Werkstatthandbuch Book 2 · Seiten 1001–1100

47-05-6 Ford and Mercury 47-05-6 3B4695 NUT AND 385107 SCREW AND WASHER WASHER ASSY 2 SHIELD-i 7C857 ASSY. 1 REOO. EA. SD. REOD. EA. SD. REINFORCEMENT.17A946 SPACER 11-23 FT-LBS. 55961 EWS Q -..... . SCR - 0 , 45265-S2 NUT AND R

47-05-7 Ford and Mercury 47-05-7 FIG. 8 Rear Bumper Installation-Mercury Except Station Wagon FIG. 9 Rear Bumper Installation-Ford and Mercury StatIon Wagon 2. Position the reinforcement to the bumper and install 3. Install shield, license plate and bracket assembly. the attaching bolts 25.30 ft-Ibs and nuts 17-23 4. Position the bumper assembly to the vehicle and ft-Ibs Fig. 9. install the isolator- ta-reinforcement bolts snug. "This publication contains material that is reproduced and distributed under a license to Detroit Iron from Ford Motor Company. No further reproduction or

4745-8 Ford and Mercury 47-05-8 Replace the spacers between reinforcement and EXTERIOR MOULDINGS isolator face plate if so equipped. Before removing the exterior mouldings, it should be 5. Adjust the bumper height so that the distance from determined by the type of retainer used whether a the top edge to the ground meets the specifications respective door, quarter or luggage compartment trim in Fig. 6. Then, adjust the bumper for body panel must first be removed to provide access Figs. 10 clearance at the centerline of the tail lamp. so that through 18. If a weld stud is distorted or broken off, the vertical and horizontal body to bumper it should be

47-05-9 Ford and Mercury 47-05-9 2-DOOR 4-DOOR AND STATION WAGON ®®® ® ®®cD C N25662A FIG. 11 Exterior Side Moulding Installation-Ford "This publication contains material that is reproduced and distributed under a license to Detroit Iron 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."

47-05-10 Ford and Mercury 47-05-10 N2589-2B FIG. 12 Exterior Moulding Installation-Ford "This publication contains material that is reproduced and distributed under a license to Detroit Iron 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."

47-05-11 Ford and Mercury 4745_Il FIG. 13 Rear Moulding Installation-Ford "This publication contains material that is reproduced and distributed under a license to Detroit Iron 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."

47-05-12 Ford and Mercury 4745-12 FRONT STATION WAGON-TYPICAL REAR SOuIRE STATION WAGON LEFT HAND SIDE SHOWN REAR CUSTOM AND LTO STATION WAGON LEFT HAND SIDE SHOWN RIGHT HAND SIDE TYPICAL EXCEPT AS SHOWN RIGHT HAND SIDE TYPICAL EXCEPT AS SHOWN

STATION WAGON N1412-2J FIG. 15 Exterior Side Moulding Installation-Mercury "This publication contains material that is reproduced and distributed under a license to Detroit Iron 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."

4745-14 Ford and Mercury 47-05-14 FIG. 16 Exterior Rear Side Moulding Installation-Mercury "This publication contains material that is reproduced and distributed under a license to Detroit Iron 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."

4745-15 Ford and Mercury 4745-15 N2511.fl FIG. 17 Optional Exterior Side Moulding Installation-Mercury with Fender Skins "This publication contains material that is reproduced and distributed under a license to Detroit Iron 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."

4745-16 Ford and Mercury 4745-16 FIG. 18 Exterior Rear Ornamentation-Mercury "This publication contains material that is reproduced and distributed under a license to Detroit Iron 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."

FRAME AND BODY MOUNTS a 387530- FORD & MERCURY SEDAN 2 REOD. 20-30 FT. LB.

‘I0 FRAME AND BODY MOUNTS FORD & MERCURY STATION WAGON -n -I0 3e U 3 ID a RH. SIDE SAME AS L.H. SIDE EXCEPT AS SHOWN 00163 2 REOD. 6200346 -‘ 6200157 38733G-SIO0 2 REOD. D.2 REGD.

4746-1 LTD II, Cougar and LTD II Ranchero 4746-1 . PART LTD II, Cougar and LTD II Ranchero 47-06 SUBJECT PAGE SUBJECT PAGE REMOVAL AND INSTALLATION REMOVAL ANO INSTALLATION Gont’d. Exterior Mouldings 06-4 Rear Bumper 06-2 Frame Dimensions 06-4 Front Bumper 06-2 Underbody Oimensions

47-06-2 LTD II, Cougar and LTD II Ranchero 4746-2 2. To remove headlamp doors, unscrew the eight FRONT BUMPER attaching screws and lift from grille opening panel LTD II and Cougar Fig. 2. 3. To remove grille opening panel, open hood and Removal detach the 12 nut and washer assemblies Fig. 2. 1. Remove three bolts attaching the bumper Lift the panel away. The panel may be removed reinforcement to each isolator, and remove the with the headlamp doors and grille attached. bumper assembly from the vehicle Fig. 4. Installation 2. Remove three screws attaching the stone deflector

47-06-3 LTD II, Cougar and LTD II Ranchero 4746-3 RE IN FOR CEMF NT -1 7A919 NUT AND WASH ER - 376785 ISOLATOR - 17C882 S PA C 8 H UP To 3 -1 7C832

47-06-4 LTD II, Cougar and LTD II Ranchero 47-06-4 387368 VIEW - C REF. N4028-28 FIG. 6 Front Stone Deflector-LTD II 4. Install the reinforcement, end brackets and license 5. Adjust the bumper for a good appearance and bracket Sedan only on the bumper. tighten the attaching bolts to speciE kation. 5. Position the bumper assembly and spacers to the 6. Install the license plate lamp, and connect the wire isolators, and install th

47-06-5 LTD II, Cougar and LTD II Ranchero 47-06-S -REAR LAMP BEZEL 2.12± .38 STONE VIEW. AA BUMPER FRONT REF. MOULDING FRONT FENDER 21.61±

47-06-6 LTD II, Cougar and LTD II Ranchero 47-06-6 1.69± 38 OUARTER PANEL MOULDING 1.2±2S 21.01 1.50 I DEFLECTOR RR. BUMPER TOP OF BUMPER REAR BUMPER STONEEND TOGROUND TRM FLANGE %25 BUMPER REAR

47-06-7 LTD II, Cougar and LTD II Ranchero 47-06-7 SPACER ASSY. - 1 1c971 SPACER - 17A761 BOLT 35-50 FT-LB TOROUE 395 ‘07 TO FRONT OF BODY ISOLATOR 17C884-5 CLP 3 REO’D. 381154

47-06-8 LTD II, Cougar and LTD II Ranchero 47-06.8 SLEEVE BUMPER - 3866 VIEW - A VIEW-S NUT & WASHER - 384695 REF, FRAME ASSY. FRAME ASSY. - 17C89O LT - 38348

47-06-9 LTD II, Cougar and LTD II Ranchero 47-06-9 - ____ 4-DOOR 2-DOOR SIMILARI 2-DOOR 4-DOOR FIG. 12 Exterior Side Moulding Installation-LTD II "This publication contains material that is reproduced and distributed under a license to Detroit Iron from Ford Motor

47-06-10 LTD II, Cougar and LTD II Ranchero 47-06-10 2-DOOR LTD II AND BROUGHAM 4-DOOR SHOWN. 2-DOOR SIMILAR LTD Is N25972C FIG. 13 Exterior and Rear Moulding-LTD II "This publication contains material that is reproduced and distributed under a license to Detroit Iron from Ford Motor Company. No further reproduction or distribution of the Ford Motor

47-06-11 LTD II, Cougar and LTD II Ranchero 47-06-11 B RO FIG. 14 Side Moulding Installation-LTD II "This publication contains material that is reproduced and distributed under a license to Detroit Iron 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."

47-06-12 LTD II, Cougar and LTD II Ranchero 47-06-12 LTD II RANCHERO LTD II RANCHEROSOLJIRE N2599 -20 FIG. 15 Rear Exterior Moulding Installation and Ornamentation-LTD II Ranchero "This publication contains material that is reproduced and distributed under a license to Detroit Iron from Ford Motor Company. No further reproduction or distribution of the Ford Motor Company material is allowed without the express written permission of Ford

47-06-13 LTD II, Cougar and LTD II Ranchero 47-06-13 S FIG. 16 Exterior Moulding Installation-LTD II Ranchero "This publication contains material that is reproduced and distributed under a license to Detroit Iron 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."

47-06-14 LTD II, Cougar and LTD Il Ranchero 47-06-14 4-DOOR SEDAN FIGURE.’ XR7 FIGURE-2 4-DOOR SEDAN FIGURE -3 FIG. 17 Exterior Side Moulding Installation-Cougar "This publication contains material that is reproduced and distributed under a license to Detroit Iron from Ford Motor Company. No further reproduction or distribution of the Ford Motor Company material is allowed without th

47-06-15 LTD II, Cougar and LTD II Ranchero 47-06-15 FIG. 18 Exterior Side Moulding Installation-Cougar FIG. 19 Exterior Side Moulding Installation-Cougar "This publication contains material that is reproduced and distributed under a license to Detroit Iron 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."

47-06-16 LTD II, Cougar and LTD II Ranchero 47-06-16 P42166-is FIG. 20 Rear Exterior Moulding Installation- Cougar XR-7 "This publication contains material that is reproduced and distributed under a license to Detroit Iron 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."

______ -U 0 p9 FRAME AND BODY MOUNTS -U LTDII, COUGAR 2 DOOR S 4 DOOR -I0 RETANER ASSY, BODY PART 3 2 REOD. 0 3 IDa 0 387675-SlOG

____ _______ _______ FRAME AND BODY MOUNTS RANCHERO ONLY r-I ‘F’ n0 C

47-08-1 Fairmont and Zephyr 47-08-1 PART Fairmont and Zephyr 47-08 SUBJECT PAGE SUBJECT PAGE REMOVAL ANO INSTALLATION REMOVAL AND INSTALLATION Cont’d. Exterior Mouldings 08-2 Rear Bumper 08-2 Front Bumper 08-2 Underbody Dimensions 08-3 Radiator Grille 08-1 REMOVAL AND INSTALLATION CN2B14-2B RADiATOR GRiLLE 4. Center ban spread snap-on fingers

47-08-2 Fairmont and Zephyr 47-08-2 5. Install the center grille support retaining screws and the grille end to mounting brackets snap rivets. FRONT BUMPER Fairmont and Zephyr Removal 1. Raise the front of the vehicle. BUMPEREND BRACE ISOLATORBRACKET AND 2. Remove six bolts attaching the bumper assembly CENTER ASSEMBLY to the isolators and remove the bumper Fig. 2. 3. Remove the license plate and bracket assembly. 4. Remove the isolator mounting, brackets, center reinforcement and end braces.

47-084 Fairmont and Zephyr 47-084 respective door, quarter or luggage tompartment trim ± .38panel must first be removed to provide access Figs. 5 DOOR HEADLAMPthrough 10.lf a weld stud is distorted or broken off, it should be replaced with an oval head blind rivet Part No. 383229-S or equivalent. Refer to General BUMPERI TOInformation Part 47-01 for installation of Pressure GROUND

47-08-4 Fairmont and Zephyr 47-08-4 FIG. 5 ExterIor Side Mouldings.-Fair,nont-2-Door Model-Zephyr Similar FIG. 6 Exterior Side Moulding Installation-Fairmont--4-Door Model-Zephyr Similar "This publication contains material that is reproduced and distributed under a license to Detroit Iron 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."

47-08-5 Fairmont and Zephyr 47-08-5 FIG. 7 Optional Exterior Belt Mouldings FIG. 8 Optional ExterIor Door Mouldings "This publication contains material that is reproduced and distributed under a license to Detroit Iron 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."

47-08-6 Fairmont and Zephyr 47-08-6 FIG. 9 Optional Exterior Ornamentation on Front Fender, Rocker and Quarter Panels "This publication contains material that is reproduced and distributed under a license to Detroit Iron 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."

a -.4 ‘U 2 -4 -J l/t 33cc I I 1 27.75

47-09-1 Pinto and Bobcat 4749-1 PART Pinto and Bobcat 47-09 SUBJECT PAGE SUBJECT PAGE REMOVAL AND INSTALLATION REMOVAL AND INSTALLATION Cont’d. Exterior Mouldings 09-2 Rear Bumper 09-2 Front Bumper 09-1 Underbody Dimensions 09-2 Radiator Grille 09-1 CN2816-2B REMOVAL AND INSTALLATION RADIATOR GRILLE BOBCAT PINTO

47-09-2 Pinto and Bobcat 47-09-2 REAR BUMPER to bumper dimensions meet the specifications in Fig. 5. Tighten the isolator- to-reinforcement boltsREMOVAL to 35-50 ft-lbs torque. 1. Remove two license lamp attaching screws and 4. Connect the license lamp to the body wiring. disconnect license plate lamp wiring from socket behind bumper. EXTERIOR MOULDINGS 2. Remove two bolts attaching each isolator to the bumper reinforcement and remove the bumper Before removing the exterior mouldings, it should be assembly ffi

47-09-3 Pinto and Bobcat 47-09-3 322400 PAD ALL MODELS R P.O. CENTER SCREW & WASHER NUT- 17CBS] 35-50 385107

47-09-4 Pinto and Bobcat 47-09-4 BOBCAT ____t___ &SSV. I.BB + .25 BOBCAT + .31 DR. çT. BUMPER

47-09-5 Pinto and Bobcat 47-09-5 FIG. 6 Front Fende, and Hood Exterior Moulding Installation-Bobcat FIG. 7 Front Fender Exterior Moulding Installation-Bobcat Station Wagon "This publication contains material that is reproduced and distributed under a license to Detroit Iron 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."

47.094 Pinto and Bobcat 47-094 FIG. 8 Optional Vinyl insert Exterior Side Moulding Installation-Pinto and Bobcat FIG. 9 Optional Body Side Exterior Maulding Installation-Pinto and Bobcat Sedan "This publication contains material that is reproduced and distributed under a license to Detroit Iron 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."

Pinto and Bobcat 47-09-7 H2103.2C FIG. 10 Front Fender and Hood Exterior Moulding Installation.......p;nto N25572FIG. II Roof-Outside Rear Exterior Moulding Installation "This publication contains material that is reproduced and distributed under a license to Detroit Iron from Ford Motor Company. No further reproduction or distribution of the Ford Motor Company mater

47-09-8 Pinto and Bobcat 47-09-8 FIG. 12 Belt-Door Window and Quarter Exterior Moulding Installation-Pinto and Bobcat Station Wagon I N2507-2B FIG. 13 Body Quarter and Rear Exterior Moulding Installation-Pinto Station Wagon "This publication contains material that is reproduced and distributed under a license to Detroit Iron from Ford Motor Company. No further reproduction or distribution of the Ford Motor Company ma

47-09-9 Pinto and Bobcat 47-09-9 N2767.ZA FIG. 14 Body Quarter and Rear Exterior Moulding Installation-Bobcat Station Wagon "This publication contains material that is reproduced and distributed under a license to Detroit Iron 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."

0.14. IN PAN-FRONT FLOOR HOLE IN REINFORCEMENT-REAR FLOOR SIDE MEMBER MOUNTING BRACKET M.C,14. IN BRACKET-REAR SPRING REAR I PLAN VIEW

C.H. IN PANFRONT FLOOR FRONT INNER HOLE IN PLATE-REAR SPRING REAR TAPPING IFOR MOUNTING SPRING SHACKLEI 28.08A PLAN VIEW NOTE: ALL PLAN VIEW DIMENSIONS SHOULD BE PROJECTED FRONT BUMPERARM REAR MOUNTING HOLE DOWNWARDPARALLEL TO& SIDEMEASUREDVIEW EASELINEON A SURFACE WHICH IS

47-10-1 Mustang II 47-10-1 PART Mustang II 47-10 SUBJECT PAGE SUBJECT PAGE REMOVAL AND INSTALLATION REMOVAL AND INSTALLATION Cont’d.} Bumper - Front and Rear 10-2 Radiator Grille 10-1 Exterior Mouldings 10-4 Underbody Dimensions 10-3 CN2018-2B REMOVAL AND INSTALLATION RADIATOR GRILLE Removal HEADLAMP DOOR 1. Open the hood and

47-10-2 Mustang II 47-10-2 FIG. 2 Front Bumper lnstaHofion-Mustang II 2. Place the bumper assembly on a clean work bench 3. Engage the "Tee Bars" on back of rub strips into to protect the painted surface while removing the the heads of the spring clips. rub strips. 4. Drive the rub strips down with a sharp blow of a 3. Remove the bumper guards if so equipped. soft-face mallet over each spring clip. 4. From the back side, remove two nuts one at each 5. Install the end retaining nuts. end attaching the end rub strip sections. 6. Install the bumper guards if so equipped and 5. Using a hammer, drive the metal spring clips

47-10-3 Mustang II 47-10-3 FIG. 3 Rear Bumper Installation-Mustang II for installation of Pressure Sensitive Tape Type Body Side Protection Mouldings. UNDERBODY DIMENSIONS The Mustang II under body dimensions are shown in Fig. 10. The under body checking dimensions are given in Part 47-01. "This publication contains material that is reproduced and distributed under a license to Detroit Iron 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."

47-10-4 Mustang II 47-10-4 I4EADLAMP DOOR MOULDING 4 BR + .25 .25 2144 t ISO TOP OF BUMPER TO GROUND 1. FRONT BUMPER AT 2c.20" FROM OF BUMPER

47-10-5 Mustang II 47-10-S PRY RUB STRIP AWAY FROM BUMPER GUARD CAUTION. PRY SCREW DRIVER IN THE DIRECTION OF ARROW TO PREVENT DAMAGE TO BUMPER GUARD RUB STRIP S FRONT AND REAR APPLY PROTECTIVE TAPE CLIP- R7044 .52 BUMPER GUARD RUB STRIP REMOVAL

47-10-6 Mustang II 47-10-6 N2725.ZB a® FIG. 6 Front and Rear Moulding Installation-Mustang II FIG. 7 Exterior Side Moulding Installation-Mustang II "This publication contains material that is reproduced and distributed under a license to Detroit Iron 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."

47-10-7 Mustang II 47-10-7 N2727-2A FIG. 8 Exterior Side Moulding Installation-Mustang II "This publication contains material that is reproduced and distributed under a license to Detroit Iron 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."

47-10-8 Mustang II 47-10-8 FIG. 9 Exterior Side Moulding Installation-Mustang II "This publication contains material that is reproduced and distributed under a license to Detroit Iron 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."

__________ ,s 47-10-9 Mustang II 47-10-9 MC H IN BRACKET REAR MCII. TOP HOLES OF 20.3S- ..hEMBER ASSY- FRONT !. 4517 *-- --* SUSPENSION CROSSI No. 2 F 3I.75A 23 71 PLAN VIEW

47-11-1 Monarch and Granada 47-11-1 PART Monarch and Granada 47-11 SUBJECT PAGE SUBJECT PAGE REMOVAL AND INSTALLATION REMOVAL AND INSTALLATION Cont’d. Air Deflector 11-2 Rear Bumper 11.3 Exterior Mouldings 11-3 Underbody Dimensions 11-3 Front Bumper 11-2 Radiator Grille 11*1 CN2883.28 REMOVAL AND INSTALLATION RADIAT

47-11-2 Monarch and Granada 47-11-2 AIR DEFLECTOR FIG. 1 3. Remove the bumper guards and pads from the bumper. GRANADA AND MONARCH 4. Remove the license plate mounting bracket from the Removal bumper. 1. Remove radiator and deflector upper attachments. 5. If the reinforcement is to be replaced, remove the sight shield attaching bolts and remove the top Installation sight shield and cooling ducts from the 1. Install screw in rou

47-11-3 Monarch and Granada 47-11-3 in Fig. 3. Then, adjust the bumper for body 2. Remove two bolts attaching the reinforcement to clearance at the centerline of the parking lamp so each isolator, and remove the bumper assembly. that the vertical and horizontal body to bumper dimensions meet the specifications in Fig. 3. Tighten 3. Remove the license bracket from the bumper. the isolator- to-reinforcement bolts to 35-50 ft-lbs Remove two screws retaining license plate light to torque. the reinforcement and remove the light. 7. Lift up the end sight shields. Apply 2.way tape to 4. Remove the nuts a

47-114 Monarch and Granada 47-11-4 REINFORCEMENT BOLT-57D4B REAR BUMPER BRACKET NUT -45266 U-NUT-452E5 BOLT

47-11-5 Monarch and Granada 47-11-5 N2740-1B rIG. S Exterior Side Moulding Installation- Granada Shown-Monarch Typical CCC ‘I fl-4 A N2141 2A FIG. 6 Exterior Side Moulding Installation-Granada Shown-Monarch Typical

47-11-6 Monarch and Granada 47-11-6 FIG. 7 Exterior Side Moulding Installation-Granada Shown-Monarch Typical NUTS REOD FUEL FILLER PANEL ASSY. NOTE: ONE PIECE ASSY. FOR 1978 N2743-20 FIG. 8 Rear Exterior Moulding Installation-Granada Shown-Monarch Typical "This publication contains material that is reproduced and distributed under a license to Detroit Iron from Ford Motor Company. No further reproduction or di

I ,-M.C.H, EXTENSION FRONT SIDE MEMBER a CR. IN MEMBER’FLOOR SIDE REAR -4 ci, 126% - 197

47- 12-1 Versailles 47-12-1 PART Versailles 47-12 SUBJECT PACE SUBJECT PAGE REMOVAL AND INSTALLATION REMOVAL AND INSTALLATION Cont’d. Exterior Mouldings 12-3 Rear Bumper 12-3 Front Bumper 121 Underbody Dimensions 12-3 Headlamp Doors 12-1 Radiator Grille 12-1 CN2883-2B REMOVAL A

47-12-2 Versailles 47-12-2 AERODYNAMIC SIGHT SHIELD AND ATTACHMENTS DJ4B-16B656 NUT & WASHER -45334 18 PLACES HEADLAMP DOOR

47-12-3 Versailles 47-124 TO FRONT OF BODY -38507 4 PLACES 35-SD FT-LBS BUMPER - 377798 HEX BOLT 2 PLACES - 56789 2 PLACES

REFERENCE 2 PLAC BUMPER PAD R.HJ PAO - 1794 L,R, 17C99 TO 7NT p 500Y pØGfr2A -

47-12-5 Versailles 47-2-5 MOULOING 54 20 780 FIG. 6 Exterior Side Moulding Installation RETAINER 651 RIVET 383229

47-12-6 Versailles 47- 12-6 ORNAMENT - 88369 VIEW A VIEW A LETTER ASSEMBLY 6540228 -V-1.-, NUT -

47-12-7 Versailles 47-12-7 DRIVER’S SIDE MIRROR ASSEMBLY -17682 MIRROR ASSEMBLY GASKET - - 17632 17724 FASTENER - SCREW -

-n I rM,C14. EXTENSION FRONTSIDE MEMBER C 0 C aS 0a ‘C a 3 Q 3 03 0-00 NOTES: ALL PLAN VIEW DOWNWARD &ME

"This publication contains material that is reproduced and distributed under a license to Detroit Iron 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."

GROUP AND PART INDEX VOLUME 5 IAUTOMATIC TRANSMISSION 50-17 BODY 50-41 BRAKES 50-12 CHARGING SYSTEM 50.31 CLUTCH AND MANUAL TRANSMISSION 50-16 COOLING SYSTEM 50-27 ENGINE EMISSION CONTROL SYSTEMS 50-29 GASOLINE ENGINE 50-21 HOISTING, JACKING AND TOWING

foreword... This 1978 Car Shop Manual has been prepared to provide information covering normal service repairs and maintenance for 1978 Ford Passenger Cars manufactured in the United States and Canada. It is divided into five volumes, each covering a specific major area: Volume 1 - Chassis Volume 2 - Engine Volume 3- Electrical Volume 4 - Body Volume 5 - Maintenance and Lubrication. Information in each volume is divided into Groups covering a general system. The table of contents on the cover of each volume indicates the Group title, number, and volume in which each Group is located. For 1978, the basic

On the first page of each Group there is an index listing the Part title and Part number for each component covered within the Group. The first page of each Part contains an index to locate service operations covered in that Part. This Group-Part breakdown is also indicated in the page number located at the top of each page. - Pages 21Example: 11-02-21 = GroupI 11 - Part 02 Metric conversion tables have been included at the back of each volume to aid in converting specifications in this manual to the metric equivalent. The descriptions and specifications in this manual were in effect at the time this manual was approved for printing. Ford Motor Company reserves the right to d

duSuspeu s o 50-01-1 Pre-Delivery, Maintenance and Lubrication 50-01-1 GROUP PRE-DELIVERV,MAINTENANCE AND 50 LUBRICATION PART TITLE PART NO. PART TITLE PART NO. Automatic Transmission - - 50-17 Identification Codes 5001 Body - - 5041 Lights, Instruments, Controls, Heating, Brakes

50-01-2 Identification Codes 5041-2 8563H1OOOO1 MFD. BY FORD MOTOR CO. IN U.S.A. I VEHICLE IDENTIFICATION NUMBER I MFD. BY FORD MOTOR CO. IN U.S.A. DATE 08/77 GVWR 5892 DATE: 08/77 GVWR 6538 GAWK: FRONT 2964 REAR 2928 GAWR: FRONT 2964. REAR 337$ THIS VEHICLE MANUEACTUREI FOR EXPORT ONLY ON DATE THIS VEHICLE CONFORMS TO ALL SHOWN

50-01-3 Identification Codes 50-014 IDENTIFICATION CODES DISTRICT CODES DISTRICT COOSS ASSEMBLY PLANT CODES LINCOLN-MERCURY FORD Code Leoter District Code District Code District A Atlanta 00 Special 00 Special B Oakville Canada 11 Boston 1 Boston E Mahviah

________ ________ ______________________ 50-01-4 Identification Codes 50-014 BODY SERIAL AND STYLE CODES Body IBudv BaJdy Serlat Style Serial Style Vehicle Code Cede Body Type Model Vehicle Code Code Body Type Model PINTO 10 628 2-Or. Sedan Base COUGAR 92 530 4-Or. Pillar Hardtop Cougar 11 MB 3-Dr. Sedan Base Dl 660 2-Or. Hardtop

50-02-1 Pre-Deliyery and Non Emission System Maintenance Schedules 50-02-1 Pre-Delivery And Non-Emission PART 50-02 System Maintenance Schedules SUBJECT PAGE SUBJECT PAGE PRE-DELIVERY SERVICES 02-1 NON-EMISSION SYSTEMS MAINTENANCE... - 02-6 CN4045-2A PRE-DELIVERY SERVICES PRE-DELI VERY SERVICES Perform the tollowing inspections and adjustments as required. UND ER H 0 0 0 ROAD TEST * Chock and top-up all fluids to specitied levels-engine oil,

50-02-2 Pre-Delivery and Non Emission System Maintenance Schedules 50-02-2 UNDERHOOD Underfill can result in transmission loss of engagement or slipping. This condition is most evident CHECK ENGINE OIL LEVEL in cold weather or when the vehicle is parked or being On all engines, the oil level should be within the driven on a hill. SAFE range on the dipstick. If the transmission fluid level is checked when the fluid is cold, the dipstick could indicate that fluid shouldCHECK BR

50-02-3 Pre-Delivery and Non Emission System Maintenance Schedules 50-02-3 CHECK BATTERY CHARGE BODY With battery temperature at 80 F,the battery should INSTALL WHEEL COVERS have a specific gravity reading of not less than 1 .230 for non-maintenance free batteries and an open circuit Inspect wheel covers or hub caps for dents or other shipping damage.voltage of not less than 1 2.45 volts for maintenance free batteries. Recharge if necessary. Center the tire valve stem in the wheel cover hole and position the cover on the wheel with the valve stemCHECK THROTTLE OPERATION AND IDLE

50-02-4 Pre-Delivery and Non Emission System Maintenance Schedules 50-02-4 CHASSIS headlight switch and observe the headlight housings for fufl opening and closing. Inspect the mount%ngs forADJUST TIRE PRESSURES looseness. Check each tire to be sure the air pressure agrees with that specified for the tire and vehicle model. Adjust CHECK LIGHTS pressure as necessary. Check head, tail, signal, courtesy, instrument CHECK EXHAUST SYSTEM warning and indicator lights for proper operation of s

50-02-5 Pre-Delivery and Non Emission System Maintenance Schedules 50-02-5 CHECK AUTOMATIC TRANSMISSION 4. Remove the protective wax from bumpers. PERFORMANCE 5. Wipe the steering wheel. Make sure no grease or Check Transmission Initial Engagement smudges have been left on any controls. 6. Check closely for any excess adhesive not removed Initial engagment checks are made to determine if by washing. initial band and clutch engagements are smooth. Check around the edges of vinyl roofs Run the eng

50-024 Pre-Delivery and Non Emission System Maintenance Schedules 50-02-6 NOTE: If the engine has the "Dura Spark I" ignition NOTE: When the white mark on the damper system grey coil tower, use the following equipment refer to Step 1 is directly in line with pointer to perform this maintenance operation: mark, the initial ignition timing is correct. 1. Timing Light-Designed for High Energy Ignition Record timing and curb idle data on Pre-Delivery Inductance Pickup Service Record FPS365-13177-A1. 2. Tachometer-Special service 02-0362 or equivalent. PERFORM IDLE EMISSIONS TEST AND 3. Optional-Special servi

__________________ ______________________________________________ _____________________________________________________________________________________________________________________________________________________________________________________________________________________________________ _________________________________________ 50-02-7 Pre-Delivery and Non Emission System Maintenance Schedules 50-02-7 SCHEDULED MAINTENANCE SERVICES - MAINTENANCE scHEoulEs A AND B SERVICE INTERVAL - lime ii, montlisor milet Schedules A and B have bee., combined into one rIsers. Fellow else schedule which correspond, to the car’s or kilometre, in thousands, whichever occurs first code letter.

50-02-8 Pre-Delivery and Non Emission System Maintenance Schedules 50-024 NONSCHEDULEO MAINTENANCE Items should be checked periodically and service performed when required. These servicee are not covered by the Warranty, you will be charged for the labor, parts and lubricants used. MAINTENANCE OPERATION WHEN PERFORMED Inspect wheels end tires for damate and tighten nuts, Periodically or if wheels ere noisy. Balance and rolale wheels and tires- Tires show uneven wear paftern or vibrate. Replace fires. When treed wear ind,cator appears. Front suspension check.

50-03-1 Lubrication Charts and Lubricant Specification5 50-03-1 Lubrication Charts and 5j3 Lubricant Specifications All Models SUBJECT PAGE SUBJECT PAGE LUBRICATION SPECIFICATIONS 03-11 Lubrication Charts 03-1 CA4240-A LUBRICATION LUBRICATION CHARTS Figs. 1 thru 9 show typical chassis and engine lubrication points for current production vehicles. Vehicles with optional or special equipment may have slightly different, or additional lubrication points. A table

50-03-2 Lubrication Charts and Lubricant Specifications 50-03-2 RADIATOR COOLANT LEVEL SEE PART 50-21 FOR FILL INSTRUCTIONS AND CHECKING PROCEDURE POWER STEERING PUMP DIPSTICK FLUID SHOULD BE BETWEEN ADD AND FULL MARKS BELT TENSION GAUGE CHECK BELT TE

50-034 Lubrication Charts and Lubricant Specifications 50-034 RADIATOR SEE PART SD-27 FOR FILL INSTRUCTIONS AND CHECKING PROCEDURE. AIR FILTER CHANGE ELEMENT AT RECOMMENDED INTERVAL CAP POWER STEERING PUMP DIPSTICK FLUID SHOULD BE BETWEEN ADO AND

50-03-4 Lubrication Charts and Lubricant Specifications 50-03-4 FRONT RADIATOR SEE PART ENGINE OIL 50-27 FOR FILL AND DRAIN PLUG CHECK POWER STEERING BELT TENSION GAUGE CHECK AT RECOMME

50-03-5 Lubrication Charts and Lubricant Specifications 50-03-5 SEE PART 50.2? ron FILL PROCEDURE AND CHECKING CROSS FLOW RADIATOR SEE PART 50-77 FOR FILL PROCEDURE AND CHECKING INSTRUCTIONS VERTICAL FLOW RADIATOR COAT GASKET DRIVE BELT WITH ENGINE OIL TENSION

50-03-6 Lubrication Charts and Lubricant Specifications 50-03-6 LUBRICATE CLUTCH LINKAGE MASTER BRAKE CVLINDER FLUID LEVEL 1/4 IN. FROM TOPI FRONT WHEEL BEARINGS INSPECT a FILL PLUG MANUAL TRANSMISSION FILL TO BOTTOM OF FILLER HOLE WITH VEHICLE ON LEVEL GROUND. LUBE AUTOMATIC TRANS

50-03-7 Lubrication Charts and Lubricant Specifications 50-03-7 LOWER BALL JOINN LUBRICATE AND TVPICAL STANDARD TRANSMISSION FLOOR SHIFT LINKAGE LUBRICATE AS REOUIREO FRONT WHEEL BEARINGS INSPECT MANUAL TRANSMISSION FILL TO BOTTOM OF FILLER HOLE WITH VEHICLE ON LEVEL GROUND.

50-03-8 Lubrication Charts and Lubricant Specifications 50-03-8 STEERING LINKAGE NOTE: UPPERJOINTS ANDHAVELOWERPOLYETHYLENEBALL REMOVE PLUGS TO LINERS AND 00 NOT REQUIRE LU BR ICATE I LUBRICATION A BALL JOINT t TYPICAL STANDARD TRAPJSMISSSION FLOOR SHIFT LINKAGE LUBRICATE AS R

50-03-9 Lubrication Charts and Lubricant Specifications 50-03-9 STEERING LINKAGE REMOVE PLUGS TO LUBRICATE A A A A V FRONT WHEEL BEARINGS INSPECT STEERING STOP PADS LUBRICATE SURFACES AXLE PARKING BRAKE L

50-03-10 Lubrication Charts and Lubricant Specifications 50-03-10 STEERING LINKAGE REMOVE PLUGS TO LUBRICATE A REMOVE PLUGS TO LUBRICATE INSPECT STEERING ARM STOPS LUBRICATE SURFACES FUEL EVAPORATIVE

___________ __________________________________ 50-03-11 Lubrication Charts and Lubricant Specifications 50-03-11 SPECI FICATIONS LUBRICANT SPECIFICATIONS Item Part NamE FDrd Part No. Ford SpeEificatiOn - Hnges, Hinge Checks and PIVOTS Polyethylene Grease C4AZ-19564-B ESB-M1C 106-B Front Suspension Bat Joinls Long Lile Lubricant C1AZ-19590-B ESA-M1CJ5-B Steering Linkage Steering Linkage Lube - C6AZ-19590-A ESA-M1CS2-A Type II Power Steering Control Valve Ball Stud -