Ford Falcon (1969) Service & Repair Manual View larger

Ford Falcon (1969) Service & Repair Manual

English Service Manual, to vehicles Ford Falcon (1969).

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LANGUAGE: English.
FORMAT: PDF file
PAGES: 1487
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FORD FALCON (1969) - WORKSHOP, SERVICE, REPAIR MANUAL

- English Service Manual, to vehicles Ford Falcon (1969).

 
CONTENTS:


VOLUME I - CHASSIS

- Group 1 - Vehicle Identification
-- Typical Warranty Plate
-- Vehicle Warranty Number
-- Vehicle Data
-- Official Vehicle Indentification Numbers
-- Model Year Code
-- Body Serial and Style Codes
-- Lincoln Continental
-- Continental Mark III
-- Cougar
-- Mercury
-- Meteor
-- Montego
-- Thunderbird
-- Falcon
-- Mustang
-- Ford
-- Rear Axle Ratio Codes
-- Transmission Codes
-- Engine Codes
-- Consecutive Unit Number
-- Exterior Paint Color Codes
-- Interior Trim Codes
-- Date Codes
-- District Codes (DSO)
-- Ford
-- Lincoln-Mercury
-- Ford of Canada
- Group 2 - Brakes
-- Part 2-1 General Brake Service
-- 1. Brake System Tests
-- 2. Common Adjustments and Repairs
-- 3. Cleaning and Inspection
-- Part 2-2 Brake System
-- 1. Description
-- 2. In-Vehicle Adjustments and Repairs
-- 3. Removal and Installation
-- 4. Major Repair Operations
-- Part 2-3 Specifications
- Group 3 - Suspension, Steering, Wheels and Tires
-- Part 3-1 Suspension, Steering, Wheels and Tires General Service
-- 1. Testing
-- 2. Common Adjustments and Repairs
-- 3. Cleaning and Inspections
-- Part 3-2 Suspension
-- 1. Description
-- 2. In-Vehicle Adjustments and Repairs
-- 3. Removal and Installation
-- 4. Major Repair Operations
-- Part 3-3 Automatic Air Leveling System
-- 1. Description
-- 2. Removal and Installation
-- 3. Major Repairs
-- Part 3-4 Automatic Air Levling System - Lincolon Continental
-- 1. Description
-- 2. Removal and Installation
-- 3. In-Vehiclel Adjustments and Repairs
-- Part 3-5 Steering Columns and Linkage
-- 1. Description
-- 2. In-Vehicle Adjustments and Repairs
-- 3. Removal and Installation
-- 4. Major Repair Operations
-- 5. Steering Linkage Repair
-- Part 3-6 Manual Steering
-- 1. Description
-- 2. In-Vehicle Adjustments and Repairs
-- 3. Removal and Installation
-- 4. Major Repair Operations
-- Part 3-7 Ford Design Non-Integral Power Steering System
-- 1. Description
-- 2. In-Vehicle Adjustments and Repairs
-- 3. Removal and Installation
-- 4. Major Repair Operations
-- Part 3-8 Ford Design Integral Power Steering Gear
-- 1. Description
-- 2. In-Vehicle Adjustments and Repairs
-- 3. Removal and Installation
-- 4. Major Repair Operations
-- Part 3-9 Saginaw Design Integral Power Steering Gear
-- 1. Description
-- 2. In-Vehicle Adjustments and Repairs
-- 3. Removal and Installation
-- 4. Major Repair Operations
-- Part 3-10 Ford-Thompson Power Steering Pump
-- 1. Description
-- 2. In-Vehicle Adjustments and Repairs
-- 3. Removal and Installation
-- 4. Major Repair Operations
-- Part 3-11 Eaton Power Steering Pump
-- 1. Description
-- 2. Removal and Installation
-- 3. Major Repair Operations
-- Part 3-12 Wheels and Tires
-- 1. Description
-- 2. In-Vehicle Adjustment and Repairs
-- 3. Removal and Installation
-- 4. Major Repair Operations
-- Part 3-13 Specifications
- Group 4 - Rear Axle
-- Part 4-1 General Axle Service
-- 1. Common Adjustments and Repair
-- 2. Cleaning and Inspection
-- Part 4-2 Rear Axle - Removable Carrier Type
-- 1. Description
-- 2. In-Vehicle Adjustments
-- 3. Removal and Installation
-- 4. Major Repair Operations
-- Part 4-3 Rear Axles - Integral Carrier Type
-- 1. Description
-- 2. In-Vehicle Adjustments and Repair
-- 3. Removal and Installation
-- 4. Major Repair Operations
-- Part 4-4 Rear Axle - Ford Light-Duty (WER)
-- 1. Description
-- 2. In-Vehicle Adjustment and Repair
-- 3. Removal and Installation
-- 4. Major Repair Operations
-- Part 4-5 Specifications
- Group 5 - Drive Shaft and Clutch
-- Part 5-1 Drive Shaft
-- 1. Drive Shaft Tests
-- 2. Description
-- 3. Removal and Installation
-- 4. In-Vehicle Repair
-- 5. Major Repair Operations
-- Part 5-2 General Clutch Service
-- 1. Flywheel Housing Alignment
-- 2. Cleaning and Inspection
-- Part 5-3 Clutch
-- 1. Description
-- 2. In-Vehicle Adjustments and Repairs
-- 3. Clutch Removal and Installation
-- Part 5-4 Specifications
- Group 6 - Manual Shift Transmissions
-- Part 6-1 General Transmission Service
-- 1. Common Adjustments and Reparis
-- 2. Cleaning and Inspection
-- Part 6-2 Model Three-speed Transmission
-- 1. Description
-- 2. In-Vehicle Adjustments and Repairs
-- 3. Removal and Installation
-- 4. Major Repair Operations
-- Part 6-3 Ford Design Four-speed Transmission
-- 1. Description
-- 2. In-Vehicle Adjustment and Repairs
-- 3. Removal and Installation
-- 4. Major Repair Operations
-- Part 6-4 Specifications
- Group 7 - Automatic Transmission
-- Part 7-1 General Transmission Service
-- 1. Automatic Transmission Tests
-- 2. Common Adjustments and Repairs
-- 3. Cleaning and Inspection
-- Part 7-2 C4 Automatic Transmission
-- 1. Description
-- 2. In-Vehicle Adjustments and Repairs
-- 3. Removal and Installation
-- 4. Major Repair Operations
-- Part 7-3 FMX Transmission
-- 1. Description
-- 2. In-Vehicle Adjustments and Repairs
-- 3. Removal and Installation
-- 4. Major Repair Operations
-- Part 7-4 C6 Automatic Transmission
-- 1. Description and Operation
-- 2. In-Vehicle Adjustments and Repairs
-- 3. Removal and Installation
-- 4. Major Repair Operations
-- Part 7-5 Specifications

VOLUME II - ENGINE

- Group 8 - Engine
-- Part 8-1 General Engine Service
-- 1. Engine Tests
-- 2. Common Adjustments and Repairs
-- 3. Cleaning and Inspection
-- Part 8-2 170 Six Engine
-- 1. Description
-- 2. In-Vehicle Adjustments and Repairs
-- 3. Engine Removal and Installation
-- 4. Major Repair Operations
-- Part 8-3 200 and 250 Six
-- 1. Description
-- 2. In-Vehicle Adjustments and Repairs
-- 3. Engine Removal and Installation
-- 4. Major Repair Operations
-- Part 8-4 240 Six Engine
-- 1. Description
-- 2. In-Vehicle Adjustments and Repairs
-- 3. Engine Removal and Installation
-- 4. Major Repair Operations
-- Part 8-5 302 and 351 V-8
-- 1. Description
-- 2. In-Vehicle Adjustments and Repairs
-- 3. Engine Removal and Installation
-- 4. Major Repair Operations
-- Part 8-6 390 and 428 V-8
-- 1. Description
-- 2. In-Vehicle Adjustments and Repairs
-- 3. Engine Removal and Installation
-- 4. Major Repair Operations
-- Part 8-7 429 and 460 V-8 Engine
-- 1. Description
-- 2. In-Vehicle Adjustments and Repairs
-- 3. Engine Removal and Installation
-- 4. Major Repair Operations
-- Part 8-8 Specifications
- Group 9 - Ignition System
-- Part 9-1 General Ignition Service
-- 1. Component Tests
-- 2. Common Adjustments and Repairs
-- 3. Cleaning and Inspection
-- Part 9-2 Autolite Dual Advance Distributors
-- 1. Description
-- 2. In-Vehicle Adjustments and Repairs
-- 3. Removal and Installation
-- 4. Major Repair Operations
-- Part 9-3 Specifications
- Group 10 - Fuel System
-- Part 10-1 General Fuel System Service
-- 1. Performance Specifications
-- 2. Performance Adjustments
-- 3. Removal and Installation
-- 4. Cleaning and Inspection
-- Part 10-2 Autolite Models 1100 and 1101 1-v
-- 1. In-Vehicle Adjustments and Repairs
-- 2. Major Repair Operations
-- Part 10-3 Carter Model YF 1-v Carburetors
-- 1. In-Vehicle Adjustments and Repairs
-- 2. Major Repair Operations
-- Part 10-4 Autolite Model 2100 2-V and 4100 4-VCarburetors
-- 1. In-Vehicle Adjustments and Repairs
-- 3. Major Repair Operations
-- Part 10-5 Autolite Model 4300 4-v Caruretor
-- 1. In-Vehicle Adjustments and Repairs
-- 2. Major Repair Operations
-- Part 10-6 Holley Model 4150C 4-v Carburetor
-- 1.In-Vehicle Adjustments and Repairs
-- 2. Major Repair Operations
-- Part 10-7 Air Cleaner and Duct System
-- 1. Hot and Cold-Type Air Intake System Tests
-- 2. Removal and Installation
-- Part 10-8 Fuel Pump
-- 1. Fuel Pump Tests
-- 2 Major Repair Operations
-- Part 10-9 Throttle Linkage
-- 1. Throttle and Downshift Linkage Adjustments
-- 2. Throttle Linkage Repair
-- Part 10-10 Fuel Tank and Fuel Lines
-- 1. Removal and Installation
-- Part 10-11 Specifications
- Group 11 - Cooling System
-- Part 11-1 General Cooling System Service
-- 1. Diagnosis and Testing
-- 2. Common Adjustments and Repairs
-- 3. Cleaning and Inspection
-- Part 11-2 Description and Operation
-- 1. Description and Operation
-- 2. Removal and Installation
-- Part 11-3 Fan Drive Clutch
-- 1. Description and Operation
-- 2. Removal and Installation
-- Part 11-4 Ford Flex Blade Fan
-- 1. Description and Operation
-- Part 11-5 Specifications
- Group 12 - Exhaust System
-- Part 12-1 General Exhaust Systems
-- 1. Description and Application
-- 2. Replacement
-- 3. Cleaning and Inspection
- Group 13 - Starting System
-- Part 13-1 Autolite Positve Engagement Starters
-- 1. Description and Operation
-- 2. Removal and Installation
-- 3. Positive Engagement Starter Testing
-- 4. Positive Engagement Starter Overhaul
-- 5. Specifications
-- Part 13-2 Autolite Solenoid Actuated Starters
-- 1. Description and Operation
-- 2. Removal and Installation
-- 3. Solenoid Actuated Starter Testing
-- 4. Solenoid Actuated Starter Overhaul
-- 5. Specifications

VOLUME III - ELECTRICAL

- Group 14 - Charging System
-- Part 14-1 Autolite Alternators
-- 1. Description and Operation
-- 2. Autolite Alternator Testing
-- 3. Removal and Installation
-- 4. Major Repair Operations - Except 65-Ampere Alternator
-- 5. Major Repair Operations - 65-Ampere Alternator
-- Part 14-2 Autolite Alternator Regulators
-- 1. Description and Operation
-- 2. Autolite Regulator Testing
-- 3. Removal and Installation
-- 4. Regulator Adjustments
-- Part 14-3 Leece Neville Alternators
-- 1. Description and Operation
-- 2. Leece Neville Alternator Testing
-- 3. Removal and Installation
-- 4. Major Repair Operations - 65-Ampere Alternator
-- Part 14-4 Leece Neville Alternator Regulators
-- 1. Description and Operation
-- 2. Leece Neville Regulator Testing
-- 3. Removal and Installation
-- 4. Regulator Adjustments
-- Part 14-5 Batteries
-- 1. Battery Tests
-- Part 14-6 Specifications
- Group 15 - Lighting Instruments and Convenience Devices
-- Part 15-1 Headlight System
-- 1. Headlights
-- 2. Headlight Swithing System
-- 3. Headlight Covers - Ford, Mercury, Cougar, Continental Mark III and Thunderbird
-- Part 15-2 Auxilary Exterior, Interior and Indicator Light Systems
-- 1. Front Parking and Turn Signal Lights
-- 2. Front Side Marker Lights
-- 3. Rear Side Marker Lights
-- 4. Rear Lights
-- 5. Interior Lights, Indicator Lights and Swithes
-- Part 15-3 Instrument Panels, Gauges and Controls
-- 1. Instrument Voltage Regulator
-- 2. Fuel Indicating System
-- 3. Temperature Indicating System
-- 4. Oil Pressure Indicating System
-- 5. Charge Indicating System, Ignition Swith and Clock
-- 6. Speedometer
-- 7. Ford and Meteor - Removal and Installation
-- 8. Mercury - Removal and Installation
-- 9. Mustang and Cougar - Removal and Installation
-- 10. Fairlane - Removal and Installation
-- 11. Falcon - Removal and Installation
-- 12. Montego - Removal and Installation
-- 13. Lincoln Continental - Removal and Installation
-- 14. Thunderbird - Removal and Installation
-- 15. Continental Mark III - Removal and Installation
-- 16. Specifications
-- Part 15-4 Turn Signals, Emergency Flasher and Horns
-- 1. Solid State Sequential Turn Signal and Emergency Flasher System - Cougar
-- 2. Sequential Turn Signal and Emergency Flasher System - Thunderbird
-- 3. Turn Signal and Emergency Flasher System - All Except Cougar and Thunderbird
-- 4. Turn Signal/Emergency Flasher Switch and Wire Assembly - All Vehicle Lines
-- 5. Horns
-- 6. Three-Spoke, Rim-Blow Horn
-- Part 15-5 Windshield Wipers and Washer
-- 1. Ford Meteor and Mercury Wipers
-- 2. Falcon, Fairlane, Montego, Mustang and Cougar Wipers
-- 3. Intermittent Wiper Governor - Ford, Meteor, Mercury, Fairlane and Montego
-- 4. Thunderbird, Continental Mark III, and Lincoln Continental
-- 5. Windshield Washers
-- Part 15-6 General Wiring, Circuit Protection and Specifications
-- 7. Specifications
-- 1. Wiring Harness Removal and Installaation - Ford, Meteor and Mercury
-- 2. Wiring Harness Removal and Installation - Mustang and Cougar
-- 3. Wiring Harness Removal and Installation - Falcon, Fairlane and Montego
-- 4. Wiring Harness Removal and Installation - Thunderbird and Continental Mark III
-- 5. Wiring Harness Removal and Installation - Lincoln Continental
-- 6. Circuit Protection
- Group 16 - Heating, Ventilating and Accessories
-- Part 16-1 Heating and Ventilation System
-- 1. Description and Operation
-- 2. Testing
-- 3. Adjustments
-- 4. Ford, Mercury and Meteor Removal and Installation
-- 5. Mustang and Cougar Removal and Installation
-- 6. Montego, Falcon and Fairlane Removal and Installation
-- 7. Thunderbird and Continental Mark III Removal and Installation
-- 8. Lincoln Continental Removal and Installation
-- Part 16-2 Heater-Air Conditioning
-- 1. Description and Operation
-- 2. Testing
-- 3. Adjustments and Service Operations
-- 4. Ford, Mercury and Meteor Removal and Installation
-- 5. Mustang and Cougar Removal and Installation
-- 6. Falcon, Fairlane and Montego Removal and Installation
-- 7. Lincoln Continental Removal and Installation
-- 8. Thunderbird and Continental Mark III Removal and Installation
-- 9. Compressor and Compressor Components Removal and Installation
-- Part 16-3 Automatic Temperature Control
-- 1, Lincoln Continental
-- 2. Thunderbird and Continental Mark III
-- Part 16-4 Speed Control
-- 1. Ford, Mercury and Meteor - Bendix Speed Control System
-- 2. Mustang and Cougar - Perfect Circle Speed Control System
-- 3. Lincoln Continental - Perfect Circle Speed Control System
-- 4. Thunderbird - Perfect Circle Speed Control System
-- 5. Continental Mark III - Perfect Circle Speed Control System
-- Part 16-5 Automatic Headlight Dimmer
-- 1. Description and Operation
-- 2. Testing
-- 3. Adjustments
-- 4. Removal and Installation
-- Part 16-6 Radio and Stereo Tape Player
-- 1. Description and Identificationn
-- 2 Testing
-- 3. Adjustments
-- Part 16-7 Specifications

VOLUME IV - BODY

- Group 17 - Body, Doors and Windows
-- Part 17-1 General Body Service
-- 1. Vehicle and Paint Identification
-- 2. Common Adjustments and Repairs
-- 3. Cleaning and Inspection
-- 4. Vehicle Hoisting
-- Part 17-2 Grille, Bumpers and Exterior Mouldings
-- 1. Removal and Installation
-- Part 17-3 Doors, Hood and Luggage
-- 1. Description and Operation
-- 2. Test and Adjustments
-- 3. Removal and Installation
-- Part 17-4 Windshield, Window Glass, and Window Mechanisms
-- 1. Removal and Installation
-- Party 17-5 Side Windows and Mechanisms
-- 1. Adjustments and Lubrication
-- 2. Front Door Window Mechanism Components, Relays and Switches Removal and Installation
-- 3. Rear Door Window Mechanism Removal and Installation
-- 4. Quarter Window Mechanism Removal and Installation
-- 3. Removal and Installation
-- Part 17-6 Tailgate
-- 1. Ford, Mercury and Meteor Dual Action Tailgate
-- 2. Falcon, Fairlane and Montego Tailgates
-- Part 17-7 Specifications
-- 1. Paint and Surface Defects
-- 2. Repair Procedures
-- 3. Materials and Tools
- Group 18 - Trim, Seats and Convertible Top
-- Part 18-1 Interior Trim and Roof Outside Cover
-- 1. Door Trim Panels
-- 2. Quarter Trim Panels
-- 3. Interior Mouldings, Package Tray Trim Panels, Carpets, Consoles
-- 4. Headlining
-- 5. Instrument Panel Pad
-- 6. Roof Outside Cover Removal and Installation
-- 7. Roof Outside Cover Repairs
-- 8. Interior Trim Codes
-- Part 18-2 Seats
-- 1. Manual Seats
-- 2. Six-Way Power Seats - Ford, Meteor, Mercury, Thunderbird and Continental Mark III
-- 3. Two-Way Power Seat - Continental Mark III
-- 4. Four-Way Power Seat - Montego
-- 5. Lincoln Continental - Power Seats
-- 6. Front Seat Features
-- 7. Seat Trim
-- 8. Seat Belts and Shoulder Harness
-- Part 18-3 Convertible Top
-- 1. Operation, Testing, and Care of Convertible Top - All Convertibles
-- 2. Removal and Overhaul of the Pump, Cylinder and Motor Assemblies - All Convertibles
-- 3. Top Adjustments - Ford, Meteor, Mercury, Mustang and Cougar
-- 4. Top Adjustments - Montego and Fairlane
-- 5. Ford Meteor and Mercury - Removal and Installation
-- 6. Montego and Fairlane - Removal and Installation
-- 7. Mustang and Cougar - Removal and Installation
-- Part 18-4 Sun Roof Panel
-- 1. Description and Operation
-- 2. Adjustments and Maintenance
-- 3. Removal and Installation

VOLUME V - PRE-DELIVERY, MAINTENANCE AND LUBRICATION

- Part 19-1 Pre-Delivery Sequence Guides
- Part 19-2 Maintenance Schedule
- Part 19-3 Lubrication
-- 1. Under Hood
-- 2. On Hoist
- 19-4 Pre-Delivery and Maintenance Procedures
-- 1. Body and Accessories
-- 2. Engine
-- 3. Transmission and Clutch
-- 4. Brakes
-- 5. Steering and Alignment