hoses,

then

remove

the

radiator.

Remove

the

fan.

Disconnect

the

battery

ground

cable

at

the

cylinder

block,

and

the

flex

fuel

line

at

the

fuel

pump.

Disconnect

the

windshield

wiper

vacuum

hose,

tem

perature

sending

unit

wire,

and

the

oil

pressure

sending

unit

wire.

Disconnect

the

primary

wire

at

the

coil.

Remove

the

starter

cable

at

the

starter,

then

remove

the

starter.

Disconnect

the

ground

cable

from

the

rear

of

the

engine.

Remove

the

air

cleaner,

then

tape

the

air

horn

closed.

Disconnect

the

choke

cable

at

the

carbu

retor.

Disconnect

the

accelerator

linkage.

Disconnect

the

muffler

inlet

pipes

at

the

exhaust

manifold.

Section

3

Engine

Removal

and

Installation

11

Too/-T52L-6000-C

Fig.

J

Lifting

Hook

6-Cylinder

Engine

Attach

the

engine

lifting

hook(s)

(fig.

1or2).

Re

move

the

right

and

left

front

splash

aprons.

On

8-cylinder

engines,

remove

the

retainer

and

lower

insulator

from

the

engine

front

steady

rest.

On

6-cylinder

engines,

loosen

the

two

engine

front

steady

rest

to

spacer

bolts.

Raise

the

car

and

position

safety

stands.

On

8-cylinder

engines,

remove

the

engine

left

insula

tor.

Remove

the

cap

screws

from

the

engine

right

insulator

at

the

engine.

Tool-T53L-300-A

ToolT53L-6000-B

Tool-

1

5

41-600

5-D

(SPLINED

SHAFT)

Tool

T54L-6005-E

(KEYED

SHAFT)

6302

Fig.

3

Engine

Mount

8

-Cylinder

Engine

On

6-cylinder

engines,

remove

the

left

insulator

to

bracket

bolts

at

the

insulator,

and

the

right

bracket

bolts

at

the

engine.

Raise

the

engine

slightly,

then

carefully

pull

it

from

the

transmission.

Carefully

lift

the

engine

out

of

the

engine

compartment.

Do

not

let

the

engine

swing

against

the

grille.

Install

the

engine

on

a

work

stand

(fig.

3

or

4).

(2)

INSTALLATION.

If

the

car

is

equipped

with

a

standard

or

overdrive

transmission,

follow

steps

(a),

(b),

and

(d).

If

the

car

is

equipped

with

Fordomatic,

follow

steps

(a),

(c),

and

(d).

(a)

Engine

Installation.

Install

the

appropriate

engine

lifting

hook,

then

remove

the

engine

from

the

work

stand.

CAUTION:

On

Fordomatic

equipped

cars,

make

sure

the

flywheel

drive

plate

is

turned

so

the

flex

plate

will

not

catch

on

the

converter

housing.

Lower

the

engine

carefully

into

the

engine

compart

ment.

On

8-cylinder

engines,

lower

the

engine

until

the

oil

pump

to

oil

pan

line

clears

the

engine

left

support.

Start

the

transmission

main

drive

gear

into

the

clutch

6304

ToolT52T6005-CJD

(Splined

Sha

ToolT52T-^>005-KJD

(Keyed

Shaft)

6289

Fig.

2

Lifting

Hooks

and

Sling

8-Cylinder

Engine

Fig.

4

Engine

Mount

Adapter

6-Cylinder

Engine

12

Chapter

1

General

Engine

Overhaul,

Inspection,

and

Repair

disc.

On

Fordomatic

units,

start

the

converter

pilot

into

the

crankshaft.

NOTE:

On

standard

or

overdrive

units,

it

may

be

necessary

to

adjust

the

position

of

the

transmission

with

relation

to

the

engine

if

the

transmission

input

shaft

will

not

enter

the

clutch

disc.

If

the

engine

"hangs

up"

after

the

shaft

enters,

turn

the

crank

shaft

slowly

(with

the

transmission

in

gear)

until

the

shaft

splines

mesh

with

the

clutch

disc

splines.

Make

sure

the

studs

on

the

manifolds

of

both

the

6

and

8-cylinder

engines

are

aligned

with

the

holes

in

the

muffler

inlet

pipe(s)

and

the

dowels

in

the

block

engage

the

holes

in

the

clutch

housing

(on

Fordomatic

units

the

block

dowels

must

engage

the

holes

on

the

converter

housing).

NOTE:

Level

the

engine

crosswise

in

relation

to

the

frame

before

installing

the

mounting

bolts

or

the

steady

rest.

On

the

6-cylinder

engine,

install

the

left

insulator

to

bracket

lockwashers

and

bolts

and

the

right

bracket

to

engine

lockwashers

and

bolts.

Tighten

the

insulator

to

bracket

bolts

to

45-50 foot-pounds

torque.

Tighten

the

engine

front

steady

rest

to

spacer

bolts

to

30-35

foot

pounds

torque.

On

the

8-cylinder

engine,

align

the

holes

in

the

en

gine

left

support

insulator

with

the

mounting

holes

in

the

block,

then

install

the

insulator

to

engine

bolts

and

the

frame

to

insulator

lockwashers

and

nuts.

Install

the

right

insulator

to

engine

lockwashers

and

bolts.

Tighten

the

insulator

to

engine

bolts

to

45-50

foot-pounds

torque

and

the

frame

to

insulator

nuts

to

50-60

foot-pounds

torque.

Install

the

engine

front

steady

rest

lower

in

sulator

and

retainer.

Tighten

the

retainer

bolt

to

23-28

foot-pounds

torque.

Install

the

right

and

left

front

splash

aprons.

Connect

the

manifold

(s)

to

the

muffler

inlet

pipe(s).

Install

the

starter,

then

connect

the

starter

cable

(ex

cept

Fordomatic).

Connect

the

ground

cable

to

the

rear

of

the

engine,

the

temperature

sending

unit

and

oil

pressure

sending

unit

wires,

the

generator

wires,

and

the

ignition

switch

wire

to

the

coil.

Connect

the

ignition

switch

wire

to

the

engine

clips.

Connect

the

accelerator

linkage

and

the

choke

wire

(6-cylinder

engine).

Connect

the

windshield

wiper

line

and

the

fuel

pump

vacuum

line.

Connect

the

fuel

pump

flexible

line.

Install

the

fan

assembly,

then

adjust

the

fan

belt.

Install

the

radiator

and

connect

the

radiator

hoses.

Connect

the

battery

ground

cable

to

the

engine.

Remove

the

tape

from

the

carburetor

air

horn

and

install

the

air

cleaner.

Install

the

heater

blower

motor

and

the

heater

inlet

duct,

then

connect

the

heater

hoses.

Install

the

hood.

Fill

the

cooling

system

and

the

crankcase.

(b)

Connect

Standard

Or

Overdrive

Transmis

sion.

Install

the

bushings

in

the

equalizer

bar

support,

then

install

the

support

on

the

flywheel

housing.

Install

the

transmission

to

flywheel

housing

bolts,

and

tighten

them

to

40-50

foot-pounds

torque.

Install

the

flywheel

housing

cover.

Connect

the

clutch

release

spring.

Remove

the

jack

supporting

the

transmission.

Check

the

clutch

pedal

free

travel

(lH-l3/8

inches)

and

adjust

it

if

necessary.

(c)

Connect

Fordomatic

Transmission.

Install

the

two

converter

housing

to

engine

lower

bolts,

and

tighten

them

to

40-45

foot-pounds

torque.

NOTE:

Tighten

the

bolts

slowly

and

evenly

to

avoid

binding

on

the

dowel

pins.

Install

the

two

converter

housing

to

engine

upper

bolts,

and

tighten

them

to

40-45

foot-pounds

torque.

Install

the

floor

pan

plugs.

Align

the

flywheel

and

drive

plate

holes

with

the

converter,

then

install

the

six

bolts,

and

tighten

them

to

25-28

foot-pounds

torque.

Install

the

starter,

and

tighten

the

bolts

to

15-20

foot-pounds

torque.

Install

the

transmission

oil

level

indicator

tube

assembly.

Install

the

idler

arm

and

bracket.

Tighten

the

idler

arm

bracket

nuts

to

28-43

foot-pounds

torque.

Install

the

converter

housing

lower

access

covers.

Install

and

connect

the

throttle

linkage

and

make

the

necessary

linkage

adjustments.

Remove

the

jack

sup

porting

the

transmission.

Fill

the

transmission

with

Automatic

Transmission

Fluid

Type

A,

following

the

recommeneded

procedure.

(d)

Check

Engine

For

Oil

Or

Coolant

Leaks.

Run

the

engine

at

fast idle

and

check

all

gaskets

and

hose

connections

for leaks.

b.

Thunderbird.

On

Fordomatic

equipped

Thunderbirds,

the

engine

may

be

removed

with

or

without

the

transmission

attached.

(1)

REMOVAL.

To

remove

the

engine

from

a

Thunderbird

equipped

with

a

standard

or

overdrive

transmission,

follow

steps

(a)

and

(c).

To

remove

the

engine

from

a

Thunderbird

equipped

with

Fordomatic,

follow

steps

(b)

and

(c).

To

remove

the

engine

and

Fordomatic

as

an

assembly,

follow

steps

(c)

and

(d).

(a)

Steps

Peculiar

To

A

Standard

Or

Overdrive

Transmission.

Disconnect

the

clutch

release

spring.

Remove

the

screws

retaining

the

equalizer

bar

support

to

the

flywheel

housing,

then

remove

the

support

and

bushing.

Remove

the

two

flywheel

housing

upper

bolts.

Remove

the

flywheel

housing

cover,

support

the

trans

mission

with

a

jack,

then

remove

the

remaining

flywheel

housing

bolts.

(b)

Steps

Peculiar

To

Fordomatic.

Disconnect

the

transmission

throttle

linkage

at

the

cross

shaft,

and

tie

the

linkage

to

the

dash

panel.

Remove

the

idler

arm

bracket.

Jack

up

the

front

of

the

car

and

position

safety

stands.

Section

3

Engine

Removal

and

Installation

13

Support

the

transmission

with

a

jack,

then

remove

the

converter

housing

to

engine

bolts.

Remove

the

converter

housing

lower

access

cover,

then

turn

the

flywheel

till

the

flywheel

drive

plate

is

in

position

so

the

three

bolts

can

be

removed.

Turn

the

flywheel

180,

then

remove

the

other

three

bolts.

CAUTION:

After

the

bolts

are

removed

from

the

converter

drive

plate,

turn

the

drive

plate

90

so

the

flex

plates

will

not

catch

on

the

converter

housing

when

the

engine

is

removed.

Drain

the

transmission.

Remove

the

bracket

that

secures

the

transmission

oil

level

indicator

tube

to

the

engine.

Disconnect

the

tube

at

the

transmission

oil

pan

and

remove

the

tube

assembly.

Remove

the

transmis

sion

control

linkage

splash

shield.

(c)

Engine

Removal.

Remove

the

hood.

Drain

the

cooling

system

and

the

crankcase.

Remove

the

fan,

then

remove

the

radiator

and

shroud

as

an

assembly.

Remove

the

air

cleaner.

Disconnect

the

engine

ground

wire

at

the

dash

panel.

Disconect

the

battery

ground

cable

at

the

engine

and

the

battery

to

starter

relay

cable

at

the

battery.

Disconnect

the

vacuum

pump

line,

and

the

fuel

inlet

at

the

fuel

pump.

Disconnect

the

starter

cable

at

the

starter

solenoid,

then

remove

the

cable

clamp

at

the

dash

panel.

Disconnect

the

ignition

switch

to

coil

wire

at

the

coil.

Disconnect

the

two

heater

hoses.

Re

move

the

generator

wires.

Remove

the

wires

from

the

oil

pressure

sending

unit

and

the

temperature

sending

unit.

Remove

the

heater

blower

assembly.

Disconnect

the

tachometer

cable.

Disconnect

the

accelerator

rod,

then

disconnect

the

link

bracket

at

the

block

(this

bracket

also

serves

as

the

ignition

cable

bracket).

Raise

the

car

and

position

safety

stands.

Disconnect

the

exhaust

pipes

at

the

exhaust

manifolds.

Remove

the

engine

front

mount

bolt,

nut,

and

lower

insulator.

Re

move

the

engine

right

and

left

steady

rest

bracket

bolts

at

the

engine,

then

turn

the

brackets

to

one

side

so

the

engine

will

clear

them

upon

removal.

Remove

the

safety

stands

and

lower

the

car.

Install

the

engine

lifting

hooks

(fig.

2).

Raise

the

engine

slightly,

then

carefully

pull

the

engine

from

the

trans

mission.

Carefully

lift

the

engine

out

of

the

engine

compartment.

Install

the

engine

on

a

work

stand

(fig.

3).

(d)

Steps

Peculiar

To

Removing

The

Engine

And

Fordomatic

As

An

Assembly.

While

the

car

is

raised

in

step

(c),

perform

the

following

additional

operations

:

Drain

the

transmission.

Disconnect

the

shift

control

linkage

at

the

transmission

and

the

throttle

control

rod.

Disconnect

the

speedometer

cable.

Remove

the

drive

shaft,

and

plug

the

transmission

with

an

extension

hous

ing

cap.

Remove

the

converter

air

duct

assembly.

Re

move

the

bracket

that

secures

the

transmission

oil

level

indicator

tube

to

the

engine.

Disconnect

the

tube

at

the

transmission

oil

pan,

then

remove

the

tube

assembly.

Remove

the

engine

rear

mount

bolt,

raise

the

transmis

sion,

then

remove

the

cross

member

that

serves

as

the

engine

rear

mount.

Remove

the

transmission

jack

and

lower

the

car.

Install

the

engine

lifting

hooks.

Raise

the

engine

slightly,

then

carefully

pull

the

engine

and

transmission

forward.

Carefully

lift

the

engine

and

transmission

from

the

engine

compartment.

(2)

INSTALLATION.

To

install

the

engine

in

a

Thunderbird

equipped

with

a

standard

or

overdrive

transmission,

follow

steps

(a),

(b),

(e),

and

(f).

To

in

stall

the

engine

only

in

a

Fordomatic

equipped

Thunder

bird,

follow

steps

(a),

(c),

(e),

and

(f).

To

install

the

engine

and

Fordomatic

as

an

assembly,

follow

steps

(a),

(d),(e),and(f).

(a)

Engine

Installation.

Install

the

engine

lifting

hooks,

then

remove

the

engine

from

the

work

stand.

CAUTION

:

On

Fordomatic

equipped

cars,

make

sure

the

flywheel

drive

plate

is

turned

so

the

flex

plates

will

not

catch

on

the

converter

housing.

Lower

the

engine

carefully

into

the

engine

compart

ment.

Start

the

transmission

main

drive

gear

into

the

clutch

disc.

On

Fordomatic

units,

start

the

converter

pilot

into

the

crankshaft.

NOTE:

On

standard

or

overdrive

units,

it

may

be

necessary

to

adjust

the

position

of

the

transmission

with

relation

to

the

engine,

if

the

input

shaft

will

not

enter

the

clutch

disc.

If

the

engine

"hangs

up"

after

the

shaft

enters,

turn

the

crankshaft

slowly

(with

the

transmission

in

gear)

until

the

shaft

splines

mesh

with

the

clutch

disc

splines.

Make

sure

the

studs

on

the

manifolds

are

aligned

with

the

holes

in

the

muffler

inlet

pipes,

and

the

dowels

in

the

block

engage

the

holes

in

the

clutch

housing

(on

Fordomatic

units

the

block

dowels

must

engage

the

holes

on

the

converter

housing).

Raise

the

car

and

position

safety

stands.

Install

the

engine

front

support

lower

insulator,

bolt,

lockwasher,

and

nut.

Tighten

the

insulator

mounting

nut

to

85-95

foot-pounds

torque.

Install

the

engine

right

and

left

steady

rest

bracket

bolts,

and

tighten

the

bolts

to

45-50

foot-pounds

torque.

NOTE:

If

the

rod

assembly

adjustment

of

either

steady

rest

was

disturbed

during

engine

removal,

adjust

the

rod

as

outlined

in

step

(e).

Connect

the

exhaust

pipes

to the

exhaust

manifolds.

Remove

the

safety

stands

and

lower

the

car.

Connect

the

accelerator

rod,

then

connect

the

accel

erator

link

bracket

to

the

block.

Connect

the

tachometer

cable.

Install

the

heater

blower

assembly.

Install

the

oil

pressure

sending

unit

and

the

temperature

sending

unit

wires.

Connect

the

generator

wires.

Connect

the

two

heater

hoses.

Connect

the

ignition

switch

to

coil