Workshop Manual
1 ENGINES
1.1 general engine service
1.1.1 General Engine Trouble Shooting
1.1.2 Tune-up
1.1.3 Manifolds and Exhaust Gas Control Valve
1.1.4 Rocker Arm Assembly, Push Rods, and Cylinder Heads
1.1.5 Valve Mechanism
1.1.6 Timing Chain,and Camshaft and Bearings
1.1.7 Crankshaft and Main Bearings
1.1.8 Flywheel
1.1.9 Connecting Rods and Bearings
1.1.10 Pistons, Pins, and Rings
1.1.11 Cylinder Block
1.1.12 Oil Pan and Oil Pump
1.1.13 Exhaust System
1.1.14 Engine Dimensions, and Clearance and Adjustment Specifications
1.2 6-cylinder engine
1.2.1 Description
1.2.2 Engine Removal and Installation
1.2.3 Engine Supports
1.2.4 Manifolds and Exhaust Gas Control Valve
1.2.5 Cylinder Head and Valves
1.2.6 Crankshaft Damper, Cylinder Front Cover, and Crankshaft Oil Seal
1.2.7 Sprockets and Timing Chain, Camshaft, Bearings, and Tappets
1.2.8 Flywheel, Crankshaft, and Main Bearings
1.2.9 Connecting Rods and Bearings, Pistons, Pins, and Rings
1.2.10 Oil Pan, Oil Filter, and Oil Pump
1.2.11 Exhaust System
1.2.12 General Specifications
1.3 8-cylinder engines
1.3.1 Description
1.3.2 Engine Removal and Installation
1.3.3 Engine Supports
1.3.4 Manifolds and Exhaust Gas Control Valve
1.3.5 Cylinder Heads and Valves
1.3.6 Crankshaft Damper, Cylinder Front Cover, and Crankshaft Oil Seal
1.3.7 Sprockets and Timing Chain, Camshaft, Bearings, and Tappets
1.3.8 Flywheel, Crankshaft, and Main Bearings
1.3.9 Connecting Rods and Bearings, Pistons, Pins, and Rings
1.3.10 Oil Pan, Oil Filter, and Oil Pump
1.3.11 Exhaust System
1.3.12 General Specifications
2 IGNITION, FUEL, AND COOLING SYSTEM
2.1.4 6-Cylinder Engine Distributor Overhaul
2.1.5 8-Cylinder Engine Distributor Overhaul.
2.1.6 Ignition System Specifications
2.2 fuel system
2.2.1 Trouble Shooting
2.2.2 Air Cleaner.
2.2.3 Holley Single-Barrel Carburetor
2.2.4 Ford Dual Carburetor
2.2.5 Holley Dual Carburetor
2.2.6 Ford Four-Barrel Carburetor
2.2.7 Holley Four-Barrel Carburetor
2.2.8 Carter Four-Barrel Carburetor
2.2.9 Throttle Linkage Adjustments
2.2.10 Fuel Pumps, Vacuum Booster, and
2.2.11 Fuel Filter
2.2.12 Fuel Tanks and Lines
2.2.13 Fuel System Specifications
2.3 cooling system
2.3.1 Trouble Shooting and Cooling System
2.3.2 Maintenance
2.3.3 Radiator, Hoses, and Thermostat
2.3.4 Fan and Belts
2.3.5 Water Pumps
2.3.6 Cooling System Specifications
3 CLUTCH, TRANSMISS AND REAR AXLE
3.1 clutch
3.1.1 Trouble Shooting
3.1.2 Clutch Pedal Adjustment
3.1.3 Clutch Overhaul
3.1.4 Flywheel Housing Alignment
3.2 conventional transmission
3.2.1 Trouble Shooting
3.2.2 Overhaul
3.2.3 Gear Shift Linkage
3.2.4 Specifications
3.3 overdrive transmissions
3.3.1 Trouble Shooting
3.3.2 Operation
3.3.3 Overhaul
3.3.4 Specifications
3.4 rear axle and drive line
3.4.1 Trouble Shooting
3.4.2 Minor Repairs
3.4.3 Overhaul
3.4.4 Drive Line
3.4.5 Specifications
4 CHASSIS SUSPENSION AND FRAMES
4.1 front wheel alignment
4.1.1 Preliminary Front End Inspection
4.1.2 Front Wheel Alignment Inspection
4.1.3 Front Wheel Alignment Adjustments . .
4.1.4 Specifications
4.2 front and rear suspensio
4.2.1 Trouble Shooting
4.2.2 Front Suspension Repair
4.2.3 Rear Suspension Repair
4.2.4 Shock Absorber Replacement
4.2.5 Specifications
4.3 wheels and tires
4.3.1 Trouble Shooting
4.3.2 Wheel Maintenance and Replacement . .
4.3.3 Front Hubs, Bearings, and
4.3.4 Grease Retainers
4.3.5 Rear Hubs, Bearings, and Oil Seals
4.3.6 Tire Maintenance and Repair
4.3.7 Specifications
4.4 frames
4.4.1 Frame Alignment Inspection
4.4.2 rame Repair and Replacement
4.4.3 Specifications
5 STEERING
5.1 steering gear and linkag
5.1.1 Trouble Shooting
5.1.2 Steering Gear Adjustments
5.1.3 Steering Gear Repair
5.1.4 Steering Linkage Repair
5.1.5 Specifications
5.2 power steering
5.2.1 Trouble Shooting
5.2.2 Fluid Pressure Test
5.2.3 Power Steering System Operation
5.2.4 Pump and Fluid Reservoir Repair
5.2.5 Control Valve Repair
5.2.6 Power Cylinder Repair
5.2.7 Power Steering Linkage Repair
5.2.8 Specifications
6 BRAKES
6.1 hydraulic and parking brake
6.2 Chapter 1
6.2.1 Trouble Shooting
6.2.2 Brake Adjustments
6.2.3 Master Cylinder, Brake Pedal, and Brake Cylinder Repair
6.2.4 Brake Assembly Repair
6.2.5 Brake Shoe, Brake Drum, and Hydraulic Line Repair
6.2.6 Specifications
6.3 power brakes
6.3.1 Trouble Shooting
6.3.2 Conventional Car Power Brake
6.3.3 Thunderbird Power Brake
7 GENERATING AND STARTING SYSTEMS
7.1.2 Generator
7.1.3 Generator Regulator
7.1.4 Battery
7.1.5 Specifications
7.2 starting system
7.2.1 Trouble Shooting
7.2.2 Starter and Circuit
7.2.3 Starter Drive
7.2.4 Specifications
8 LIGHTS, INSTRUMENTS AND ACCESSORIES
8.1 LIGHTING SYSTEM, HORNS, INSTRUMENTS
8.1.1 Trouble Shooting
8.1.2 Lighting System
8.1.3 Horns
8.1.4 Instruments
8.2 accessories
8.2.1 Trouble Shooting
8.2.2 Radio
8.2.3 Heater
8.2.4 Windshield Wiper
8.2.5 Miscellaneous Accessories
9 BODY MAINTENAN AND REPAIR
9.1 general maintenance
9.1.1 Body Tune-up
9.1.2 Eliminating Rattles
9.1.3 Exterior Cleaning
9.1.4 Care of Convertible Top Fabric
9.1.5 Interior Cleaning
9.1.6 Care of Country Squire Paneling
9.2 sealing and undercoating
9.2.1 Body Construction and Sealer Application
9.2.2 Body Undercoating
9.3 repair and refinishing
9.3.1 Body Alignment
9.3.2 Quarter Panel Repair
9.3.3 Fiberglas Repair—Thunderbird Hard Top
9.3.4 Paint Refinishing
9.4 top assemblies
9.4.1 Car Convertible Top
9.4.2 Thunderbird Convertible Top
9.4.3 Thunderbird Hard Top
9.4.4 Thunderbird Tonneau Cover
10 DOORS, DECK LID, AND FRONT SHEET METAL
10.1 doors and deck lid
10.1.1 Door Replacement and Alignment
10.1.2 Door Locks
10.1.3 Deck Lid Replacement and Alignment
10.1.4 Deck Lid and Tail Gate Lock and Handle
10.2 hood and grille
10.2.1 Car Hood
10.2.2 Car Grille
10.2.3 Thunderbird Hood
10.2.4 Thunderbird Grille
10.3 front fenders
10.3.1 Car Front Fenders
10.3.2 Thunderbird Front Fenders
11 INTERIOR TRIM, SEATS, AND WINDC
11.1 interior trim
11.1.1 Door and Quarter Trim Panels.
11.1.2 Headlining
11.2 seats
11.2.1 Manual Seats
11.2.2 Power Seats
11.3 windows
11.3.1 Vent Windows
11.3.2 Door Glass and Regulator
11.3.3 Quarter Glass and Regulator
11.3.4 Power Windows
11.3.5 Windshield and Back Window
12 BODY INST DRAWINGS
12.1 Basic Body Construction
12.2 Windshields and Exterior Mouldings
12.3 Back Windows and Exterior Mouldings
12.4 Door Lock and Window Mechanisms
12.5 Door Weatherstrips and Garnish Mouldings
12.6 Roof Bows and Headlinings
12.7 Convertible Tops
12.8 Miscellaneous
13 MAINTENANCE AND LUBRICATION
13.1 Maintenance Chart
13.2 Lubrication Chart
13.3 Tools and Equipment
