1977 Ford Car Shop Manual Volume 4 Body

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foreword...

This 1977 Car Shop Manual has been prepared to provide information

covering normal service repairs and maintenance for 1977 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 — M aintenance 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 1977,

the

basic

part

number for components covered

in the Group is

also

included in parenthesis after the Group number.

Example: Cooling System Group 27 (8000)

General System Covered Group Num ber Basic Part Num ber

in Group for Cooling System

Components

Some components covered w ithin a Group do not have the same basic part

number. In these cases , more than one basic part number will appear on the

Group ind ex.

Exam ple: Gasoline Engines Group 21 (6000 & 9000)

General System

Covered in Group

Basic Part

Number for

Gasoline

Engine

Components

Intake and

Exhaust Manifold

Basic Part

Number Only

For

easy referen ce, information

in each Group has

been d ivided into smaller

units

or Parts.

There

is

on e

Part

for

each

component

in the

system,

as

well as

a General Service Part in some Groups to cover procedures common to

several components within the Group. In general, each Part contains the

Description, Operation, Diagnosis and Testing, Removal and Installation

and Disassembly and Assembly procedures for the component covered in

the Part. Diagnosis Charts are also included in some Parts to help you

systematically locate and correct problems encountered. In most cases,

specifications are included at the end of each Part.



To aid in locating specific items in this ma nua l, the index at the front of each

volume provides an alphabetical listing, with page number, for all Parts in

the vo lum e. The tab lo cator on the right side of this index will help you find

the first page of each Group.

On the first page of each Grou p there is an index listing the Pa rt 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.

Ex am ple: 11-02-21 = (Group) 11 — (Part) 02 — (Page) 21

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 de scription s and specifications in this manual we re in effect at the time

this manual was approved for printing. Ford Motor Company reserves the

right to discontinue models at any time, or change specifications or design

without notice and without incurring obligation.

Ford Parts and Service Division

Training and Publications Department



40-00-1 Identification Codes

40-0

IDENTIFICATION CODES

GROU

Car Identification Codes

GENERAL DESCRIPTION

OFFICIAL VEHICLE

IDENTIFICATION NUMBER

The official Vehicle Identification

Number (VIN) (Fig.

1) for

title

and

registration purposes

is

stamped

on a

meta l tab t h a t is fas tened to the

instrument panel close to the windshield

on the driver's side of the car and is

visible from outside.

VEHICLE CERTIFICATION LABEL

The Vehicle Certification Label (V.C

Label) (Fig. 1) is attached to the rear face

of the left front door on all 4-door models

and Mustangs and Cougars, and to the

left door lock pillar on all other 2-door

models .

The

upper half

of

the label

contains

the

name

of

manufacturer,

month and year of manufacture, Gross

Vehicle Weight Rating (GVWR), Gross

Axle Weight Rating (GAWR), and

the

certification statement.

The V.C. label also contains the

Vehicle Identification Number. This

number

is

also used

for

w ar ran ty

identification

of

the vehicle. The first

number indicates the model year. The

letter following the model year number

indicates

the

manufacturing assembly

plant. The next two numbers designate

the Body Serial Code followed by a letter

expressing the Engine Code.

The last six digits of the Vehicle

Identif ication Number indicate

the

Consecutive Unit Number of each unit

bui l t at each assembly plan t. The

Consecutive Unit Numbers begin

as

follows:

100,001—Ford, LTD II, Ranchero,

M us tang , Thu nderb i rd , G ran ada ,

Maverick, and Pinto.

500,001—Mercury, Cougar, Comet,

Monarch and Mercury Bobcat.

800,001—Lincoln Continental and

Continental Mark V.

The remaining information

on the

V.C. Label consists of the following

vehicle identification codes:

The BODY code is two numerals

a letter identifying the body style.

The COL (color) code is a num

and letter code indicating the ext

paint color code and vinyl roof type

color (if equipped).

The TRIM code consists

of a

letter or a letter-number combina

designating the interior trim.

The AXL E code is a number or l

indicat ing

the

rear axle ratio

standard or locking type axles.

The TRNS. code is a number or l

indicating the type

of

transmission.

The DSO code, consisting

of

numbers, designates the district in w

the car was ordered and may appea

conjunction with

a

Domestic Spe

Order

or

Foreign Special Order num

when applicable. Ford of Canada D

codes consist of a letter and numbe

The following charts provide

various codes and their respe

identification:



40-01-2


40-01-2

<f~7S63H 1 0 0 0 0 1 ^

(VEHICLE IDENTIFICATION NUMBER

MFD. BY FORD M OTOR CO. IN U.S.A.

DATE: 07/76 GVWR 5892

GAWR: FRONT 2964, REAR 2928

THIS VEHICLE CONFORMS TO ALL

A P P L I C A B L E F E D E R A L M O T O R

VEHICLE SAFETY STANDARDS IN

EFFECT ON THE DATE OF MANU-

FACTURE SHOWN ABOVE.

F 0 0 3 3 / R 0 1 5 5

7 S 6 3 H 1 0 0 0 0 1 .

PASSENGER

'VEH. ihENT. NO. I TYPE

6 H 7 U 8 ) ( 9 l (10) (11

(UNITED STATES)

T ) CONSECUTIVE UNIT NO. ( ? ) V INYL ROOF TYPE/COLOR

^ ) BODY SERIAL CODE ( j T ) TRIM CODE

j j ) MODEL YEAR CODE MO ) TRANSMISSION CODE

jT) ASSEMBLY PLANT CODE ( 7 f ) REAR AXLE CODE

J ) BODY TYPE CODE Q ? ) DISTRICT - SPECIAL EQUIPMENT

6 J ENGINE CODE H 3 ) VEHICLE TYPE

7 ) BODY COLOR CODE ( 1 4 J ACCESSORY RESERVE LOAD

MFD. BY FORD MOTOR CO. IN U.S.A.

DATE: 07/76

GAWR: FRO NT 2964

GVWR 5892

REAR 2928

THIS VEHICLE MANUFACTURED FOR

EXPORT ONLY ON DATE

SHOWN ABOVE.

7 S 6 3 H 1 0 0 0 0 2

VEH. IDENT. NO. I

P A S S E N G E R

TYPE

BODY I COLOR | TRIM | TR A N S| AXLE | DSO

53H 1C-CA D X 6 90

(EXPORT)

MFD.

BY FORD MOTOR CO.

OF CANADA LTD.

THIS VEHICLE CONFORMS TO

ALL APPLICABLE FEDERAL MOTOR

VEHICLE SAFETY STANDARDS IN

EFFECT ON THE DATE OF

MANUFACTURE SHOWN ABOVE

VEH. IDENT. NO. |

TYPE

BODY I COLOR I TRIM I TRANS. I AXLE

MADE IN CANADA

DSO

( C A N A D A )

Y1410-J

FIG. 1 Vehicle Identification and Certification Labels



40-01-3


40-0

SPECIFICATION CODES

1977 IDENTIFICATION CODES

ASSEMBLY PLANT CODES

Code Letter

District

A Atlanta

B Oakville (Canada)

E

,

Mahwah

F Dearborn

G Chicago

H Lorain

J Los Angeles

K Kansas City

P Twin Cities

R San Jose

S Allen Park (Pilot)

T Metuchen

U Louisville

W Wayne

X

St .

Thomas

Y Wixom

Z St. Louis

ENGINE CODES

Codes

No.

of

Cyls.

Displacement

A

8

460-4V

r

8

460 -4V (Police)

F 8

302-2V

H ; : : : : : a : . " : : . ' . ; . 3 5 1 - 2 V

L

6 .

250-1V

8 400-4V

S

8 . . . .. ....

400-2V

T

6

200-1V

Y 4 139-2V (2.3L)

Z

6

169-2V (2.8L)

DISTRICT CODES

LI NCOLN- M ERCURY

Code

00

11

15

16

17

21

22

23

26

31

32

33

34

41

42

.

46

51

52

53

54

84

90's

District

. . .

Special

. .

Boston

. . . New

York

. . .

Philadelphia

. . .

Washington

Atlanta

. . .

Dallas

.

Jacksonville

Memphis

Buffalo

Cincinnati

. Cleveland

.

Detroit

. . . Chicago

. . . S t

Louis

. .. Twin Cities

. . .

Denver

. . .

Los Angeles

Oakland

. . . Seattle

Home

O ff

Reserve

. .

Export

DISTRICT CODES

FORD

FORD OF CANADA

TRANSMISSION CODES

Codes Type

M A N U A L

1

3

Speed

6

4

Speed @

7

4

Speed

(b )

AUTOMATIC

V XP(C-3)

W XP( C- 4 ) '

X F M X ]

U

•

XPL( C- 6 )

Z

X PL

(Special)

Mercury

Code

, A1

A2

A3

A4

A 6

A7

12

Region

Central

Eastern

Atlantic

Midwestern

. .

Western

. .

Pacific

. . Export

Ford

Code

B1

B2

B3

B4

B6

B7

12

REAR AXLE RATIO CODES

Conventional Lock

B

1

J

8

2

3

6 0

4

. . .

7

Ratio

2.47

2.50

2.73

2.75

2.79

3 0 0

3

1 8

3 40

EXTERIOR PAINT COLOR CODES

Code

00

11

12

13

14

15

16

17

21

22

23

24

25

26

28

41 .

42

43

45

46

47

48

52

53

54

55

56

57

58

71

72

73

74

75

76

83

84

85

86

87

89

90's

District

Special

Boston

Buffalo

New York

Pittsburgh

Newark

Philadelphia

Washington

Atlanta

Charlotte

Memphis

Jacksonville

Richmond

New Orleans

Louisville

Chicago

Cleveland

Milwaukee

Lansing

Indianapolis

Cincinnati

Detroit

Dallas

Kansas City

Omaha

St. Louis

Davenport

Houston

Twin Cities

Los Angeles

San Jose

Salt Lake City

Seattle

Phoenix

Denver

Government

Home

Off.

Reserve

American

Red

Cross

Recreational Veh. Po

Body Company

Transportation Servic

Export

Code Ref .#

Color

Code Ref. # Color Code Ref. #

Color

1 C .

1G .

1N .

I P .

1Q .

2M .

2R .

2 U .

3G .

3 U .

31 .

3 4 .

4 6 .

47 .

4 V .

5 0 .

6 E .

6 P .

6 U .

1 7 2 4

5 2 9 9

5 4 7 6

5 5 2 3

5 5 2 7

3 4 1 3

5 4 4 0

5 4 5 5

5 0 9 4

5 4 6 7

5 4 9 9

5 0 4 1

5 3 2 8

5 4 0 4

5 2 3 3

5 4 7 7

5 0 8 0

5 4 0 6

5 4 4 1

. . .

Black

. . .

Silver

Met.

. . .

Dove Gray

. . . Med.

Gray Met.(Tie Tone only)

. . .

Med. Silver

Met.

. . .

Dark

R ed

. . . Brt. Red

. . .

Lipstick

R ed

.. . Brt. Dk.

Blue

Met.

. . . L t .

Blue

. . .

Midnig ht Blue

. . . Med. Blue

. . . D k .

Jade

Met.

. . . L t .

Green

. . . D k .

Yellow Green

Met.

— Ok.

Brown

Met.

. . . B r t . Yellow

. . .

Cream

. . .

Lt .Tan

7 0 . . .

7 S . . .

8 G . . .

8 H . . .

8 K . . .

8 N . . .

8 P . . .

8 Y . . .

8 3 . . .

8 4 . . .

9 D . . .

. 5479

. 5489

. 5466

. 5470

. 5486

. 5496

. 5471

. 5494

. 5524

. 5525

. 5418

Lt. Aqua M t . .

Dk. Emerald

Met.

Vista Orange

Tan

Brt. Saddle Met.

Dk. Cordovan

Met.

Lt. Cordovan

Champagne

Met.

Chamois

Dk. Cordovan

White

7T 5490

8J 5484

8W

5 4 9 1

Med.

Emerald

Met.

Med.

Tan Met.

Chamois

Met.

(RPO) DIAMOND BRIGHT (POLISH) " W "

2 S . . .

2 G . . .

3 2 . . .

8 V . . .

8 Z . . .

1 R . . .

.. 5 4 4 4

..

5 0 7 0

.. 5 5 1 1

..

5 4 9 5

.. 5 5 1 0

.. 5 5 1 2

Dk: Red Met.

Med. Red

Met.

Med.

Blue

Met.

Med.

Ember

Met.

Med.

Nectarine

Met.

Lt. Silver

Met.

(RPO) UNIQUE COLORS

(NON

POLISH)

" D "

2 Y . . .

3 V . . .

6 V . . .

7 H . . .

7 L . . .

5 4 9 2

5 4 8 0

5 2 9 8

5 4 6 0

5 4 8 2

5 4 8 3

Rose

Met.

Brt. Blue

Met.

Tan Met.

Med.

Gold Met.

Brt. Aqua

Met.

Lt. Jade

Met.

(RPO) DIAMOND FLARE (POLISH)

" G "

U

5411

Silver

Met.

1L 547 2 Black

Met.

2T 546 2 Rose

Met.

6 Y

5461 Brt.

Yellow Gold

Met.

7B 546 3 Crystal Jade

Met.

CY1



40-01-4


40-01-4

BODY SERIAL AND STYLE CODES

Vehicle

PINTO

BOBCAT

MUSTANG

II

MAVERICK

COMET

G R A N A D A

MONARCH

LT D II

Body

Serial

Code

10

11

12

20

22

23

24

25

02

03

04

05

91

9 2

30

31

81

82

83

84

34

35

37

38

84

25

27

30

31

32

33

40

42

Body

Style

Code

62 B

64 B

73B

64 H

73H

62 B

64B

73B

60 F

69 F

60 H

69 R

62 A

54 A

54 B

62 B

54 H

66H

54 K

66K

54 H

66H

54 K

66 K

54 M

65B

53 B

65 D

53 D

65 K

53 K

71 B

71 D

Body Type

2-Dr. Sedan

3-Dr. Sedan

Wagon

3-Dr. Sedan

Wagon

2-Dr. Sedan

3-Dr. Sedan

Wagon

2-Dr. Notchback

3-Dr. Hatchback

2-Dr. Notchback

3-Dr. Hatchback

2-Dr. Sedan

4-Dr. Sedan

4-Dr. Sedan

2-Dr. Sedan

4-Dr. Sedan

2-Dr. Sedan

4-Dr. Sedan

2-Dr. Sedan

4-Dr. Sedan

2-Dr. Sedan

4-Dr. Sedan

2-Dr. Sedan

4-Dr. Sedan

2-Dr. Hardtop

4-Dr. Pi l lar Hardtop

2-Dr. Hardtop


2-Dr. Hardtop


LT D

I I S

LT D II

Model

Base

Base

Base

U. S. A. & Canada

U. S. A. & Canada

Canada Only

Canada Only

Canada Only

Base

Base

Ghia

Mach 1

Base

Base

Base

Base

Base

Base

Ghia

Ghia

Base

Base

Ghia

Ghia

Lincoln 5700

LT D I I S

LT D

I I S

LT D

II

LT D

II

LT D II

Brougham

Wagon

Wagon

Vehicle

COUGAR

THUNDERBIRD

FORD

MERCURY

M A R K V

LINCOLN

Body

Serial

Code

43

47

48

49

9 0

91

92

9 3

94

95

9 6

87

52

53

62

63

64

65

72

74

50

52

60

61

62

63

64

66

76

89

81

82

Body

Style

Code

71 K

97D

97 R

97 K

53 D

65 D

71 D

65 L

53 K

65 K

71 K

60H

60D

5 3 D *

60 H

53 H

5 3L

60 L

7 1 D *

71 H

53 H

65 H

53 L

65 L

53 K

53 H

65 K

65 H

71 K

65 D

C

O

C

L

O

Body Type

LT D II Squire

50 0

GT

Squire


2-Dr. Hardtop

Cougar

2-Dr. Hardtop


2-Dr. Hardtop

Cougar Vi l lager








Custom 5 00 Ranch

L T D * *


2-Dr. Hardtop


2-Dr. Hardtop



2-Dr. Hardtop

2-Dr. Hardtop

M a r q u i s * * *

2-Dr. Hardtop



Model

Wagon

LT D II

Ranchero

Cougar

Cougar

Wagon

CougarXR VII

Cougar Brougham

Cougar Brougham

Wagon

Base

Custom 5 00

Custom

50 0

LT D

LT D

LTD Landau

LTD Landau

Wagon

Wagon

Marquis ( F L D )

Canada Only

Grand Marquis

Grand Marquis

Marquis Brougham

Marquis

Marquis Brougham

Marquis

Wagon

Base

Base

Base

i

Released a nd scheduled for Canada and fo r f leet only in U. S. A. - * *A lso Squi re Opt ion - * ** Also Colony Park an d Decor Opt ion .

VINYL ROOF TYPE/COLOR CODE

(FIRST LETTER OF CODE = TYPE OF ROOF)

Code Vinyl Type Code Vinyl Type

B Cross Hatch Full 2-Door

Q

Cayman Full

C Cross Hatch Halo Style

R

Cross Hatch (1/2)

4

-

D o o r

T Valino Coach

G

^

e n S G

^

U

Cayman (1/2)

H Odense(3/4)

v

Valino Full

J Cayman Coach

w

Lugano Full

o

?

denS

u

(1 /

,

2)

/o

// n

x

Lugano (1/2)

P Cross Hatch (3/4)

Y

Valino (1/2)

Example Code^^-GA^^^

'Odense Full' Black

(SECOND LETTER OF CODE = COLOR OF ROOF)

Code Vinyl Color Code Vinyl Colo

A Black Q Emerald Dk.

B Blue R Jade Dk.

C Ember S Med. Blue

D Red T Brown

H Rose U Chamois

J Taupe V Cream

L Aqua W White

M Lt.Jade Y Gold

IM Red, Lipstick

P Silver

CY1615D1



40-01-5


40-

INTERIOR TRIM CODES

Code

Trim Scheme

Code

Trim Scheme Code

Trim Scheme

Code

Trim Sche

PINTO

Colton/Cor inth. Vinyl

(H/B Bucket)

AA Black

AB Blue

AD Red

AG Green

AT Chamois

Alpine B/Cloth &

Corinth.

V iny l

(L/B Bucket)

DB Blue

DD Red

DG . .

Green

DT Chamois

Kirsten B/Cloth &

Corinth. V i n y l

(H/B Bucket)

GA Black

GB Blue

G D . . . R e d

GG Green

GT Chamois

Ruff ino/Cor inth. Vinyl

(L/B Bucket)

HA Black

HB Blue

HD Red

HG Green

HT Chamois


(H/B Bucket)

JA Black

JB Blue

JD Red

JG Green

JT Chamois

Alpine B/Cloth &

Corinth.

V i n y l

(L/B Bucket)

KB Blue

KD Red

KG Green

KT Chamois

Kirsten B/Cloth &

Corinth. V iny l

(H/B Bucket)

LA Black

LB Blue

LD Red

LG Green

LT Chamois

Ruf f ino/Cor in th . V iny l

(L/B Bucket)

MA Black

MB Blue

MD Red

MG Green

MT Chamois

Carerra/Corinth. Vinyl

(H/B Bucket)

NT Chamois

BOBCAT


(H/B Bucket)

AA Black

AB Blue

AD Red

AG Green

AT Chamois

Alpine B/Cloth &

Corinth. V iny l

(L/B Bucket)

DB Blue

DD Red

DG Green

DT Chamois

Kirsten B/Cloth &

Corinth.

V iny l

(H/B Bucket)

GA Black

GB Blue

GD Red

GG Green

GT Chamois


(L/B Bucket)

HA Black

HB Blue

HD Red

HG Green

HT Chamois


(L/B Bucket)

JA Black

JB Blue

JD Red

JG Green

JT Chamois

Alpine B/Cloth &

Corinth.

V iny l

(L/B Bucket)

KB Blue

KD Red

KG Green

KT Chamois

Kirsten B/Cloth &

Corinth. V iny l

(H/B Bucket)

LA Black

LB Blue

LD Red

LG Green

LT Chamois


(L/B Bucket)

MA Black

MB Blue

MD Red

MG Green

MT Chamois

MUSTANG

Corinth.

V iny l

(L/B Bucket)

AA Black

AD Red

AK Aqua

AN W/Red

AT Chamois

AV Cream

AW W/Black

A2 W/Chamois

A5 W/Emerald

A7 W/Aqua

A8 W/Gold

Corinth.

V iny l

(L/B Bucket)

BA Black

BD Red

BK Aqua

BN W/Red

BT Chamois

BV Cream

BW W/Black

B2 W/Chamois

B5 W/Emerald

B7 W/Aqua

B8 W/Gold

Media B/Cloth &

Corinth.

V iny l

(L/B Bucket)

CK Aqua

CT Chamois

CV Gold/Cream

Corinth.

V i n y l

(L/B Bucket)

DT Chamois

Sterl ing B/Cloth &

Corinth.

V iny l

(L/B Bucket)

ED Red

EK Aqua

EV Gold/Cream

E5 W/Emerald

Corinth.

V iny l

(L/B Bucket)

GA Bl

GD R

GN W/R

GW W/Bl

G5 W/Emer

Corinth. V i n y l

(L/B Bucket)

HA Bl

HD R

HN W/R

HW W/Bl

H5 W/Emer

Sterl ing B/Cloth &

Corinth.

V i n y l

(L/B Bucket)

K D . . . . R

K5 W/Emer

Corinth.

V iny l

(L/B Bucket)

LT Cham

Sterling B/Cloth &

Corinth.

V i n y l

(L/B Bucket)

QD R

QK Aq

Sterling B/Cloth &

Corinth. V i n y l

(L/B Bucket)

RD R

RK Aq

Corinth. V i n y l

(L/B Bucket)

SA Bl

SD R

SK Aq

SN W/R

ST Cham

SW W/Bla

S2 W/Cham

S5 W/Emer

S7 W/Aq

S8 W/G

Corinth.

V iny l

(L/B Bucket)

TA Bl

TD R

TK Aq

TN W/R

TT Cham

TW W/Bl

T2 W/Cham

T5 W/Emer

T7 W/Aq

T8 W/G

CY1




40-01-6

-

Continued

Code

Trim Scheme

C o d e

Trim Scheme Code Trim Scheme

Barletta B/Cloth

&

Corinth.

Vinyl

(L/B Bench)

JA Black

JB Blue

JG Green

JU

Tan

Corinth.

Vinyl

(L/B Bench)

KA Black

KB Blue

KD

Red

KG Green

KU

Tan

Corinth.

Vinyl

(L/B Bucket)

LA Black

LB Blue

LD

Red

LU

Tan

Corinth.

Vinyl

(L/B Bucket)

PB Blue

PU

Tan

Alpine B/Cloth

&

Corinth. Vinyl

(L/B Bucket)

QB Blue

QG Green

QU

Tan

Alpine B/Cloth

&

Corinth. Vinyl

(L/B Bucket)

RB Blue

RG Green

RU

Tan

Corinth. Vinyl

(L/B Bucket)

SA Black

SB Blue

SD

Red

SU

Tan

Alpine B/Cloth

&

Corinth.

Vinyl

(L/B Bucket)

TB Blue

TG Green

TU

Tan

GRANADA

Corinth.

Vinyl

(L/B Bucket)

AB Blue

AD

Red

AR Jade

AS Gray

AU

Tan

C o d e

Trim Scheme

Media B/Cloth &

Corinth.

Vinyl

(L/B Bucket)

UK Aqua

UT Chamois

UV Gold/Cream

Sterling B/Cloth

&

Corinth.

Vinyl

(L/B Bucket)

VD

Red

VK Aqua

VV Gold/Cream

V5 W/Emerald

V7 W/Aqua

Corinth.

Vinyl

(L/B Bucket)

WA Black

WD

Red

WN W/Red

WW W/Black

W5 W/Emerald

Corinth.

Vinyl

(L/B Bucket)

YA Black

YD

Red

YN W/Red

YW W/Black

Y5 W/Emerald

Sterling B/Cloth

&

Corinth. Vinyl

(L/B Bucket)

ZD

Red

MAVERICK

Random Stripe B/Cloth

&

Corinth.

Vinyl

(L/B Bench)

BA Black

BB Blue

BD

Red

BG Green

BU

Tan

Tooled/Corinth. Vinyl

(L/B Bench)

HA Black

HB Blue

HD

Red

HG Green

HU

Tan

Corinth.

Vinyl

(L/B Bucket)

PA Black

PB Blue

PD

Red

PU

Tan

Alpine B/Cloth &

Corinth.

Vinyl

(L/B Bucket)

QB Blue

QG Green

QU

Tan

Corinth. Vinyl

(L/B Bucket)

SA Black

SB Blue

SD

Red

SU

Tan

Alpine B/Cloth

&

Corinth.

Vinyl

(L/B Bucket)

TB Blue

TG Green

TU

Tan

Barletta B/Cloth

&

Corinth. Vinyl

(L/B Bench)

UA Black

UB Blue

UG Green

UU

Tan

Corinth.

Vinyl

(L/B Bench)

VA Black

VB Blue

VD

RGd

VG Green

VU

Tan

Sterling B/Cloth

&

Corinth.

Vinyl

(L/B Bucket)

WU

Tan

COMET

Random Stripe B/Cloth

&

Corinth.

Vinyl

(L/B Bench)

BA Black

BB Blue

BD

Red

BG Green

BU

Tan

Tooled/Corinth. Vinyl

(L/B Bench)

HA Black

HB Blue

HD

Red

HG Green

HU

Tan

AV Cream

Kasman B/Cloth &

Corinth.

Vinyl

(L/B Flight Bench)

B B B l u e

BD

Red

BR Jade

BS Gray

BU

Tan

Corinth. Vinyl

(L/B Bucket)

CB Blue

CD

Red

CR Jade

CS Gray

CU

Tan

CV Cream

Corinth.

Vinyl

(L/B Flight Bench)

DV Cream

Corinth. Vinyl

(L/B Flight Bench)

EB Blue

ED

Red

ER Jade

ES Gray

EU

Tan

EV Cream

Natural Grain Leather

(L/B Bucket)

FB Blue

FD

Red

FR Jade

FS Gray

FU

Tan

FV Cream

Corinth.

Vinyl

(L/B Flight Bench)

GB Blue

GD

Red

GR Jade

GS Gray

GU

Tan

GV Cream

Westminster B/Cloth &

Corinth.

Vinyl

(L/B Flight Bench)

HB Blue

HD

Red

HR Jade

HU

Tan

Corinth. Vinyl

(L/B Bench)

JB Blue

JD

Red

CY1419-H1



40-01-7


40-0

INTERIOR TRIM CODES - Continued

Code

Trim Scheme

C o d e

Trim Scheme Code Trim Scheme Code

Trim Sche

JR Jade

JU Tan

JV Cream


(L/B Bucket)

MD Red

MM Lt /DkJade

MS Gray

MU

Tan

Chain mail Viny l

(L/B Bucket)

PD Red

PU Tan

Touraine B/Cloth

&

Corinth.

Vinyl

(L/B Flight Bench)

QD Red

QR Jade

QS Gray

QU

Tan


(L/B Flight Bench)

RD Red

RM Lt /DkJade

RS Gray

RU Tan

MONARCH

Corinth. V inyl

(L/B Bucket)

AB Blue

AD

Red

AR Jade

AS Gray

AU Tan

AV Cream

Kasman B/Cloth &

Corinth. Vinyl

(L/B Flight Bench)

B B B l u e

BD

Red

BR Jade

BS Gray

BU Tan

Corinth. V inyl

(L/B Bucket)

C B B l u e

CD Red

CR Jade

CS Gray

CU

Tan

CV Cream

Corinth.

V inyl

(L/B Flight Bench)

EB Blue

ED

ER

ES

EU

Red

Jade

Gray

Tan

EV Cream


(L/B Bucket)

FB Blue

FD

Red

FR Jade

FS Gray

FU Tan

FV Cream

Corinth.

Vinyl

(L/B Flight Bench)

GB Blue

GO Red

GR Jade

GS Gray

GU

Tan

GV Cream

Westminster B/Cloth

&

Corinth.

Vinyl

(L/B Flight Bench)

HB Blue

HD Red

HR Jade

HU

Tan

Corinth.

Vinyl

(L/B Bench)

JB Blue

JD Red

JR Jade

JU

Tan

JV Cream

Chainmail Vinyl

(L/B Bucket)

PD Red

PU Tan

Dorchester B/Cloth

&

Corinth.

Vinyl

(L/B Flight Bench)

S B B lu e

SF Cordovan

SS Gray

ST Chamois


(L/B Flight Bench)

TB Blue

TF Cordovan

TQ W/Blue

TS Gray

TT Chamois

T2

..

W/Chamois

T6 W/Cordovan


(L/B Bucket)

UB Blue

UF Cordovan

UQ W/Blue

US Gray

UT Chamois

U2 W/Chamois

U6 W/Cordovan

Wilshire B/Cloth

&

Corinth.

Vinyl

(L/B Flight Bench)

V B B l u e

VF Cordovan

VS Gray

VT Chamois

THUNDERBIRD

Wilshire B/Cloth &

Corinth.

Vinyl

(L/B Bench)

AB Blue

AD

Red

AR Jade

AS Gray

AT Chamois

AZ Saddle

Kiwi/Corinth. Viny l

(L/B Bench)

B B B l u e

BD

Red

BR Jade

BS Gray

BT Chamois

BZ Saddle

Lamar Vinyl

(L/B Bucket)

CB Blue

CD

Red

CL W/Lip

Red

CN W/Red

CQ W/Blue

CR Jade

CS Gray

CT Chamois

CZ Saddle

C2 W/Chamois

C5 W/Jade

C9 W/Saddle

Ardmore B/Cloth

&

Corinth.

Vinyl

(L/B Split Bench)

D B B l u e

DD Red

DR Jade

DS Gray

DT Cham

DZ Sad

Mateao/Corinth.

Vinyl

(L/B Split Bench)

EB B

ED

R

EL W/Lip R

EN W/

EQ W/B

ER ................ J

ES G

ET Cham

&

...............

Sa

E2 " " w / C h a m

E3 Sadle/W

E5 W/

E9 W/Sa


& Mateao Vinyl

(L/B Split Bench)

F B

FD

R

FL W/Lip

FN W/

FQ W/

FR J

FS G

FT Cha

FZ Sa

D2 W/Cha

F3 Sadle/W

F5 W/

F9 .W/Sa

Lamar Vinyl

(L/B Bucket)

GB

GD R

GL W/Lip

GN W

GQ W/

GR

GS G

GT Cha

GZ Sa

G2 W/Cha

G3 Sadle/W

G5 W/

G9 W/Sa

Newberry B/Cloth

&

Corinth.

V inyl

(L/B Bucket)

HB

HD R

HR

HS G

CY14



40-01-8


40-01-8


Code

Trim Scheme

C o d e

Trim Scheme

Code Trim Scheme

Mateao/Corinth. V inyl

(L/B Flight Bench)

KB Blue

KD Red

KR Jade

KS Gray

KT Chamois

KZ Saddle

Ardmore B/Cloth &

Corinth. Vinyl

(L/B Flight Bench)

LB Blue

LD Red

LR Jade

LS Gray

LT Chamois

LZ Saddle

Mateao/Corinth. Vinyl

(L/B Flight Bench)

MB Blue

MD Red

MR Jade

MS Gray

MT Chamois

MZ Saddle

Mateao/Corinth. Viny l

(L/B Split Bench)

PV Cream/Blue

C O U G A R

Ashton B/Cloth &

Corinth. Vinyl

(L/B Flight Bench)

AB Blue

AD Red

AR Jade

AS Gray

AT Chamois

AZ Saddle


(L/B Flight Bench)

BB Blue

BD Red

BL W/Lip Red

BN W/Red

BQ W/Blue

BR Jade

BS Gray

BT Chamois

BZ Saddle

B2 W/Chamois

B5 W/Jade

B9 W/Saddle

C o d e

Trim Scheme

HT Chamois

HZ Saddle

Newberry B/Cloth &

Corinth. Vinyl

(L/B Bucket)

JB Blue

JD

Red

JR Jade

JS Gray

JT Chamois

JZ Saddle


(L/B Bucket)

PS Gray/Red

Mateao/Corinth. Vin yl

(L/B Split Bench)

QS Gray/Red

Media Velour B/Cloth

(L/B Split Bench)

RB Blue

RD Red

RR Jade

RS Gray

RT Chamois


(L/B Split Bench)

SB Blue

SD

Red

SR Jade

SS Gray

ST Chamois

LTD

Kirsten B/Cloth

&

Corinth. Vinyl

(L/B Bench)

AB Blue

AD

Red

AR Jade

AT Chamois

Colton/Corinth. Vinyl

(L/B Bench)

BB Blue

BD Red

BR Jade

BT Chamois

Porto B/Cloth

&

Corinth. Vinyl

(L/B Bench)

CB Blue

CD Red

CR Jade

CS Gray

CT * Chamois

CZ Saddle

Kiwi/Corinth. Vinyl

(L/B Bench)

DB

DD

DR

DS

B l u e

Red

Jade

Gray

DT Chamois

DZ Saddle

Doral B/Cloth &

Corinth. Vinyl

(L/B Split Bench)

EB Blue

ED Red

ER Jade

ES Gray

ET Chamois

EZ Saddle


(L/B Split Bench)

FB Blue

FD Red

FR Jade

FS Gray

FT Chamois

FZ Saddle

F3 Sadle/Whte

Lamar Vinyl

(L/B Bucket)

GB

GD

GR

GS

Blue

Red

Jade

Gray

GT Chamois

GZ Saddle

G3 Sadle/Whte

Lamar Vinyl

(L/B Bucket)

HB Blue

HD Red

HR Jade

HS Gray

HT Chamois

HZ Saddle

H3 Sadle/Whte

Ardmore B/Cloth

&

Corinth. Vinyl

(L/B Flight Bench)

JB Blue

JD Red

JR Jade

JS Gray

JT Chamois

JZ Saddle

Newberry B/Cloth &

Corinth.

Vinyl

(L/B Split Bench)

C B B l u e

CD Red

CR Jade

CS Gray

CT Chamais

CZ Saddle


(L/B Split Bench)

DB Blue

DD Red

DL W/Lip Red

DN W/Red

DQ W/Blue

DR Jade

DS Gray

DT Chamois

DZ Saddle

D2 W/Chamois

D3 Sadle/Whte

D5 W/Jade

D9 W/Saddie


(L/B Split Bench)

EB Blue

ED Red

EL W/Lip Red

EN W/Red

EQ W/Blue

ER Jade

ES Gray

ET Chamois

EZ Saddle

E2 W/Chamois

E3 Sadle/Whte

E5 W/Jade

E9 W/Saddle

Lamar Vinyl

(L/B Bucket)

FB Blue

FD R»d

FL W/Lip Rod

FN W/R«d

FQ W/Blue

FR Jade

FS Gray

FT Chamois

FZ Saddle

F2 W/Chamois

F3 Sadle/Whte

F5 W/Jade

F9 W/Saddle

CY141SUH3



40-01-9 Car Identification Codes

40-0


C o d e

Trim Scheme

C o d e

Trim Scheme Code Trim Scheme

Code Trim Sche

Newberry B/Cloth

&

Corinth. Vinyl

(L/B Bucket)

GB Blue

GO Red

GR Jade

GS Gray

GT Chamois

GZ Saddle

Newberry B/Cloth &

Corinth. Vinyl

(L/B Split Bench)

HB Blue

HD Red

HR Jade

HS Gray

HT Chamois

HZ Saddle


(L/B Split Bench)

JB Blue

JD Red

JL W/LipRed

JN W/Red

JQ W/Blue

JR Jade

JS Gray

JT Chamois

JZ Saddle

J2 W/Chamois

J5 W/Jade

J9 W/Saddle


(L/B Split Bench)

KB Blue

KD Red

KL W/ Lip Red

KN W/Red

KQ W/Blue

KR Jade

KS Gray

KT - . Chamois

KZ Saddle

K2 W/Chamois

K5 W/Jade

K9 W/Saddle

Newberry B/Cloth

&

Corinth. Vinyl

(L/B Bucket)

LB Blue

LD

Red

LR Jade

LS Gray

LT Chamois

LZ Saddle

Lamar Vinyl

(L/B Bucket)

MB Blue

MD Red

ML W/ Lip Red

MN W/Red

MQ W/Blue

MR Jade

MS Gray

MT Chamois

MZ Saddle

M2 W/Chamois

M5 W/Jade

M9 W/Saddle

Newberry B/Cloth &

Corinth. Viny l

(L/B Flight Bench)

N2 W/Chamois

Newberry B/Cloth &

Corinth. Vinyl

(L/B Bucket)

P2 W/Chamois

Newberry B/Cloth

&

Corinth. Viny l

(L/B Split Bench)

QT Chamois

Porto B/Cloth &

Corinth. Viny l

(L/B Bench)

RB Blue

RD Red

RR Jade

RS Gray

RT Chamois

RZ Saddle

Kiwi/Corinth. Vinyl

(L/B Bench)

SB Blue

SD Red

SR Jade

SS Gray

ST Chamois

SZ Saddle

Ardmore B Cloth &

Corinth. Vinyl

(L/B Flight Bench)

T B B l u e

TD

Red

TR Jade

TS Gray

TT Chamois

TZ Saddle


(L/B Flight Bench)

UB Blue

UD Red

UR Jade

US Gray

UT Chamois

UZ Saddle

Doral B/Cloth &

Corinth. Vinyl

(L/B Split Bench)

VB Blue

VD Red

VR Jade

VS Gray

VT Chamois

VZ Saddle


(L/B Split Bench)

WB Blue

WD Red

WR Jade

WS Gray

WT Chamois

WZ Saddle

W3 Sadle/Whte

Lamar Vinyl

(L/B Bucket)

YB Blue

YD Red

YR Jade

YS Gray

YT Chamois

YZ Saddle

Y3 Sadle/Whte

Lamar Vinyl

(L/B Bucket

ZB

ZD

ZR

ZS

Blue

Red

Jade

Gray

ZT Chamois

ZZ Saddle

Z3 Sadle/Whte

FORD

Barletta B/Cloth

&

Corinth. Vinyl

(L/B Bench)

AB Blue

AD

Red

AZ Saddle

Ruffino/Corinth. Vinyl

(L/B Bench)

BB Blue

BD

Red

BR Jade

BZ Saddle

Logan B/Cloth &

Corinth. Vinyl

(LB Bench)

C B B

CD

R

CR J

CY G

CZ Sad

Redondo B/Cloth

&

Corinth. Vinyl

(L/B Bench)

DB B

DD

R

DR J

DS G

DY G

DZ Sad

Ruffino Corinth. Vinyl

(L/B Bench)

EB B

ED

R

ER J

ES G

EY G

EZ Sad

Ardmore B/Cloth

&

Corinth. Vinyl

(L/B Split Bench)

FB B

FD R

FR J

FS G

FY G

FZ Sad


(L/B Split Bench)

GB B

GD R

GR J

GS G

GY G

GZ Sad

Ardmore B/Cloth &

Corinth. Vinyl

(L/B Flight Bench)

HB B

HD

R

HR J

HS G

HY G

HZ Sad


(L/B Split Bench)

JB B

JD

R

JR J

CY14



4 0 0 1 - 1 0


40-01-10


C o d e

T r i m S c h e m e C o d e T r i m S c h e m e C o d e T r i m S c h e m e C o d e

Trim

Schem»5

JS Gray

JY Gold

JZ Saddle

Ardmore B/Cloth &

Corinth.

Vinyl

(L/B Split Bench)

KB Blue

KD Red

KR Jade

KS Gray

KY Gold

KZ Saddle

Dynasty Polyknit &

Corinth.

Vinyl

(L/B Split Bench)

NB Blue

ND

Red

I\IR Jade

NU Saddle/Tan

Kasman B/Cloth &

Corinth.

Vinyl

(L/B Split Bench)

PB Blue

PD Red

PR Jade

PS Gray

PY Gold

PZ Saddle

Valino Vinyl

(L/B Split Bench)

QB Blue

QD Red

QR Jade

QS Gray

QV Gold/Cream

QZ Saddle

Q3 Sadle/Whte

Valino Vinyl

(L/B Split Bench)

RV Cream/Blue

Ruffino/Corinth.

Vinyl

(L/B Split Bench)

SB Blue

SD

Red

SR Jade

SY Gold

SZ Saddle

Dynasty Polyknit

&

Corinth.

Vinyl

(L/B Bench)

UB Blue

UD Red

UR Jade

UU Saddle/Tan


(L/B Split Bench)

YB Blue

YD Red

YR Jade

YS Gray

YV Gold/Cream

YZ Saddle

Y3 Sadle/Whte

MERCURY


(L/B Split Bench)

FB Blue

FD Red

FR Jade

FS Gray

FV Gold/Cream

FZ Saddle

F3 Sadle/Whte

Redondo B/Cloth

&

Corinth.

Vinyl

(L/B Bench)

GB Blue

GD Red

GR Jade

GS Gray

GY Gold

GZ Saddle

Ruffino/Corinth.

Vinyl

(L/B Bench)

HB Blue

HD Red

HR Jade

HY Gold

HZ Saddle

Touraine B/Cloth &


(L/B Split Bench)

JB Blue

JD

Red

JR Jade

JS Gray

JY Gold

JZ Saddle

Ruffino/Corinth.

Vinyl

(L/B Bench)

KB Blue

KD Red

KR Jade

KS Gray

JY Gold

KZ Saddle

Ardmore B/Cloth &

Corinth.

Vinyl

(L/B Bench)

LB Blue

LD Red

LR Jade

LZ Saddle

Wilshire B/Cloth &

Corinth.

Vinyl

(L/B Split Bench)

MB Blue

MD

Red

MR Jade

MS Gray

MY Gold

MZ Saddle

Kasman B/Cloth

(L/B Split Bench)

NS

Gray

Wilshire B/Cloth &

Corinth. Vinyl

(L/B Flight Bench)

RB Blue

RD Red

RR Jade

RY Gold

RZ Saddle

Valino/Corinth.

Vinyl

(L/B Flight Bench)

SB Blue

SD Red

SR Jade

SV Gold/Cream

SZ Saddle

Valino/Corinth.

Vinyl

(L/B Split Bench)

VB Blue

VD

Red

VR Jade

VS Gray

VV Gold/Cream

VZ Saddle

MARKV

Venezia B/Cloth &

Corinth.

Vinyl

(L/B Split Bench)

AA Black

AB Blue

AD Red

AF Cordovan

AR Jade

AT Chamois

AY Gold


& Mateao Vinyl

(L/B Split Bench)

BA Black

BB Blue

BD

Red

BF Cordovan

BN W/Red

BQ W/Blue

BR Jade

BT Chamois

BW W/Black

BY Gold

B2 W/Chamois.

B5 W/Jade

B6 W/Cordovan

B8 W/Gold

Romano/Media Velour

B/Cloth

(L/B Split Bench)

CF Cordovan

CY Gold


& Mateao Vinyl

(L/B Split Bench)

DF Cordovan

DH Red/Rose

DR Jade/Lt

DS Gray

DT Chamois

DV Gold/Cream


(L/B Split Bench)

EB Blue

Kasman B/Clo th &

Corinth.

Vinyl

(L/B Split Bench)

FS Gray

Majestic B/Cloth &

Corinth.

Vinyl

(L/B Split Bench)

GB Blue

GD Red

GR Jade


(L/B Split Bench)

JS Gray

LINCOLN

Kasman B/Clo th

&

Corinth.

Vinyl

(L/B Bench)

BB Blue

BD Red

BF Cordovan

BR Jade

CY1419-H5



40-01-11 Car Identification Codes 40-0

INTERIOR TRIM CODES

-

Continued

Code

Trim Scheme

Code

Trim Scheme

C o d e

Trim Scheme

HT Chamois

HY Gold

Media Ve lour

B/Cloth

(L/B Split Bench)

JA Black

JB Blue

JD

Red

JF Cordovan

JR Jade

JS Gray

JT Chamois

JY Gold


& Mateao Vinyl

(L/B Split Bench)

KA Black

KB Blue

KD

Red

KF Cordovan

KN W/Red

KQ W/Blue

KR Jade

KS Gray

KT Chamois

KW W/Black

Code Trim Sche

KY G

K2 W/Cham

K5 W/J

K6 W/Cordo

K8 W/G


& Mateao Vinyl

(L/B Bench)

LF Cordo/W


& Mateao Vinyl

(L/B Split Bench)

MF Cordo/W


NV Cream/Co

Westminster B/Cloth

&

Corinth.

Vinyl

(L/B Bench)

PB B

PD

R

PF Cordo

Mateao Vinyl

(L/B Bench)

QB B

QD

R

QF Cordo

BT Chamois

BY Gold


& Mateao Vinyl

(L/B Bench)

DA Black

DB Blue

DD

Red

DF Cordovan

DN W/Red

DQ W/Blue

DR Jade

DT Chamois

DW W/Black

DY Gold

D2 W/Chamois

D5 W/Jade

D6 W/Cordovan

D8 W/Gold


&Mateao Vinyl

(L/B Split Bench)

EA Black

EB Blue

ED

Red

EF Cordovan

EN W/Red

EQ W/Blue

ER Jade

ET Chamois

EW W/Black

EY Gold

E2 W/Chamois

E5 W/Jade

E6 W/Cordovan

E8 W/Gold

Kasman

B/Cloth &

Corinth. Vinyl

(L/B Split Bench)

FB Blue

FD

Red

FF Cordovan

FR Jade

FT Chamois

FY Gold


& Mateao Vinyl

(L/B Bench)

HA Black

HB Blue

HD

Red

HF Cordovan

HR Jade

CY141



41-00-1

Seats

41-00

SEATS

PART TITL E PART NO.

Conv entional Rear Seats 41-14

Fo ld Do wn Rear Seats 41-20

Head Restraints 41-40

Lum bar Power Seat 41-35

Power Seat - 4-Way 41-07

Power Seat - 6-Way 41 08

GROUP

(70000)

PART TITL E PART N

Re clining Seat Back 41-

Seat Back Latch - Auto ma tic 41

Seat Back Latch - Manual 41-

Seat and Shoulder Belts 41

Seat Tracks - Manual 41-

Seat Tri m 41

CR2002-A

Seat Tracks -- Manual

P A R T

41-01

SUBJECT PAGE SUBJECT

PAG

DESCRIPTION AND OPERATION 01-1 REMOVAL AND INSTA LLAT ION 01-

ADJUSTMENTS 01-1

DESCRIPTION AND OPERATION

cushion, and the passenger seat re-

lease handle (Bucket and Split

Bench), is located at the lower right

side of the seat cushion. On all other

car lines with manual seat tracks, the

SEAT TRACKS—MANUAL

On the Ford and Mercury the

driver's seat release handle is located

at the lower left side of the seat

CR2009-

seat release handle is located at

front (Bucket and Split-Bench). T

ping the seat release handle will al

forward or rearward movement of

seat assembly.

ADJUSTMENTS

TIE ROD

The tie rod adjustments are made

individually for each pair of tracks and

affects (only) the track farthest away

from the seat release handle. All seat

t racks do not have t ie rods for

adjustment. See Figs. 1 through 8. If the

latch retaining the track fails to release

(on tie rod equipped vehicles), turn the

adjusting turnbuckle clockwise, just

enough to shorten the tie rod travel and

release the track latch (Figs. 1 thro

8). If the latch fails to secure the

travel, turn the adjusting turnbu

counterclockwise to allow the latc

fully engage the locking position.



41-01-2

Seat Tracks—Manual

41-01-2

CUSHION ASSY.

CUSHION ASSY.

HANDLE

61755

SCREW

384871 -

TORQUE -

12-20

F T.

LBS.

4 REQUIRED

NUT 45344

STUD 384599

(12-20 FT-LB TORQUE)

4-REQ'D

NUT AND WASHER ASSY.

45344 -

TORQUE - 18-32 FT. LBS.

4-REQ'D

FRONT AND REAR

ON MANUAL TRACKS

RETAINER

618B58

SCREW VIEW A

NUT AND WASHER

ASSY. 45344

STUD 385009

4-REQ'D

FIG. 1 Manual Seat Track Installation—Full Bench Seat—Ford and Mercury

R13G2-G

CUSHION

ASSEMBLY

45344-NUT AND

TRACK ASSY. ' WASHER ASSY.

618B46 I TORQUE-18-32 FT. LB.

TO FRONT OF BODY

ROD ASSEMBLY

61802

-NUT AND WASHER ASSY.

TORQUE-18-32 FT. LB. 4-REQ'D

R. H. SHOWN

L.H. SIMILAR

R1310-J

FIG. 2 Manual Seat Track Instal lation - Sp li t Bench Seat — Ford and Mercury



41-01-3 Seat Tracks—Manual

41-01

CUSHION ASSEMBLY

SEAT TRACK

INSULATOR

TO FRONT OF BODY

PASSENGER

SIDE CUSHION

SHOWN

NUT AND WASHER

TORQUE 12-25 FT-LB

N2550-A

FIG. 3 Manual Seat Track Installation—Bucket Seat—Pinto and Bobcat

SCREW-PART OF

SEAT TRACK

61704-5

NUT AND WASHER 45341

TORQUE 12-20 FT-LBS. BOTH SIDES

VIEW

J 3

R17

F IG .

4 Manual Seat Track Insta l lat ion—Bench Seat—Maverick , Comet, Granada and Monarch



41-01-4


41-01-4

SCREW

4 REQ'D.

TORQUE

12-20 FT-LB

EACH SIDE OF BODY

OUTBOARD I

TRACK

NUT AND

WASHER

4 REQ'D. DRIVER SIDE

3 REQ'D. PASS. SIDE

TORQUE 12-20 FT-LB

DRIVER SIDE

SEAT TRACKS

PASSENGER SIDE SHOWN

DRIVER SIDE TYPICAL

NUT

TORQUE

18-32 FT-LB

NOTE: DRIVER'S SIDE INBOARD

TRACK DIFFERENT BETWEEN

MAVERICK AND COMET AND

GRANADA AND MONARCH.

OUTBOARD

3te

TO FRONT OF BODY

OUTBOARD

INSULATOR

VIEW B

P A S S . S I D E R E A R ( L . H . )

I N S U L A T O R

P A S S .

S ID E F R O N T ( L . H . )

N2551-A

FIG.

5 Manual Seat Track Installation—Bucket Seat—Granada, Monarch, Maverick and Comet

CUSHION ASSEMBLY

SCREW

TORQUE 7-17

FT. LB. 4 REQ'D

INSULATOR

NUT TORQUE 7-17

FT.

LB.4 REQ'D.

FIG. 6 Manual Seat Track Installation—Bucket Seat—Mustang



41-01-5


41-0

CUSHION ASSE

HAN

NUT AND WASHER

TORQUE 18-32 FT-LB

1 REQ'D. EACH SIDE

STUD

REQ'D. EACH SIDE

TORQUE 16-22 FT-LB

R19

FIG. 7 Manual Seat Track Installation—Bench Seat—LTD II, Thunderbird and Cougar

CUSHION ASSEMBLY

RETAINER

SCREW

4 REQ'D.

EACH SIDE OF BODY

TORQUE 12-20 FT-LB

STUD

2 REQ'D. EACH SIDE OF BODY

TORQUE 16-22 OUTBOARD ONLY

NU T

2 REQ'D.


NUT

2 REQ'D.

EACH SIDE OF BODY

TORQUE 14-32 FT-LB

R1911-A

FIG.

8 Manual Seat Track Installation—Split Bench and Bucket on LTD II, and

Cougar—Split Bench on Thunderbird

REMOVAL

AND

INSTALLATION

are removed from inside and/or

emoval

Manual seat tracks are retained to the

floor pan by studs with nuts and washers,

or screws (washer head type). The nuts

and/or screws retaining the seat tracks

underneath

the

vehicle (Figs. 1 through

8).

1.

Remove

the

seat track retaining

screws and/or nuts and washers from

inside or underneath the veh

Then, lift the seat and seat t

assembly from

the

vehicle.

P l a c e

the

sea t

and

sea t t r

assemblies

on a

clean working



41-01-6


41-01-6

and disconnect the adjusting springs

(Figs. 1 through 8).

3. Remove the seat track-to-seat cushion

attaching screws and remove the seat

cushion from the tracks.

4. Disconnect the latch tie rod from the

seat tracks.

5. If the seat tracks are being replaced,

t r a n s f e r t h e r e t r a c t i n g s p r i n g s ,

spacers, anti-squeak, seat side shields

and adjusting lever knob to the new

track assembly.

Installation

1. Mount the seat tracks with the side

shield supports (if so equipped) to the

seat cushion, and connect the tie rod

to the two tracks as they are being

positioned.

2.

Install the seat track-to-seat cushion

re ta in in g sc r ews an d t ig h ten to

specifications shown in appropriate

figures (Figs. 1 thro ugh 8).

3. C o n n e c t t h e a d j u s t i n g s p r i n g s

between the seat t racks and seat

cushion.

4.

Place the seat assembly in to the

vehicle and insure proper alignment.

5. Then, install the screws an d/o r nuts

and washer assemblies and tighten to

specification shown in appropriate

figures (Figs. 1 thro ugh 8).



41-07-1 Power Seat-4-Way 41-07

SUBJECT

DESCRIPTION

TESTING

Power Seat~4-Way

PAGE SUBJECT

AND OPERATION 07-1 REMOVAL AND INSTALLATION ..

07-1 DISASSEMBLY AND ASSEMBLY ..

P A R T

41-07

PAGE

07-2

07-2

CR2010-A


The 4-way power seat mechanism front edge of the seat, resulting in a tilting desired movem ent. A control swit

provides fore and aft movement of

the

action.

The

seat is driven by an electric located on the driver's side in the

driver's (bucket

or

flight bench) seat,

as

dual motor through two gear boxes and lower seat side shield, directs curren t

well as up and down movement of the two flexible drive cables to provide the the motor.

TESTING

Disconnect motor leads from circuit. leads

at the

motor connector. Motor binds

and

gear transmission lock-

Connect ground and positive lead wires should run in the reverse direction. Al so , ins pe ct the t racks and d

from the battery to the motor. Motor If

the

motor does not operate the seat mechanism for foreign material tha t m

should operate in one direction. Reverse trac ks, inspect the tracks for possible cause binding.



41-07-2

Power Seat-4-Way

41-07-2

FRON T OF VEHICLE

WAY KNOB

BLACK WHITE DOT

B+POWER FEED

BLACK

NEG. (GROUND)

978) YEL-BLUE STRIPE

179) YELLOW

SEPARATE THE CONNECTORS FROM UNDER THE SEAT AND TEST THE

SWITCH AND WIRE ASSEMBLY AS SHOWN

CONNECT ONE SIDE OF OHMMETER OR TEST LIGHT TO CIRCUI T#51

SWITCH POSITION

NEUTRAL

UP

DOWN

FOREWARD

REARWARD

CONTINUITY BETWEEN TERMINALS

51 AND NONE

51

AN D

978

51 AND 979

51

AND 180

51 AND 179

CONNECT ONE SIDE OF OHMMETER OR TEST LIGHT TO CIRCUIT:#57

SWITCH POSITION

NEUTRAL

UP

DOWN

FOREWARD

REARWARD

CONTINUITY BETWEEN TERMINALS

57 AND 179-180-978-979

57 AND 179-180-979

57 AND 179-180-978

57 AND 179-978-979

57 AND 180-978-979

R1967-A

FIG. 1 Power Seat Switch Tests—Granada and Monarch



41-07-3

Power Seat-4-Way

41-07

REMOVAL AND INSTALLATION

Removal

1. Using the control switch, raise the

seat and position it to the rearmost

position.

2.

Remove the seat track rear attaching

screws (Fig. 2).

3. Remove the outboard seat track front

attaching screw and the inboard seat

track attaching nuts.

4. Disconnect the feed and switch wiring

connectors and remove the driver's

seat assembly from the vehicle and

place on a clean work surface.

Installation

1. Position the seat in the vehicle and

connect feed and switch wiring.

2. Install the front and rear attaching

screws and nut and washer and

tighten to specifications shown in Fig.

2 and connect the seat sensor switch.

3. Using the control switch, test the

operation of the seat in all positions.

SCREW 384871

TORQUE 12-20 FT. LBS

CUSHION ASSEMBL

BOLT 379488-

TORQUE 14-32 FT. L

379488 BOLT-3 REQUIRED

TORQUE 14-32 FT. LBS.

DRIVER SIDE ONLY

SEAT TRACK ASSEM

61700

N21

FIG. 2 Seat and Track Installation 4-W ay Power

DISASSEMBLY AND ASSEMBLY

1.

Remove the four sea t cushion

attaching screws at each corner of the

upper track and remove the track

assembly from the seat assembly (Fig.

2).

2. Remove the two front seat track

motor mounting bracket attaching

screws from the bottom side of the

track assembly and remove the motor

and bracket, then remove the two

motor assembly attaching nuts and

remove the mounting bracket from

the motor.

3. Remove the horizontal cable, vertical

cable and tube from the drive

assemblies.

4. Remove the front seat track assist

sp r ing , t he n r e m ove the tw o

horizontal front seat track drive

assembly attaching screws.

5. Remove (grind or drill) the two front

seat regulator horizontal nut support

assembly attaching riv ets and remove

the support assembly and horizontal

drive assembly. See Fig. 3.

6 . Re m ove the hor i z on ta l d r ive

assembly attaching roll pin and

remove the front seat regulator

horizontal support from the drive

. assembly.

7. Remove the vertical drive assembly

stop nut roll pin and remove the nut

from the drive screw.

8. Remove the vertical drive assembly

roll pin at the attaching bracket and

remove the vertical drive assembly by

unscrewing the drive screw out of the

vertical nut.

9. Remove the front seat upper track

assembly from the front seat lower

track assembly by sliding the upper

t rack forward unt i l the t racks

disengage.

10. Remove the four seat track slides

from the lower track assembly.

Assembly

1. Assemble the four seat track slides to

the lower track, then slide the upper

track into position (Fig. 3).

2.

Install the vertical drive assem

roll pin and stop nut.

3.

Install the front seat regul

support on the drive assembly. In

the roll pin.

4. Install the regulator horizontal

support, using two rivets.

5. Install the front seat track d

assembly with two attaching scr

Then, install the .assist spring.

6. Install the vertical cable and tube

the horizontal cable.

7.

Install the mounting bracket on

motor, then install on the tr

assembly.

8. Install the seat cushion on the t

assembly and tighten to specifica

shown in Fig. 2.

9. Install the seat and track assemb

t h e v e h i c l e a s d e s c r i b e d

Disassembly and Assembly.

10. Check seat operation.



41-07-4

Power Seat-4-Way

41-07-4

FRONT SEAT TRACK

UPPER ASSEMBLY

61710

FRONT SEAT TRACK ASSIST SPRING 61828

FRONT SEAT ADJUSTING VERTICAL

ACTUATOR TUBE

618A82

FRONT SEAT TRACK

VERTICAL DRIVE

618A49

ROLL PIN

VERTICAL STOP NUT

RONT SEAT

REGULATOR

NU T

HORIZONTAL SUPPORT

AND ATTACHING

RIVETS

617A98

-9

FRONT SEAT TRACK MOTOR

MOUNTING BRACKET

AN D

ATTACHING SCREW"

617B48

FRONT SEAT TRACK SLIDE 619A34

FRONT SEAT LOWER TRACK 61714

HORI ZONTAL CABLE

FRONT SEAT REGULATOR

HORIZONTAL SUPPORT

AND ATTACHING SCREWS

60446

N 2104-A

FIG.

3 Exploded Seat Track Assembly Four-Way



41-08-1

Power Seat-6-Way

41-0

Power Seat - 6-Way

P A R T

41-08

SUBJECT PAGE

DESCRIPTION AND OPERATION 08-1

TESTING 08-2

DIAGNOSIS 08-3


Motor and Drive Cables

08-7

Right or Left Track Q8-7

SUBJECT PA

REMOVAL AND INSTALLATION (Cont 'd . )

Seat Track 08

MAJOR REPAIR OPERATIONS

Lincoln Continental Seat Track (Bench Seat) . . 08

Six Way Power Seat - Full Bench 08

Six Way Power Seat - Split Bench 08


The 6-way power seat (Figs. 1 and 2)

provides horizontal, vertical and vertical

tilt adjustments. It consists of a reversible

three armature motor (TRI-MOTOR), a

switch and housing assembly, vertical

gear drives and horizontal rack and

pinion drives.

The mechanical portion of the seat

track in the horizontal drive consists of

a rack and pinion on each track. The

pinion housing and motor is attached to

the movable section of the track. When

the switch is actuated, the front armatu re

is energized and the ho rizontal drive

units are activated . The seat is then

propelled forward or rearward by the

pinion gears traveling in a rack in each

lower track section.

In the vertical drive, w orm gear

mechanisms are utilized. The drive units

CR2011-A

are located in the front and rear of th

hand track (standard bench). Whe

switch is actuated, the center and

armatures are energized simultane

and the vertical drive units are activ

The seat is then propelled up or dow

the worm gears.

When the tilt switch is actuated

center armature drives the front ve

worm gear and moves the seat t

SCREW

384871

T O R Q U E 1 2 - 2 0

FT LB

NUT AND WASHER

STUD 45344

384599 TORQUE 18-32

FT. LB

SCREW

382062

TORQUE 18-32 FT LB

VIEW

A

F IG .

1

Six-W ay Power Seat Tracks Bench and Split Bench Ford, Mercury and Mete or



41-08-2

Power Seat-6-W ay

41-08-2

CUSHION ASSEMBLY

NUT

TORQl-E

14-32 FT.LB

SCREW '

384871 n NU T

TORQUE U 4526E

12-20 FT.LB.


DRIVER SIDE TYPICAL

RVI52-E

FIG.

2 Six-Way Power Seat Tracks Bench and Split Bench—LTD II, Cougar, Thunderbird and Continental Mark V

desired position. When the rear tilt

switch is actuated, the rear armature

drives the rear vertical worm gear and

moves the seat to the desired position.

The power seat circuit is protected

either by a 20 or 30 amp circuit breaker.

The circuit breaker is mounted on the

starter solenoid (Ford, Mercury,

Thunderbird, LTD II and Cougar)

and, in the fuse panel (Lincoln Conti-

nental and Continental Mark V).

Both the horizontal and vertical drive

units are servicable individually. The

armatures is serv iced only at an

assembly. The flexible shafts are serviced

individually and can be removed by

removing the securing corbin clamps.

The switch and housing assembly is

moto r assembly which contains three serviceable separately.

TESTING

The power seat switch tests are shown

in Figs. 3 and 4.



41-08-3

Power Seat-6-Way 41-08

REAR TILT

4 WAY KNOB

UP

REARWARD

TO TEST WHEN SEPARATED FROM CONNECTOR,

USING SELF-POWERED TEST LIGHT OR OHMMETER

B+POWER FEED

14A701

SWITCH ASSEMBLY FRONT TILT

NEGATIVE GROUND

TO TEST SWITCH WHILE STILL

ATTACHED TO CONNECTOR

4 WAY KNOB

NEUT.

FOREWARD

REARWARD

UP

DOWN

NEUT.

NEUT.

NEUT.

NEUT.

©TERMINAL NO.

F I G . 3 P o w e r

REA R TILT

NEUT.

NEUT.

NEUT.

NEUT.

NEUT.

UP

DOWN

NEUT.

NEUT.

SWITCH TERMINAL S

SWITC H POSITIONS

FRO NT TILT

NEUT.

NEUT.

NEUT.

NEUT.

NEUT.

NEUT.

NEUT.

UP

DOWN

CONNECTOR ATTACHED TO SWITCH

CONTINUITY

1-2-4-5-6-7-8- (H

3

I S O L A T E D )

2-3,

1-4-5-6-7-8

3-8,1-2-4-5-6-7

34-6,1-2-5-7-8-

3-5-7,

1-2-4-6-8

3-6,1-24-5-7-8

3-7,

1-2-4-5-6-8

3-4,1-2-5-6-7-8

3-5,1-24-6-7-8

4 WAY KNOB

NEUT.

.

FOREWARD

REARWARD

UP

DOWN

NEUT.

NEUT.

NEUT.

NEUT.

SWITCH POSITIONS

REA R TILT

NEUT.

NEUT.

NEUT.

NEUT.

NEUT.

UP

DOWN

NEUT.

NEUT.

FRO NT TILT

NEUT.

NEUT.

NEUT.

NEUT.

NEUT.

NEUT.

NEUT.

UP

DOWN

POWER

©

GROUN

3 O N L Y

2-3

3-8

34-6

3-5-7

3-6

3-7

3 4

3-5

-24-5-

4-5-6-

-2-4-5-

-2-5-7

-24-6-

-24-5-

-2-4-5

1-2-5-6-

-24-6-

1 IS ALWAYS GROUNDED AND TERM INAL NO. 3 IS ALW AYS HOT. N2

Seat Switch Tests—Armrest Mounted Switch—Lincoln Continental and Continental Mark V

UP

FORWARD

UP

REARWARD

DOWN

REAR TILT

NEGATIVE GROUND

FORW RD

^- fo\ *

REARWARD

DOWN

FORWARD-

SWITCH:

HOUSING ASSEMBLY

SEAT REGULATOR CONTROL

14B711

14B711

14B692

TEST SWITCH WITH SELF POWERED TEST LIGHT OR OHMMETER

WHEN SWITCH IS DISCONNECTED FROM W IRING

4-WAY KNOB

NEUT. (DEAD)

FORWARD

REARWARD

UP

DOWN

NEUT. (DEAD)

NEUT. (DEAD)

NEUT. (DEAD)

NEUT. (DEAD)

SWITCH POSITION

REAR TILT FRONT TILT

NEUT. (DEAD)

NEUT. (DEAD)

NEUT. (DEAD)

NEUT. (DEAD)

NEUT. (DEAD)

UP

DOWN

NEUT. (DEAD)

NEUT. (DEAD)

NEUT. (DEAD)

NEUT. (DEAD)

NEUT. (DEAD)

NEUT. (DEAD)

NEUT. (DEAD)

NEUT. (DEAD)

NEUT. (DEAD)

UP

DOWN

B+ POWER FEED

CONTINUITY

2-3-4-5-6-7-8, 1 ISOLATED

1-7,2-34-5-6-8

1-8, 2-34-5-6-7

14 -6 ,

2-3-5-7-8

1-3-5,24-6-7-8

1-6, 2-34-5-7-8

1-5,2-34-6-7-8

14,2-3-5-6-7-8

1-3, 2 4-5-6-7-8

N2

FIG.

4 Power Seat Switch Tests—Seat Mounted Switch—Ford Mercury Thunderbird LTD II and Cougar

DIAGNOSIS

Consul t the following diagn osis

charts for problems encountered in the

power seat system.



41-08-4

Power Seat-6 -W ay 41-08-4

PROBLEM

1.

Inoperative - All Modes.

POSSIBLE CAUSE

A. Circuit Breaker Open.

B. Circuit Breaker Damaged.

C. Terminal Connector (Motor to

Harness) pulled apart (under seat).

D. Switch Damaged.

Test: As shown in Figure No. 1

(P ar t 41-07 ) .

Granada, Monarch

-

Figure

No. 2.

Lincoln, Mark V, Thunderb i rd -

Figure No's. 3 and 4. Ford , Mercury ,

L T D II , Cougar.

E. Ineffective Ground .

F. Motor Damaged.

Test: Disconnect motor leads from

circuit. Connect ground and positive

lead wires from

the

battery

to the

motor . Motor should operate

in one

direction . Reverse leads

at the

motor

connector. Motor should

run in the

reverse direction.

If the

motor does

not operate

the

seat tracks, inspect

the tracks

for

possible binds and/or

gear transmission lock-up condition.

Also, inspect the tracks and drive

mechanism for foreign material th at

may cause binding.

CORRECTION

W a i t

90

seconds

and try

again.

Check circuit breaker (Test for 12 volts each

terminal ) . Replace

if

defective. Check circuit

for short between circuit breaker

and

swi ten.

Repair

if

necessary.

Reconnect.

Replace switch.

Check

and

repair

if

required.

Replace motor.

C I M 2 8 5 7 - A



41-08-5

Power Seat-6-Way

41-08

PROBLEM

2.

Inoperative

—

One Mode, Either

Direct ion.

3. Noisy Cable.

4. Horizo ntal Chucking.

5. Binding.

POSSIBLE CAUSE

A. Switch worn or damaged.

B. Terminal connector (motor to

switch) pulled apart.

C. Motor worn or damaged.

D. Cable disengaged from motor or

transmission.

NOTE:

Before e ngaging cables, in-

sure RH & LH bench seat tracks

are synchronized with each other.

E. Transmission wo rn or damaged.

F. Insuff icient length.

A, Insuff icient cable length.

B. Disengaged fro m transmission or

mo tor drive hole.

C. Frayed cable ends.

D. Broken cable.

E. Lack of lubrication.

A. Horizontal movement over 1/32".

B. Out of round pinio n gear.

C. Missing slide .

A. Loose transmission attaching nuts.

CORRECTION

Same as above N o. 1 D.

Reconnect.

Same as above No. 1F.

Engage cable - install spring clamp s. Check

cable for square form ed ends - replace if

frayed o r distorted . Check for prope r cable

length as specified in parts info rm ation

source. Check motor and transmission cable

entry holes for square op ening.

Replace transm ission.

Replace cable with proper length specified

in parts information source.

Replace cable with proper length specified

in parts information source.

Check for proper engagement and presence

of spring clamps. Engage cables and install

spring clamps if required.

Replace c able.

Remove broken cable ends from the tube

and replace cable.

Remove cable from the tube and apply

Polyethylene Grease Part No. DOAZ-

19584 A or equ ivalent, to the cable and

assemble.

Replace transmission if pinion gear permits

carriage to move over 1/8" fore and aft.

Replace mounting base if movement occurs

without pinion gear moving.


Install slide (4) required each side.

Tighten transmission attaching nuts (2)

required, (Torque 7-12 ft-lbs).

CIM2857-



41-08-6

Power Seat-6-Way

41-08-6

PROBLEM

6. Seat Cushing Roc king.

7. Seat Looseness.

8. Upper and Lowe r Track Looseness

(Vertical Chucking).

9. Inoperative Vertical Mode.

10.

Inoperative Horizo ntal Mode.

11. Lateral Chucking.

12.

Binding

or

Slow Operation.

POSSIBLE CAUSE

A. Loose cushion attach ing screws.

A. Loose track to f loor attaching nuts.

B. Floor carpet or deadener interference.

A. Missing spring (clock ty pe ).

B. Missing slide .

A. Missing pinio n gear retaining pin.

B. Transmission worn

or

damaged.

C. Broken cable

A. Missing ho rizo ntal assist spring.

B. Broken ho rizo ntal assist spring.

C. Disconnected horizontal assist

spring.

D. Transmission worn or damaged.

E. Cable wo rn or damaged.

A. Missing slide.

A. Floor attaching screws torque d w ith

tracks positioned tight against rear

or front stops.

B. Broken rear assist spring (ve rtical or

hor izontal) .

C. Low charge battery .

CORRECTION

Tighten

the (4)

cushion

to

track attaching

screws (Torque 12-20 ft-lbs).

Tighten the (4) track to f loor attaching nuts

(Torque 14-32 ft- lbs).

Check floo r mo unting surface for any ob-

struction and remove if required

Install spring.

Install slide (4) required each side.

Engage pinion gear. Replace pin through

attaching hole in pinion gear shaft.

Replace transmission.

Replace cab le.

Install spring.

Replace spring.

Connect spring.


Replace cab le.

Install slide

(4)

required each side.

Loosen floor attaching nuts. Cycle tracks

-

position tracks away fro m stops

—

t ighten

attaching nuts (Torque 14-32 ft- lbs).

Replace sp ring.

Check for proper state of charge

—

at least

1.200 spec ific grav ity. Charge as specified

in Car Shop Manual.

CN2857-A2



41-08-7

Power Seat-6 -W ay

41-0


SEAT TRACK

Removal

1. Remove the nuts and washers and /or

bolts retaining the seat track assembly

to the floor pan (Figs. 1 and 2).

2. Lift the seat up enough to disconnect

the seat motor wires. Then, remove

the two bolts attaching the seat belts-

to-floor and disconnect the multiple

connector. Remove the seat and track

assembly from the vehicle.

3. Place the seat upside down on a clean

bench.

4. Remove the shield(s) f rom the

outboard side of the seat cushion (if

so equipped).

5.

Remove two bolts attaching each

track to the seat frame and remove

the track assembly from the seat.

Installation

1. Position the track assembly to the seat

cushion. With a Thunderbird or

Continental Mark V track, install

the side shield support(s) between

the track and cushion (if so equip-

ped).

2.

Install the four track-to-cushion

attaching screws and washers and

tighten to specification shown F igs. 1

and 2. To be sure that the two tracks

are mounted in parallel, move the J-

nut at the right front corner so that

the distance between the tracks at the

f ront equa ls tha t a t the rear .

M e a sur e m e nt shou ld be m a de

between the track base channels.

3. Install the side shield(s) to the seat

cushion (if so equipped).

4. Connect the seat control to the

track assembly at the connectors.

5. Position the seat and track assembly

in the vehicle and connect the seat

motor wires at the connector and the

seat sensor switch wires. Install the

two bolts attaching the seat belts to

the floor and connect the multiple

connector.

6. Install the seat track-to-floor pan

retaining nuts and/or bolts and

tighten to specification shown in Figs.

1 and 2.

RIGHT OR LEFT TRACK

Removal

1.

Remove nuts and washers and/or

bolts retaining the seat track to the

floor pan (Figs. 1 and 2).

2. Lift the seat up enough to disconnect

the seat motor wires. Then, remove

the two bolts attaching the seat belts

to floor. Remove the seat and track


3. Remove the right and left cushion

side shields from the seat cushion (if

so equipped).

4.

Remove the retaining clamps and

disconnect the drive cables from the

seat tracks.

5.

If the motor mounting bracket is

attached to the track being replaced,

remove the bracket-to-track screws

and remove the bracket, motor and

drive cables as an assembly. If the

motor mount ing bracke t i s not

attached to the track being replaced,

remove the three motor-to-mounting

bracket screws and remove the motor

and drive cables as an assembly.

Installation

1. Position the side shield sup port(s) (if

s o e q u i p p e d ) a n d t h e n t h e

replacement track to the seat frame.

Ins ta l l the a t taching bol ts and

washers and tighten to specification

shown in Figs. 1 and 2.

2. If the motor mounting bracket was

a t tached to the t rack tha t was

replaced, position the bracket, motor

and drive cable assembly to the track'

and install the two bracket-to-track

screws; otherwise, position the motor

and drive cables and install the three

motor-to-bracket screws.

3. Connect the drive cables to the tracks

and install the retaining clamps.

4. Install the right and left cushion side

shields (if so equipped).

5. Position the seat and track assembly

into the vehicle and connect the

motor. Install the two bolts attaching

the seat belts to the flo or and connect

the multiple connector.

6. Install the four seat track-to-floor pan

retaining nuts and washers and

tighten to specification shown in

1 and 2.

7. Check the operation of the seat.

MOTOR AND DRIVE CABLES

Removal

1. Remove nuts and washers retai

the seat track to the floor pan (

1 and 2).

2. Lift the seat and disconnect

seat motor. Remove the two

attaching the seat belts to

and disconnect the multiple

nector. Then, remove the seat

seat track from the vehicle.

3. Remove three motor assembl

mounting bracket attaching bolt

4. Remove the clamps retaining

drive cables to the seat tracks. T

open the wire retaining straps

remove the motor assembly

cables from the seat track assem

5.

Remove the cable retaining bra

and remove the drive cables from

motor assembly.

Installation

1. Position the cables and retai

brackets to the motor and instal

retaining screws.

2. Position the cables to the seat t

and the motor to the moun

bracket.

3. Install the three motor-to-mou

bracket attaching bolts.

4. Install the clamps retaining the

cables to the seat tracks.

5. Insert the motor wire in the

straps and connect the wire a

connector.

6. Position the seat and track in

vehicle and connect the seat m

Install the two bolts attaching the

belts to the floor and connec

multiple connector.

7. Install the seat track-to-floor

retaining nuts and washers

tighten to specification shown in

1 and 2.

8. Check the operation of the seat


LINCOLN CONTINENTAL BENCH

SEAT TRACK

To replace any component of a seat

track, remove the track as outlined under

R e m o v a l a n d I n s t a l l a t i o n a n d

disassemble the track as required to

replace the damaged component.

On each power seat assembly, each

track uses a vertical assist spring. The

motor and mounting bracket is bolted to

the le f t sea t t r ack. The Lincoln

Continental left seat track is the primary

seat track. The right seat track is the

secondary seat track (Fig. 5).

Two vertical drive units (front and

rear) and one horizontal drive unit are

located in both the primary (left) and

secondary (right) tracks (Fig. 6).

Disassembly

1. Remove the motor bracket mounting

bolts (3) from the motor mount

bracket to motor (Fig. 6).

2. Disconnect the cable housing

clamps (3) and remove the term

block connector from the term

block bracket (Fig. 6).

3. When disassembling an inoper

seat track, it is helpful to position

track upper channel in the ful

position. If the channel is not in

up position, insert the square en

the drive cable into one of

the

ve

drive couplings, and manually



41-08-8

Power Seat-6-W ay

41-08-8

DRIVE CABLES

•SECONDARY TRACK

R1846-A

VERTICAL ASSIST

SPRING

HOSE CLAMPS

UPPER CHANNEL

CU P

VERTICAL (REAR)

DRIVE CABLE

HORIZONTAL DRIVE

CABLE

TERMINAL

CONNECTOR

FIG. 6 Primary Seat Track Components, Bench Seat

FIG.

5 Six Way Bench Power Seat Assembly—Lincoln Continental, Bench Seat

the vertical drive to the full up

position (Fig. 8). Once the vertical

drive is run against the stop, it is

necessary to back it off 1/4 turn. T his

is done to provide working clearance.

If the vertical drive is inoperative,

insert the drive cable into the drive

coupling and turn it to the full

forward position. Again, back off

from the full stop position 1/4 turn.

4. When taking apart the primary (left)

track, hold the upper front channel

against the vertical assist spring while

removing the front clevis pin (Fig. 7).

CAUTION: Release the upper

channel carefully so that the upper

channel will not spring open quickly.

The upper channel is under spring

tension. Remove the assist spring and

cup (Fig. 9).

The secondary (right) track upper

channel is removed in the same

manner as described above.

5. Remove the roll pin from the rear end

of the two side rails. Also remove the

front and rear pivot bolts and nuts

(Fig. 9).

When disassembling the primary

(left) track, remove the through bolts (2)

and nuts (2) that retain the horizontal

drive and motor mount bracket to the

side rails. Remove the motor mounting

bracket. Lift the drive carriage and drive

assembly out of the base channel.

When disassembling the secondary

(right) track, remove the through bolts

(2) and nuts (2) from the side rails. Lift

the horizontal drive carriage out of the

base channel. If the horizontal drive is

inoperative replace it.

I f the f ront ver t ica l dr ive i s

inoperative remove the front bell crank

assembly by unscrewing the front bell

crank from the screw. If the rear vertical

drive is inoperative, remove the roll pin

and rotate the rear bell crank off the d rive

VERTICAL DRIVE

(FRONT) CABLE

MOTOR MOUNTING

BRACKET

MOTOR MOUNT BOLTS

R1347-A

UPPER CHANNEL

(FULL UP POSITION)

REAR BELL CRANK

VERTICAL ASSIST \ REAR RIVET

REAR PIVOT BOLT

VERTICAL (REAR

DRIVE

THROUGH BOLTS

SLIDE BLOCK

(4 PLACES)

FRONT BELL CRANK

R1H48-A

FIG.

7 Primary Seat Track Components—Lincoln Continental, Bench

screw. Replace the defective vertical

drive.

Assembly

1.

Install the rear bell crank to the

vertical drive by turning it onto the

threaded drive screw. If either of the

vertical drives are being replaced,

mount the new drive to the carriage



41-08-9

Power Seat-6-Way

41-0

by installing the roll pin into the

correct roll pin hole.

2. Properly position the four horizontal

slide blocks on the base channel as

shown (Fig. 10).

3. Install the horizontal drive to the

drive carriage.

4. I ns t a l l t he d r ive c a r r i a ge by

positioning the pinion retainer block

(Fig. 10), in the full forward position

before engaging the pinion with the

horizontal rack. Make sure the pinion

is retained by the retainer block.

5. Install the through bolts (2) that hold

the motor bracket (primary track),

the horizontal drive and slide rails (2)

together (Fig. 7).

6. Align the vertical drive (front and

rear) bell crank bolt holes manually,

by turning the vertical drive(s) input

coupling(s) (Fig. 8). Secure the motor

bracket bolts evenly. Manually turn

the vertical drive to the stop position

in the full up mode.

7. Install the roll pin at the rear end of

the side rails (2).

8. With the primary (left) track, install

the vertical assist spring and cup in

the drive carriage. The boss on the

cup should enter the hole in the

bottom of the carriage. Install the

wear plates, one on each side of the

front upper channel. Force the upper

channel down, against the spring and

secure the forward end to the front

bell crank (Fig. 9).

9. Connect the drive cables (3) to the

drives (3). Secure the hose clamps.

Connect the terminal block to the

terminal block bracket. Secure the

motor to motor mount bracket with

the attaching bolts (3) (Fig. 6).

SIX W A Y POW ER SEAT—SPLIT

BENCH

Disassembly

1. Remove the motor mount bracket

mounting bolts f rom the motor

mount bracket to motor. Disconnect

the hose clamps (3) from the drive

input shafts (Fig. 11).

2. Manually position the seat track in

the full up, and mid-horizontal

position. To do this, insert the square

end of a drive cable in one of the

vertical drives and manually turn the

drive unit until it is in the full up

position. Using the horizontal drive

unit, insert the cable drive and

m a nua l ly t u r n i t t o t he m id-

horizontal position.

3.

Remove the front and rear clock

springs using vise grips (Fig. 12).

4. Remove the cotter pins from the pivot

pins on the secondary track (Fig. 13).

5. Remove the retaining rings from the

horizontal pinions (primary and

secondary tracks).

c

HAND DRILL

MOTOR MOUNT BRACKET

DRIVE CABLE

VERTICAL DRIVE COUPLING

LOWER CHANNEL

R184

FIG. 8 Positioning the Upper Channel in the Full Up Position

6. Remove the base and carriage from

the secondary track by driving the

pinion gear through the carriage rack

(Fig. 14).

7. Remove the bolts (2) and nu ts (2) on

the primary track that retain the drive

assembly to the carriage (Fig. 11).

8. Move the horizontal pinion rack gear

manually (using the procedure in Step

2),

to gain access to the retaining hair

pins,

holding the vertical clevis pins.

9 . Replace the inopera t ive dr ive

assembly.

Assembly

1. Position the drive assembly, inserting

the horizontal pinion into the pinion

cage (Fig. 14).

2. Install the drive assembly retaining

nuts and hair pins into the front and

rear vertical drives (2).

3. Manually position the front and r

vertical drives in the full up positi

Also manually position the horizon

drive to the extreme forward positi

4. Using vise grips, pre-load th e fr

and rear clock springs and install

springs on the spring studs (Fig. 1

5.

Assemble the secondary track

inserting the horizontal pinion gea

the extreme forward position in

pinion cage.

Be sure

that th e front

rear torsion bar holes are aligned w

the pivot pins, on the seconda

carriage. Also properly seat

pinion gear bushing in the carri

(Fig. 12).

6. Install the cotter pins (2) and sn

rings (2) on the horizontal pinion

7. Install the motor mou nting brac

and connect the drive cables (3) to

drive unit (3) assembly.



41-08-10

Power Seat-6-Way

41-0810

UPPER CHANNEL

WEAR PLATE

(2 PLACES)

FRONT

BELL CRANK

ASSIST SPRING

REAR

BELL CRANK

SLIDE BLOCK

R1850 A

FIG.

9 Removing the Upper Channel—Lincoln Continental, Bench Seat

VERTICAL DRIVE

DRIVE SCREW

VERTICAL DRIVE

SLIDE BLOCK

SLIDE BLOCK

PINION RETAINER BLOCK

R1K51-A

FIG. 10 Pinion, Horizontal Rack and Pinion Retainer Block—Lincoln Continental, Bench Seat

SIX W A Y POW ER SEAT—FULL

BENCH

The six way power seat full bench seat

tracks (Fig. 15) are serviced in the same

way as the split bench primary seat track.

The difference is that the bench seat

adjusters are both primary tracks. The

right primary track has a horizontal

assist spring that helps the right trask in

moving forward. Refer to Split Bench

Major Repair Operations for serv icing

the full bench seat tracks.



41-08-11 Power Seat-6-Way

41-08-

RETAINING NUTS

(PRIMARY TRACK

TO CARRIAGE)

DUST SHIELD

PRIMARY (RIGHT) TRACK

MOTOR MOUNTING BRACKET

SECONDARY TRACK

R1852-A

FIG.

11 Six Way Power Seat Track Assembly—Split Bench Full Up and

Mid-Horizontal Position Shown

VICE GRIP

CLOCK SPRING

(PRE-LOADED)

TORSION BAR

TORSION HOLE

PINION GEAR

PINION GEAR BUSHING

TORSION HOLE

R1853-A

FIG.

12 Removing the Clock Springs



41-08-12

Power Seat-6-Way

41-08-12

COTTER PIN

PIVOT PIN

HORIZONTAL RACK

PINION

FIG.

13 Removing the Cotter Pins from the Pivot Pins

PINION GEAR SHAFT

TORSION BAR

PINION CAGE

DRIVE

R1855-A

FIG.

14 Driving the Pinion Gear Through the Carriage Rack



41-08-13

Power Seat-6-Way

41-08

HORIZONTAL

ASSIST SPRING

LEFT

TRACK ADJUSTER

R18

F IG . 15 Six W ay Power Seat Assembly—Full Bench— Ford, Mercury, LTD I I , Cougar and Thunderbird



41-14-1

Conventional Rear Seats

41-14-1



All Models Except Pinto, Bobcat

and Mustang

Removal

1. Apply knee pressure to the lower

portion of the rear seat cushion; then

push rearward to disengage the seat

cushion from the retainer brackets

(Fig. 1).

2. Remove one of the rear quarter arm

rests (if so equipped), to remove the

seat back assembly.

3.

Remove the seat back lower retaining

screws (Fig. 2).

4. Grasp the seat back assembly at the

bottom and lift up to disengage the

hanger wire f rom the re ta iner

brackets.

5. Remove the seat back assembly from

the vehicle.

Installation

1.

Position the seat back assembly into

the vehicle so that the hanger wire is

engaged with the retaining brackets

(Fig. 2).

2. Install the seat back lower retaining

screws and tighten securely.

3. Position the seat cushion assembly

into the vehicle.

4. Apply knee pressure to the lower

portion of the seat cushion assembly

and push rearward and down to lock

the seat cushion into position (Fig. 1).

5.

Install the rear quarter arm rest (if

removed).

6. Check rear seat cushion to be certain

it is secured into its floor retainer.

Pinto, Bobcat and Mustang

Removal

1. Remove the two lower retaining

screws securing the rear seat cushion

(Fig. 3) and remove the seat cushion

from the vehicle.


screws securing the rear seat back.

3. Then, grasp the seat back assembly at

the bottom and lift up to disengage it

from the retainers (Fig. 3).

4. Remove the rear seat back assembly

from the vehicle.

Installation

1. Position the rear seat assembly to all

four retainers and install the two

lower retaining screws. Tighten

securely.

2. Position the rear seat cushion into the

vehicle and install the two lower

retaining screws. Tighten securely.

R 697-A

FIG.

1 Rear Seat Cushion Retainer—Ford and Mercu ry. Linco ln Contine ntal, Mark V, LTD II , Thu nde rbird and Cougar

have welded retainer. Others typical.



41-14-2


41-1

CUSHION BACK

VIEW-A

VIEW-B

R1

FIG .

2 Rear Seat Back Installation—Typical

BACK ASSEMBLY

VIEWBB

N21

FIG . 3 Rear Seat Back and Cushion Installation—Granada, Monarch, Mustang, Pinto and Bobcat



41-20-1

Fold Down Rear Seats

41-20-1


P A R T

41-20

SUBJECT PAGE

ADJUSTMENTS

Au xilia ry Seat Back Latch 20-1

Panel Exte nsion Rear Seat Back Flo or 20-1

Rear Seat and Au xilia ry Floo r 20-1

SUBJECT PAGE

ADJUSTMENTS (Cont 'd.)

Second Seat Back Latch Striker 20 1

Stowage Com partment Door Latch 20 1

REMOVAL AND INSTALLATION 20 1

CR2013-A

ADJUSTMENTS

REAR SEAT AND AUXILIARY

FLOOR

Pinto, Bobcat and Mustang

Vertical adjustment for the seat back

latch striker can be made by loosening

the four attaching nuts, and moving the

s tr iker pla te up and down to obta in

proper engagement to the seat back latch

(Fig. 1).

Lateral adjustment of the seat back

latch can be made by removing the rear

seat back, loosening the 2 latch attaching

screws and moving the latch inboard or

outboard as required to properly engage

the latch striker.

Ford, Mercury, LTD II and

Cou gar—( Typ ica l )

There are four adjustment locations

on a l l s ta t ion wagon models for the

folding second seat and rear auxiliary

floor seats. See Figs. 2 through 4.

PANEL EXTENSION REAR SEAT

BACK FLOOR

Should the rear seat back extension

panel become difficult to fold in a locking

position, loosen the two attaching bolts

on each side of the seat. Move the panel

extension fore or aft to obtain proper

locking position.

SECOND SEAT BACK-LATCH-

STRIKER

The striker adjustment to the second

rea r s ea t s top a s s embly i s made by

turning the striker in or out to obtain the

desired locking clearance. Install shims

(not more than 4), and tighten to 20 ft-

lbs.

See Fig. 2.

The Ford and Mercury adjustment is

located on the right side of the back seat.

The LT D II and C ougar is located on the

left side of the back seat.

AUXILIARY SEAT BACK-LATCH

The release handle and latch assembly

located on each side of the auxiliary seat

back has an up and down adjus tment .

(See Figs. 3 and 4.)

L o o s e n t h e t w o s c r e w s d i r e c t l y

behind the seat back latch assembly to

obta in the des ired locking c leantnce .

Install shims if required and tighten to

specification.

ST OWAGE COM PART M ENT

DOOR-LATCH

To adjust the latch assembly, loosen

the two screws holding the lock assembly,

and raise or lower the lock to obtain

desired position. Add shims if required

and tighten the attaching screws. See Fig.

4.

VIEW A VIE W B

V I E W D

V IE W E V IE W F

VIEW Hf

FIG . 1 Fold-Do wn Rear Seat Back Instal lat ion - Mustang Shown — Pinto and Bobcat Similar



41-20-2


41-2


Refer to the illustrations shown in

Figs.

1 through 6 and

Fig.

2 in Part 41-14.

Removal


screws securing the rear seat back to

the floor.

2.

On the Mustang, Bobcat and Pinto,

rotate the bottom kidney pads up and

remove the two screws retaining the

upper back to the folding floor.

3.

Lift up and disengage the upper clips

of the rear back from the top of the

folding floor .

Installation

1. Center the seat back on the folding

floor and push down, engaging the

upper channel of the back to the top

of the folding floor.

2. On the Mustang, Bobcat and Pinto,

rotate kidney pads up and install 2

screws retaining the upper seat back

to the folding floor.

3. Install two screws engaging the

kidney pads to the floor pan.

4.

Position the rear seat cushion into the

vehicle and install the two lower

retaining screws.

STOP ASSEMBLY

62426

BUTTON-REAR SEAT BACK

LATCH RELEASE

62432

SCREW AND WASHER

382542

SCREW

55927

BRA

CARPET

R1

F IG . 2 Rear Seat Back Floor Extension Panel Ford, Mercury, LTD II and Co



41-20-3


41-20-3

LOCK SET

SCREW

380926

SCREW AND WASHER

57472

V I E W C

LATCH ASSY

61142

V I E W D

COVER

V I E W E

RHS27-C

F IG .

3 Folding Floor Rear Facing 3rd Seat LTD II and Cougar



41-20-4


41-2

STOWAGE COMPARTMENT

PANEL ASSY. 11698

SHIM 431 E 74

SCREW AND

WASHER 382622

VIEW-A

SCREW 51 751

COVER 605A16-7

WITH DUAL FACING

REAR SEATS

HINGE ASSY. 116A00-1

SCREW 57032

\ & & - — / S T UD P RO TE CT OR 3 5 35 3 8

SCREW 57032

WITHOUT DUAL FACING

REAR SEATS VIEW-B

LATCH ASSY.

EW 57471

LOCK SET VIEW-C

SCREW 5 7472

STRIKER

105A90 //

VIEW-D

R1

FIG. 4 Rear Seat Auxiliary Floor Ford—Mercury



41-20-5


41-20-5

CUSHION ASSEMBLY - AUX ILIAR Y SEAT

BACK ASSEMBLY

BACK ASSEMBLY

R17 M-C

FIG. 5 Auxiliary Seat Cushion and Back Installation—Ford and Mercury

AUXILIARY SEAT BACK ASSEMBLY

AUXILIARY SEAT CUSHION ASSEMBLY

FROf^T

R 1743 A

FIG.

6 Auxiliary Seat-to-Body LTD II and Cougar



41-25-1

Seat Back Latch—Manual

41-

Seat Back Latch-Manual


All folding seats have a latc h designed

to hold the seat back in the normal

position. For rear seat passenger entry

and exit, a latch handle is located on the

left side of all bucket and split bench seats

(drivers side), and on the right side of all

bucket and split bench seats, (passenger

side).

See Figs. 1 throug h 3.

If the seat back will not latch in

position or the latch mechanism will not

unlock, remove the seat trim as required

to inspect the latch mechanism. Then,

replace any damaged parts to put the

CR2014

latch system in proper working ord

Figs.

1 through 3.

Check the front seat back latche

door models only) for smooth ope

The latch should not stick or bind

check to be sure that the latch re

the seat back from moving forwar



41-25-2


41-25-2

LATCH SPRING

HANDLE

PAWL

ESCUTCHEON

BENCH SEAT

SPLIT BENCH SEAT TYPICAL

LINCOLN

SCREW

VIEW A

SPRING

ASSEMBLY

SPRING

PAWL

SPLIT BENCH

AND

FLIGHT BENCH

SEAT BACK

FORD AND MERCURY

R.H. SHOWN,

L.H.

SIMILAR

PASSENGER BUCKET SEAT

DRIVER SEAT - SIMILAR

V I E W E

LATCH ASSEMBLY -

BENCH SEATS

LATCH ASSEMBLY -

FLIGHT AND

SPLIT BENCH

BENCH, FLIGHT BENCH,

AND SPLIT BENCH SEAT

LTD I l .THUNDERBIRD

AND COUGAR

R142' 2-I

FIG. 1 Front Seat Back Latching Mechanism Typical Left and Right Side



41-25-3


41-25

BUCKET SEATS

PINTO. BOBCAT

VIEW A

PAWL

BRACKET

V I E W B

BEZEL

SCREW

LATCH AND

CABLE ASSEMBLY

SCREW

2 R E Q ' D .

SCREW 2 REQ 'D.

VIEW C - MUSTANG

BRACKET AND

CABLE

ASSEMBLY

SCREW

HANDLE

SCREW

RETAINER RING

R.H. SIDE OF SEAT

BUCKET SEATS BACK SHOWN -

MAVE RICK. L.H. TYPICAL

COMET. GRANADA

AND MONARCH

SCREW 2 RE Q'D.

VIEW F - MAVER ICK, COMET.

GRANADA. MONARCH

P IN

V I E W D

SPRING

V I E W E

PAWL

VIEW H

COVER

V I E W G

BENCH SEATS

MAVERICK, COMET,

GRANADA AND MONARCH

SPACER

V I E W G

WASHER

PAWL

R195

FIG. 2 Front Seat Back Latching Mechanism Typical Left and Right Side



41-25-4


41-215-4

TRIM PANEL

-

60762

MAVERICK/COMET/GRANADA/MONARCH

BUCKET SEAT BACK TRIM PANEL SHOWN

- GRANADA/MONARCH FLIGHT BENCH

SEAT SIMILAR

HANDLE

SCREW

VIEW-A

FRAME

ASSY.

SCREW

VIEWC

N27 '0-B

FIG. 3 Front Seat Back Latching Mechanism—Granada and Monarch Flight Bench



41-28-1

Seat Back Latch—Automatic

41-28

Seat Back Latch

--

Automatic

P A R T

41-28

S U B JE C T P A G E


TESTING

Relay Test 28-4

Solenoid Test 28-4



Relay 28-4

Solenoid 28-4

Wiring Routes 28 -4

CR2015-A

WASHER


Both f r on t s e a t ba c k l a t c he s

automatically release when either front

door is opened. In each front door hinge

pillar there is a switch connected to

battery power. Opening the door closes

the switch and sends power to energize

a relay switch. When the relay switch is

closed, it sends power to two solenoids,

one mounted on each seat back (Figs. 1

through 4). The actuating rod of the

solenoid is connected to the latch pawl.

When the solenoid is energized i t

operates the pawl to release the latch. If

the electric system does not function, the

latch can

be

released manually

by

moving

the seat back release handle. If the seat

back fails to release automatically when

the door is opened, remove the seat back

trim cover and/or carpet far enough to

inspect and test latch mechanism. See

Figs. 1,2 and

3.

NO TE : After performing

any work on the seat back latches, check

for smooth operation of the latches. The

latch should not stick or bind. Check that

the latch does restrain the seat back from

moving forward. Be sure that the latches

f u n c t i o n b o t h a u t o m a t i c a l l y a n d

manually.

SPRING

SOLENOID

LATCH

R194

FIG . 1 Seat Back Latch—Automatic—Lincoln Continental 2-Door Models



41-28-2


41-28-2

BRACKET

CLIP

1 REQ'D.

EACH SIDE

INSTALLATION WITH BENCH SEAT

R.H.SIDE SHOWN

L.H.SIDE SIMILAR

INSTALLATION WITH FLIGHT BENCH

& SPLIT BENCH WITHOUT RECLINER

F1941-B

FIG. 2 Seat Back Latch—Automatic—Ford and Mercury 2 -Door Mo dels



41-28-3


41-28

GROUND WIRE

SOLENOID

ASSEMBLY

(NOTE:

LINK IS

PART OF SOLENOID

ASSEMBLY, DO NOT

ATTEMPT TO SERVICE

SEPARATELY.)

AUTOM ATIC SEAT BACK LATCH - ALL MODELS WITH RECLINER SEAT

SPRING

62600-1

RETAINER

610B66

SCREW

384871

SCREW

56903

SHIELD

/ \

62718-9 / S O L E N O I D - 6 2 6 9 0

55926

S P L I T B E N C H S E A T

BUCKET SEAT

LTD H,THUNDERBiRD

AND COUGAR ONLY

FIG. 3 Sea t Back Latch—Autom atic-—LTD I I, Couga r, Thunderbird, Continental Ma rk V



41-28-4


41-28-4

TESTING

SOLENOID TEST

Remove the solenoid and connect

battery power to the connector terminal

and ground the case of the solenoid

assembly to the negative side of the

battery. If the solenoid plunger does not

move quickly, replace the solenoid.

NOTE: Solenoid must be held in

normal position for this test.

RELAY TEST

See Removal and Installation for

relay locations. Disconnect the relay

connector, noting the color of the three

wires at each terminal, and remove the

relay. Connect battery power to the relay

(positive post to the pink-white siripe

wire terminal and negative post to the

relay case). Connect a self powered test

light between the other two r^lay

terminals. If the test light does not light,

replace the relay.


RELAY

The relay is mounted in various

locations according to car line as follows:

Lincoln Continental, on the front floor

pan assembly under the passenger's seat;

Thun derbird in left hand cow l side;

Continental Mark V, on the brake

pedal support bracket to the right of

the fuse panel; Ford and Mercury on

the front part of the floor near the

No. 1 crossmember; and LTD II and

Cougar inside the left-hand cowl side

panel assembly. The 1976 Granada

and Monarch is mo unted at the right

side of the instrument panel (Fig. 4).

Disconnect the battery negative post.

Disengage the 3-way hardshell connector

from the relay. Remove the mounting

screws and remove the relay.

When installing the relay, be sure to

engage the 3-way hardshell connector to

the relay.

4

SOLENOID

Ford ,

Mercury, L inco ln Con t inental ,

and Continental Mark V . Also

Recliner Seal on LTD II , Cougar,

Thunde rbird and Cont inental

Mark V.

Remove the seat back trim cover far

enough for access (Figs. 1, 2 and 3).

Disconnect the wires at the connector

plug. Remove the clip that connects the

solenoid plunger to the latch pawl, and

remove the solenoid mounting screws

(Figs. 1, 2 and 3). Remove the solenoid

from the seat assembly and, at the same

time, disengage the plunger rod from the

latch pawl.

LTD II, Cougar, Thunde rbird and

Cont inenta l Mark V (Wi thout

Recliner)

Cut the hog rings from the carpet to

gain access to the solenoid assembly.

Remove the three shield retaining screws

and disconnect the w ires at the connector

plug. Remove the two solenoid assembly

retaining screws (Fig. 3). Then, loosen

the two back pivot bracket assembly

screws and slide the latch assembly out

far enough to remove the solenoid and

link from the latch stem. To install,

reverse the procedures.

Granada and Monarch

For Removal and Ins ta l la t ion

procedure, refer to Fig. 4.

WIRING ROUTES

Refer to Figs. 5 and 6 for c o r e d

wiring routes.

SOLENOID ASSY.

- 62690

PIN

LOCATOR

GRANADA AND MONARCH

FLIGHT BENCH SEAT BACK

R.H. SHOWN, L.H. S YMM . OPPOSITE

WIRING HARNESS

CONNECTS TO -

14C692

RELAY ASSY.

- 14C690

RIGHT SIDE OF

INSTRUMENT PANEL

R1£'70-B

FIG. 4 Seat Back Latch Automatic—Granada and Monarch



41-28-5


41-28

ROUTING OF 14C692 WIRING ASSY.

(L.H.) WITH POWER SEAT OPTION

ROUTING OF 14C692 WIRING ASSY. (R.H.)

ROUTING OF 14C692 WIRING ASSY.

(L.H.) MANUAL

INSTALLATION OF WIRING RETAINER

L.H. SHOWN, R.H. SYMM. OPPOSITE

N2858

FIG .

5 Automatic Seat Back Latch (Bucket Seats)

WIRING ASSEMBLY

14C691 (2 PLACES)

STRAP 42359

(2 PLACES)

STRAP 42359

(2 PLACES)

SCREW 389184

(2 PLACES)

SCREW 389184

(2 PLACES)

WIRING ASSEMBLY

14C691 (2 PLACES)

N2859-A

FIG .

6 Automatic Seat Back Latch (Bench Seats)



41-30-1

Reclining Seat Back 4 1 -3 0 -1

Reclining Seat Back


The mechanical reclining seat back is

available on all vehicles except Pinto,

Bobcat and Mustang.

The reclining seat is adjusted by a

latch handle on the seat cushion right

side of the passenger seat (inboard side of

both seats—backs on the Granada,

Monarch, Maverick and Comet bucket

seat cars). To recline the seat, turn the

handle and push the seat back to the

desired position and release the handle.

Spring action will return the seat to

normal position when the handle is

released at the seat back. See Figs. 1

through 4.

If the reclining seat will not fold down

or return to its normal position, it will be

necessary to remove the seat cushion or

back trim cover, carpet and/or seat back

trim panel far enough to inspect the

recliner mechanism. Then replace any

damaged parts to put the recliner system

in proper working order (Figs. 1 through

4).

RETAINER

383740 ^ O \\

LOCK OUT PIN

611 B24

(4 -DOORONLY)

EXPLODED VIEW OF MECHANISM

FIG. 1 Reclining Seat Back Installation—Lincoln Continental

R1629-D



41-30-2 Reclining Seat Back

41-3

SEAT BACK

LATCH HANDLE

BEZEL

SEAT BACK

SCREW

ESCUTCHEON

TRIM PANEL

LATCH CAM

AFTER SEAT BACK HA S BEEN

REMOVED, SERVICE THE AUTOMATIC

SEAT BACK SOLENOID BY PUSHING

FORWAR D ON THE PAD AND REMOVING

THE TW O ATTACHING SCREWS.

SUPPORT

PANEL

REINFORCEMENT

RING

H E X N U T - T O R Q U E

MUST BE 60-93 FT-LB

BRACKET

REINFORCEMENT

SCREW

BEZEL

VIEW

A

CLIP

R1789

FIG . 2 Reclining Seat Latch and Mechanisms—Thunderbird and Continental

Mark V Shown—Typical for Cougar and LTD II



41-30-3 Reclining Seat Back

41-30-3

RECLINING SEAT LATCH

AND MECHANISMS -

FORD,MERCURY AND

METEOR

R1-I38-B

FIG. 3 Reclining Seat Latch and Mechanisms—Ford and Mercury

SEAT BACK VIEW >\

SEAT BACK

LATCH MECHANISM

NOTE: PASSENGER SEAT

SHOWN DRIVER'S

RECLINING HANDLE

IS ALSO INBOARD.

R 939-C

FIG. 4 Reclining Seat and Mechanisms—Granada and Monarch Shown—Maverick and Comet Similar



41-35-1

Lumbar Power Seat

41-35

Lumbar Power Seat

SUBJECT PAGE


REMOVA L AND INSTALL ATION 35-1

TESTING

Seat M o t o r . . . ; 35 -4

SUBJECT

PAGE

TESTING (Cont'd.)

Seat Switch

35

Wiring Checks 35


LUMBAR POWER SEAT

The lumbar power seat provides

adjustable control of the contour of the

driver's seat. It enables the driver to

select the amount of support he desires

for the lumbar region of

his

back (Fig. 1).

It consists of a reversible motor

driven directly off of the battery, a driver

controlled switch for reversing the

motor's direction of rotation and a

mechanical drive train from the motor

output shaft to a metal plate which is

driven forward and backward to effect

the change in seat contour. The drive

train consists of a flexible drive cable, a

gearbox with a worm shaft output and a

lever between the worm shaft and seat

plate (Fig. 2).

When the lumbar power seat control

switch is pressed to the forward (OUT)

position, the motor drives the contour

plate toward the forward maximum

support position. When this switch is

pressed to the rear (IN) position the

motor drives the contour plate toward

the back minimum support position.

When the switch is released the contour

plate remains in the position selected by

the driver. The range of plate travel is 1.9

inches. The lumbar power seat adjuster

mechanism is installed into the seat back

assembly as a com plete assembly.

LUMBAR POWER SEAT

MECHANISM LOCATION

LUMBAR POWER SEAT

CONTROL SWITCH N2729-A

CR2017-A

MO

FLEXIBLE DR

ADJUSTOR PLA

FIG. 1 Lumbar Power Seat

GEARB OX LEVER ASSEMBLY

FIG . 2 Lumbar Power Seat

Mechanism

N27


Removal

1. Disconnect the seat back control

wiring assembly connector sleeve

from the body main wiring assembly.

Use Fig. 3 as a guide.

2.

Remove the driver's seat and track

assembly from the vehicle and place

on a clean work surface. Refer to

Group 41 for removal procedure of

the complete seat and track assembly.

3. Use a putty knife or a similar tool to

pry loose the four retaining clips

which secure the front seat back rear

panel assembly to the back assembly

of the front seat on those vehicles

equipped with the optional Midas

trim (Fig. 4).

4. Remove the front seat back shield

assembly four retaining screws and

separate the shield from the seat back

(Fig. 4).

5. Disconnect the front seat back

control wiring assembly at the motor

connector and wiring locator retainer

(Fig. 3).

6. Tilt the seat back assembly forward

and disengage the outboard retainer

and pivot pin (Fig. 3).

7. Disengage the inboard pivot pin from

the center pivot hole and remove the

seat back assembly from the cushion

and place on a clean work surface.

8. Disengage the front seat back cover

plastic retainers and four hog rings

and pull back the cover sufficiently to

gain access to the adjustor assembly

attaching screws (Fig. 4).

9. Remove the five attaching screws

which secure the adjustor assembly to

the front seat back pad (Fig. 5).

10. Slide the front seat back pad adjuster

assembly downwards so that it slides

out the bottom of the seat b

between the seat back pad and fra

11. Cut and remove the three plastic

holding the motor wiring and m

drive cable together.

12.Remove the lower two mo

mounting screws and separate

motor and bracket assembly (Fig

13.Unsnap the motor wiring conne

from the retainer and remove

motor and bracket assembly.

14. Remove the two shaft support bra

attaching bolts and separate

bracket from the support assem

and the shaft assembly (Fig. 6).

15. Remove the shaft assem bly

spacer from the drive levers and

support assembly.

16.

Remove the two p late atta ch

retainers, pins, and springs



41-35-2

Lumbar Power Seat

41-35-2

disengage the plate from the shaft

assembly (Fig. 6).

17. Remove the two gear assembly

attaching bolts and nuts and cable

retainer (Fig. 6).

18.

Disengage and remove the cable

assembly from the gear assembly (Fig.

6).

19. Remove the gear assembly and the

drive assembly.

20. Remove the front seat back latch

handle attaching screw and remove

the handle (Fig. 3).

21.

Remove the four front seat cushion

side shield assembly attaching screws

(Fig. 3).

22.

Remove the two front seat back

switch bezel attaching nuts and

remove the side shield and bezel from

the cushion (Fig. 3).

23 . Disconnect the control switch

assembly from the seat back control

wiring assembly and remove the

switch (Fig. 3).

24. Turn the front seat cushion upside

down and remove the two wiring

shield attaching screws and remove

the seat back control wiring assembly

Installation

1. Turn the front seat cushion upside

down and insert the seat back control

wiring assembly. Fasten in place with

the two wiring shield attaching screws

(Fig. 3). Return seat cushion to

upright position.

2. Connect the control switch assembly

to the seat back control wiring

assembly (Fig. 3).

3. Insert the front seat back switch bezel

in the front seat cushion side shield

assembly and push threaded studs on

the bezel through the control switch

assembly/Install the attaching nuts

and tighten (Fig. 3).

4.

Position the front seat cushion side

shield assembly to align the shield

screw holes with those in the seat

cushion (Fig. 3). Install and tighten

the four front seat cushion side shield

assembly attaching screws.

5. Insert the front seat back latch handle

through the shield onto the seat

cushion latch and attach with screw

(Fig. 3).

6. Connect the flexible drive cable to the

gear assembly using the cable retainer

and mount the gear assembly to the

support assembly with attaching

bolts.

7. Install the two plate attaching

retainers, pins, and springs to attach

the plate to the shaft assembly.

NOTE: A No. 8-32 x 1-1/2 inch

pan head screw can be used as a

service replacement for the pin and a

No. 8-32 hex nut and washer can be

used for the retainer.

8. Install the shaft assembly through the

MOTOR CONNECTOR & WIRING

LOCATOR RETAINER

SEAT BACK CONTROL

WIRING ASSY. (14B719)

CONNECTOR SLEEVE

TO

BODY MAIN WIRING ASSY

(14A005)

SCREW 2 REQ'D

(56904)

SCREW

2

REQ'D.

(56910)

RETAINER (38374C

PIVOT PIN (611B24

LATCH HANDLE (67622)

& SCREW (51763)

SCREW 2 RHQ'D.

(56902)

SHIELD (6:?185)

NU T 2 REQ'D

(370713)

SWITCH (14529)

BEZEL (13C704)

N2J33-A

FIG. 3 Lumbar Power Seat Wiring—Driver's Side

PANEL ASSY. (60762)

MIDAS OPTIONAL TRIM

VEHICLES ONLY

DRIVER'S FRONT

SEAT BACK ASSY

CLIP4 REQ'D.

(371520)

SCREW 4 REQ'D.

(56914)

REMOVE SEAT BACK COVER ASSY.

SUFFICIENTLY TO GAIN ACCESS TO

ADJUSTOR ATTACHING SCREWS

N:?V34-A

FIG.

4

Driver's Side Front Seat Back Panel Assembly

drive assembly, the spacer and into the

support assembly. Insert the other

end of the shaft assembly into the

shaft support bracket and mouni the

shaft support bracket to the support

assembly (Fig. 6).



41-35-3

Lumbar Power Seat

41-35

9. Mount the motor and bracke t

assembly to the support assembly

using the mounting screws.

10. Snap the motor wiring connector into

the retainer on the motor and bracket

assembly.

11.

Use tape or adjustab le straps to

bundle the drive cable and wiring

harness together (Fig. 6).

12.

Slide the assembled front seat back

pad adjuster assembly up into

position between the seat back pad

and frame and secure it to the front

seat back pad using the five attaching

screws (Fig. 5).

13.

Insert the front seat back cover plastic

retainers and hog rings to replace the

plastic back cover.

14.

Mate the seat back assembly to the

cushion by inserting the inboard pivot

pin in the pivot holes of the back

assembly and cushion pivot brackets.

15.

Tilt the seat back assembly forward

and insert the outboard retainer and

pivot pin (Fig. 3).

16.

Connect the front seat back control

wir ing assembly a t the motor

connector and wiring locator retainer

(Fig. 3).

17. Insta ll the front seat back shield

assembly on the seat back using the

four retaining screws (Fig. 4).

18. Secure the front seat back rear panel

assembly to the back assembly of the

front seat on those vehicles equipped

with the optional Midas trim, using

the four retaining clips (Fig. 4).

19.

Install the d river's seat and track

assembly in the vehicle. Refer to

Group 41 for installation procedure

of the complete seat and track

assembly.

20. Connect the seat back control wiring

assembly connector sleeve from the

body main wiring assembly (Fig. 3).

FRONT SEAT BACK PAD ASSY.

SCREW 5 REQ 'D.

(384653)

FRONT SEAT BACK

PAD SHIELD (PLASTIC)

(610A68)

FRONT SEAT BACK PAD ADJUSTOR

ASSY. (D5LB-6565500-AB)

NOTE: SEAT BACK TRIM COVER ASSY. & PAD ASSY. REMOVED FOR

ILLUSTRATION PURPOSES ON LY - THEY DO NOT HAVE TO BE

REMOVED TO REMOVE THE ADJUSTOR ASSEMBLY

N273

FIG. 5 Driver's Side Front Seat Back Internal Assemblies

CABLE ASSY. (65502)

CABLE RETAINER (65503)

GEAR ASSY. (65516)

MOTOR WIRING

CONNECTOR

MOTOR & BRACKET

ASSY. (14C696)

CABLE &WIR INGTIES3 REQ'D .

SHAFT SUPPORT BRA

SUPPORT ASSY

(65514)

SPACER (373596)

SHAFT ASSY. (6551

DRIVE ASSY

(65504)

RETAINER & PIN 2 EA. REQ'D.

N27

FIG .

6 Driver's Side Front Seat Back Pad Adjuster Assembly



41-35-4 Lumbar Power Seat

41-35-4

TESTING

MOTOR TEST

To test the current draw of the

lumbar power seat adjuster assembly

motor, remove the adjuster assembly

from the front seat back assembly using

the procedure provided under Removal

and Installation and remove the motor

from the adjuster assembly as instructed

in this procedure.

Test Procedure

1.

Connect an external power source

(Power Pac or a fully charged battery)

to the motor with an ammeter in

series as shown in Fig. 7.

2. Observe the current draw. It should

not exceed specifications and should

not fluctuate. Reversal of the motor

wire connections will reverse the

direction of motor rotation. If current

draw exceeds the specified value

check for binding of the motor shaft

and replace the motor if the binding

is not correctible.

SEAT SWITCH TEST

Testing of the lumbar power seat

adjuster switch should be performed with

the switch removed from the vehicle. Use

a self-powered test light or an ohmmeter.

Test Procedure

1. With the switch in the neutral

position, there should be continuity

between terminals 1 and 3, 2 and 5,

and 4 and 6 (Fig. 8).

2.

With the switch toggle pushed

downward, there should be continuity

between terminals 2, 4 and 5, and 1

and 3 . Te r min a l 6 s hou ld be

disconnected from every other

terminal.

3. With the toggle switch pushed

upward, there^ should be continuity


and 6 . Te r m ina l 1 s hou ld be

d i s connec ted f rom any o the r

terminal.

4.

If the switch does not test correctly,

replace the switch.

W IRING CHECKS

Refer to the wiring diagram in

Fig.

9

when performing continuity checks

between the battery and switch and

between the switch and motor.

N2370-B

FIG. 7 Adjuster Motor Current Draw Test

CONTROL SWITCH (SAME PART

AS WINDOW REG. CONTROL

SINGLE SWITCH ASSY. 14529)

SEAT BACK CONTROL

WIRING ASSEMBLY (14B719)"

POWER SW ITCH TEST

BEZEL ATTACHING

HOLES 2 REQ'D.

.TO FRONTOF VEHICLE

(?) GROUND OR HOT FEED

( D POWER FEED

(3) MOTOR TER MINA L - FORWARD MOVEMENT

(4) MOTOR TERMINA L - REARWARD MOVEMENT

(5) BLANK (BUSS BAR TO PIN NO. 2)

(§) GROUND OR HOT FEED

N2731-B

FIG.

8 Switch Pin Locations



41-35-5

Lumbar Power Seat

41-35

TO 14630 FOR R.H.

POWER SE AT

51 A

51B-

51 (14631)

51 (14401)

30 AMR C.B.

37

BATTERY

FUSE PANEL

N2732-A

FIG.

9 Wiring Diagram



41-40-1

Head Restraints

41-40-1

Head Restraints

P A R T

41-40

SUBJECT

PAGE SUBJECT

PAGE

DESCRIPTION

AND

OPERATION

40-1


Mounting Bracket and Catch Assembly

40-2

REMOVAL

AND

INSTALLATION

Head Re straints

40-2


CR2018A

All vehicles (except high back bucket

seats) are equipped with a single post-

design head restraint.

The head restraint has a single post with

notch, to engage a spring-loaded ca tch in the

mounting bracket. The mounting bracket

retains the post and guide sleeve, as shown

in Fig. 1. The mounting is a part of the seat

back assembly. A shoulder strap loop

attaches to the head restraint on Ford,

Mercury, and Mark V 2-door m odels.

LOOP -

60611C32 (R.H.)

60611C33 (L.H.)

HEAD RESTRAINT

- 6 5 6 1 1 A 0 8

S C R E W -

40927

(4 PLACES)

TO FRONT

ASSEMBLED

MARK

V

SHOWN

-

FORD. MERCURY

AND LINCOLN SIMILAR

SCREW

40927

(4 PLACES)

(TORQUE TO 45-95

IN.-LBS.)

MAVERICK -COMET SHOWN-

THUNDERBIRD,

LTD II ,

COUGAR,

GRANADA, MONARCH, PINTO AND

BOBCAT SIMILAR

R1J80-G

FIG.

1

Front Seat Headrest Installation—Typical



41-40-2

Head Restraints

41-4


HEAD RESTRAINT

Removal

The head restraint is removed by

pulling the head restraint post upward

and ou t of the guide sleeve and m ounting

bracket.

If the mounting bracket spring clip

will not disengage from the detent on the

head restraint post to allow removal (Fig.

1), insert a 12-inch length of thin flat

stock into the sleeve at the front side of

the post and push the spring clip out of

the detent while withdrawing the head

restraint.

The guide sleeve is removed by

pulling the sleeve out of the mounting

bracket after first removing the head

restraint. Occasionally, i t may be

necessary to trip the locking tab on the

guide sleeve in order to remove it from

the bracket (Fig. 1). Insert a short piece

of wire having a hooked end into the

sleeve, hook onto the locking tab and pull

it inward. On cars equipped with the

flight or split bench seat, it may be

necessary to remove the front seat back

trim panel to release the head restraint.

Installation

The head restraint is installed by

inserting the post into the sleeve in the

seat back. It can be adjusted by app

hand pressure , e i ther upwar

downward, to the center area of the

restraint assembly. The head res

must operate smoothly througho

full range of travel and must rem

any fixed position.

MOUNTING BRACKET AND

CATCH ASSEMBLY

Remove the head restraint and

assembly from the sleeve and remo

sleeve. Remove the seat back trim

for access, and remove the screw

retain the mounting bracket t

mounting in the seat back.



41-50-1

Seat and Shoulder Belts

41-50-1


P A R T

41-50

SUBJECT PAGE

GENERAL INFORMATION 50-1


Descript ion 50-1

Operation 50-2

RE M OV A L A ND I NS TA LLA TI ON

Front Seat Belt Retractor

and Harness Assem bly 50-3

Rear Seat Belt Retracto r Assembly 50-12

SUBJECT PAGE


Cleaning 50-13

Seat and Shoulde r Belts 50-12

Seat and Shoulder Harness Belt With

Damaged Anc ho r Plate Threads 50-12

Seat Belt With No Anchor Plate

Thread Damage 50-12

CR2019 A

GENERAL INFORMATION

Two distinct front outboard seat belt

systems are being installed in 1977. One

system, used in previous years, is the

three point system. A new system is also

used and it is called the continuous loop

system.

The thre e point system has a fixed

tongue on the front outboard lap/

shoulder belt and two retractors. The

continuous loop system has a movable

tongue on the front outboard lap/

shoulder belt and only one retractor.

The seat belts and shoulder belts are

factory installed in their proper locations.

If the seat belts or shoulder belts are

removed for any reason, they should be

installed as shown in Figs. 3 through 16.

Sealer should be placed around all seat

belt anchor bolt holes in the floor pan.

Tighten the anchor bol ts to the

specification shown at the end of this

Part.

Belt assemblies must be installed in

matched sets as received and must not be

interchanged between vehicle models.

If a component portion (buckle

portion, retractor portion, etc.) of a seat

belt or shoulder belt assembly is

nonfunctional or damaged, the entire

assembly (buckle, tongue and shoulder

harness portions) must be replaced.

The

replacement assembly must be installed

as a matched set and the identification

labels on all portions must bear exactly

the same code, date of manufacture and

m a n u f a c t u r e r ' s n a m e . U n d e r n o

circumstances are seat belt or shoulder

belt components to be replaced as

individual components.


DESCRIPTION

Both systems incorporate a buzzer

and light w arnings. The seat belt warning

light illuminates for about eight seconds

after the ignition switch is turned on—

regardless of seat belt usage. The seat belt

warning buzzer is grounded by a switch

in the left lap retractor, on the three point

system and by a switch in the left inboard

buckle on the continuous loop system.

The seat belt warning buzzer will sound

for approximately eight seconds unless

the driver's belt is used.

When the occupant restraint system

for front outboard passengers is a 3-point

sy s tem, the outboard lap belt and

shoulder harness are sewn together at the

tongue. To secure the belts, the tongue is

inserted into the buckle.

On the three point system, the

webbing for the lap belt extends from a

belt retractor that automatically locks

when the belt is being worn. This lock

prevents the belt from being pulled out

further, but allows the belt to retract, and

thus maintains a snug fit around the user

for optimum safety. This lap belt

retractor is located

on

or

in

the rocker

panel (depending on car line and model).

With the continuous loop system, the

outboard lap/sh ould er bel t uses a

common sliding tongue. To secure, insert

the tongue into the inboard buckle.

The webbing for the lap belt is

anchored to the side of the sill without

a retractor.

On both systems, the shoulder

harness webbing has the other end fixed

in a retractor, which is located in or on

the rocker, in the " B" pillar post or in the

quarter panel (depending on car lint; and

model). The Mustang, Pinto, Bobcat,

Thunderbird, Ford, Lincoln, Granada

and Monarch (2-doors) shoulder har-

ness retractor is located in the quarter

panel. The Mark V shoulder belt

retractor is located in the headlining

above the opera window. This webbing



41-50-2


4 1 - 5

then passes through a guide above and

behind the occupant's shoulder which

directs the webbing at the proper

downward angle over the occupant's

shoulder and chest, and attaches to the

lap belt connector.

The shoulder harness

retractor is designed to let the webbing

freely move in or out at all times, except

during vehicle deceleration, when it is

automatically locked by a mechanically

actuated inertia sensor (Fig. 1).

The inboard belt with the buckle

passes through the seat on bench seat

installations and directly to a fixed

anchorage on the floor on bucket seat

installations. Attaching the tongue and

buckle secures the occupant with both

lower and upper res t ra in ts . This

attachment of the tongue and buckle can

be accomplished by a single continuous

movement.

The 2-point system (lap belts only)

continues for the front seat center

position and all rear seat positions.

OPERATION

To fasten the front lap shoulder belts

after entering the car on the three point

system, adjust the front seat to obtain the

best position for your driving comfort

and visibility. Then, use the following

sequence for fastening belts.

1. Pull the lap-shoulder belt from the

retractor in one continuous motion,

so shoulder portion of belt crosses

your shoulder and chest and insert the

belt tongue into the proper buckle. If

the pulling motion is interrupted

while extending the belt, it may be

necessary to return the lap belt to the

stowed, or fully retracted positon, in

order to release the stop mechanism

in the lap portion of the belt.

2. Adjust lap portion of seat belt snugly

around the hips

—not the waist, by

allowing any excess belt to return into

the retractor.

3.

The shoulder restraint portion of the

belt adjusts automatically to a snug

position. The inertia reel attached to

the shoulder belt allows freedom of

movement, locking tightly only on

h a r d b r a k i n g o r i m p a c t s o f

approximately 5 mph or more. The

reel cannot be made to "lock up" by

jerking on the webbing.

Front Center Lap Belt

The center seat belts do not have

retractors. To lengthen the belt, tip the

tongue.

To fasten the belt, insert the tongue

into the open end of the buckle until you

hear a snap. Shorten the belt, if necessary,

by pulling on the loose end of the

webbing. The belt should be snug across

the hips; never across the waist.

Webbing Cannot Be Pulled From

Lap Belt Retractor

F ord ,

Merc ury, Linco ln Continental -

Al l Models Cougar, Thund erbird ,

Continental Mark V, and LTD I I

(2-Door Models)

1. Pull webbing from the shoulder

harness retractor, allowing the lap

belt to retract fully into the retra

Pull webbing from the lap

retractor.

2. If OK, withdraw lap belt webbin

buckle up while sitting in seat. Re

five times to insure proper oper

If not OK, replace the seat

assembly.

3. If the webbing does not come

from lap belt retracto r, uns

retractor cover door and disen

locking bar from the ratchet

(Fig. 2). (Use a small com

screwdriver which has no burr

sharp edges.) Hold the locking

down and pull the webbing from

retractor. Inspect the webbing

foreign material and/or twist

remove. Allow webbing to retrac

the retractor. Withdraw lap

webbing and buckle up while si

in seat. Repeat five times to in

proper operation. If not OK, rep

the seat belt assembly.

LTD II and Cougar—(4 Door

Models)

1. Pull webbing from the shou

harness retractor, allowing lap b

retract fully into the retractor.

webbing from the lap belt retrac

2. If OK, withdraw lap belt w ebbin

buckle up while sitting in seat. Re

five times to insure proper oper

If not OK, replace the seat

assembly.

3. If the webbing does not come

from lap belt retractor, remove c

pillar tr im cover and seat

LOCKED POSITION

FREE POSITION

R187

FIG. 1 Shoulder Harness Retractor



41-50-3


4 1 - 5 0 - 3

retractor. Pull the retractor cover

away from retractor frame at the area

of the attaching bolt hole and

disengage locking bar from the

ratchet gear. (Use a small common

screwdriver which has no burrs or

sharp edges.) Hold the locking bar

down and pull the webbing from the

retractor. Inspect the webbing for

foreign material or twisting. Remove

foreign material or roping/twisting.

Allow webbing to retract back into

retractor. Cycle retractor five times,

if not OK, replace the seat belt

assembly.

4.

If OK, reinstall in vehicle. Withdraw

lap belt webbing and buckle up while

sitting in seat. Repeat five times to

insure proper operation. If not OK,

replace the seat belt assembly.

Thunderbird, Maverick and

Comet—All Models

1. Pull webbing from the shoulder

harness retractor, allowing lap belt to

retract fully back into the retractor.

Pull webbing from the lap belt

retractor.

2.

If OK, withdraw lap belt webbing and

buckle up while sitting in seat. Repeat

five times to insure proper operation.

If not OK, replace the seat belt

assembly.

3.

If the webbing does not come loose

from the lap belt retractor, visually

check the webbing inside the snout

(look down the snout opening) for


roping by untwisting belt. Remove

foreign material with tweezer or any

appropriate tool that does not have

burrs or sharp edges that would

damage the webbing. Allow webbing

to re t ract back in to re t ractor .

Withdraw lap belt webbing and

R1874-A

FIG. 2 Disengaging Seat Belt

Retractor Locking Bar

buckle up while in seat. Repeat five

times to insure proper operation,

4.

If not OK, tighten the webbing on the

spool in the retractor, by trying to

pull the webbing from the retractor.

(Use both hands to pull webbing.)

Allow webbing to retract by pushing

the webbing into the retractor.

Withdraw webbing and inspect for


foreign material or roping/twisting.

Withdraw lap belt and buckle up

while in seat. Repeat five times to

insure proper operation. If not OK,

replace the seat belt assembly.

Lap Belt Retractor Does Not Lock

Lap Belt Retractor Does Not Lock

Ford ,

Mercury, Lincoln Continental

—

All Models Cougar, Thunderbird,

Continental Mark V and LTD II

(2-Door Models)

1. Withdraw a minimum of 18 inches of

webbing from lap belt retractor and

check for lock-up. (Retractor must

lock-up after 18 inches of webbing

withdrawal.) Return 2 inches into

retractor and pull out.

2.

Unsnap retractor cover door and

check locking bar spring. Pull

webbing from the lap belt retractor

and check for broken spring on

locking bar by moving locking bar

away from ratchet gear. (Use a small

common screwdriver which has no

burrs or sharp edges.) Spring should

fo rce lock ing ba r back in to

engagement with ratchet gear (Fig.

2).

3.

If not OK, replace the seat belt

assembly. If OK, check locking bar

for foreign material. Remove foreign

material. Withdraw lap belt webbing

and buckle up while sitting in seat.

Repeat five times, to insure proper

operation. If not OK, replace the seat

belt assembly.

LTD II and Cougar (4-Door

Models)

1. Withdraw a minimum of 18 inches of

webbing from lap belt retractor and

check for lock-up. (Retractor must

lock-up after 18 inches of webbing

withdrawal.) Return 2 inches into

retractor and pull out.

2.

Remove center pillar trim cover and

seat belt retractor. Pull the retractor

cover away from retractor frame at

the area of attaching bolt hole and

check for broken spring on locking

bar, by moving locking bar away from

ratchet gear. (Use a small common

screwdriver which has no buns or

sharp edges). Spring should force

locking bar back into engagement

with ratchet gear (Fig. 2).

3. If not OK, replace seat belt assembly.

If OK, check locking bar for foreign

material. Remove foreign material.

Withdraw lap belt webbing and allow

to retract. Repeat five times to insure

proper operation. If not OK, replace

seat belt assembly. If OK, install in

vehicle and withdraw lap belt and

buckle up while sitting in seat. Repeat

five times to insure proper operation.

If not OK , replace seat belt assembly.


FRONT SEAT BELT RETRACTOR

AND HARNESS ASSEMBLY

2-Door Mercury, Cougar, LTD II

and Thunderbird

NOTE: Figs. 3 and 4 show the front

seat belt, shoulder harness, inboard and

outboard locations. Tool T70P-2100B (or

equivalent) should be used for Removal

and Installation. Refer to Group 45 for

trim removal.

1. Fold back the 9 inch sling "boot"

cover (portion covering the roof rail

anchor bolt) and remove the anchor

bolt.

2.

Unlatch the inboard attachment boot

cover and remove the anchor bolt

attaching the front inboard belt and

buckle assembly.

3. Remove the belt and buckle assembly

by pulling the attaching anchor plate

through the seat grommet.

4.

Flip over the cover on the dual

retractor boot (mounted on top of the

sill).

5.

Disconnect the electrical connector

located at the front of the dual

retractor boot on the driver's side.

6. Remove the two (2) anchor bolts

attaching the dual retractor assembly

and remove the retractor assembly.

Installation

To assemble, reverse the preceding

steps.

Torque all bolts to 22-32 ft-lbs.

Cycle system several times to assure

proper retractor operation.

2-Door Ranchero (Standard

System)

1.

Unlatch shoulder strap boot and

remove roof rail anchor bolt attaching

the shoulder belt (Fig. 4).

2.

Unlatch the inboard attachment boot

cover and remove the anchor bolt



41-50-4


41-50

VIEW A

V I E W B

V I E W C

V I E W D

F IG .

3 Front Seat Belt Installation—Mercury, Thunderbird, and LTD II

R1

COVER

VIEW A

V I E W B

V I E W C

V I E W D

V I E W E

R1

FIG. 4 Front Seat Belt Installation—2-Door LTD II and Ranchero



4 1 - 5 0 - 5


41-50-5

attaching the front inboard belt and

buckle assembly.

3. Remove the belt and buckle assembly

by pulling attaching anchor plate

through the seat grommet.

4.

Flip open the cover on the dual

retractor boot (mounted on top of the

sill).

5.

Disconnect the electrical connector

located at the front of the driver's side

retractor boot.

6. Remove the two (2) anchor bolts

attaching the dual retractor assembly

and remove the retractor assembly.

Installation


steps. Torque all attaching bolts to 22-32

ft-lbs. Cycle system several times to

assure proper operation of the retractor.

Maverick and Comet (2-Door

Models)

Removal

1. Remove the bolt attaching the

shoulder harness sling at the roof rail

(Fig. 5).

2.

Remove the front seat assembly. See

Part

41-01.

3. Remove the bolt from the front

inboard belt.

4.

Remove retractor cover-to-quarter

trim panel screw.

5.

Remove the scuff plate.

6. Unsnap three covers in the retractor

assembly and remove the retractor

assembly (three (3) bolts).

Installation





4-Door Maverick and Comet

1. Remove the bolt attaching shoulder

harness "D" ring on "B" pillar (Fig.

6).

2.

Remove the front seat assembly, see

Part 41-01.

3.

Remove the scuff plate.

4. Remove " B " pillar trim covers.

5.

Remove shoulder harness retractor.

6. Remove the bolt from the front

inboard belt.

7. Unsnap the cover in the retractor

assembly and remove the retractor

assembly (two (2) bolts).

Installation





4-Door Ford, Mercury, and

Lincoln Continental

Removal

1. Unsnap the cover on upper " D " ring

attachment and remove the attaching

bolt (Fig. 7).

2.

Remove upper and lower "B " pillar

trim panels.

3. Remove the bolt from the upper

retractor and remove the retractor

from the pillar.

4.

Unsnap the driver's side front cover

from the retractor on top of sil I and

disconnect electrical connector.

5. Unsnap the other cover on the

retractor assembly, remove the

at taching bol t and remove the

retractor assembly.

6. With the seat in full forward position,

remove the center anchor cover by

spreading sides and lifting off cover.

7. Remove bolt attaching buckle ends.

Installation




assure proper operation of retractors.

4-Door LTD II and Cougar

1. Unsnap the cover on upper " D " ring


bolt (Fig. 8).

2.

Remove upper and lower "B ' pillar

trim panels.

3. Disconnect driver's side electrical

connector from the lower retractor.

VIEW A ACCESS HOLE COVERS

FIG. 5 Front Seat Belt Assemblies—2-Door Maverick and Comet

V I E W B

BUCK ET SEAT BENCH SEAT

H1587-A



41-50-6


4 1 -

VIEW A

VIEW B R1

F IG . 6 Front Seat Belt Assembly—4-Door Maverick and Comet

INBOARD ATTACHMENT

V I E W D

OUTBOARD ATTACHMENT

(MODEL 57 ONLY)

TO FRONT OF VEHIC

VIEW A

V I E W B

V I E W C

V I E W E

F IG .

7 Front Seat Belt Assemblies—4-Door Ford, Mercury and Lincoln Continental



41-50-7


41-50-7

FRONT SEAT BELT ASSEMBLY

OUTBOARD ATTACHMENT

4 DOOR MODELS

FRONT SEAT BELT ASSEMBLY

INBOARD ATTACHMENT

R1589-C

FIG.

8 Front Seat Belt Assemblies—LTD II and Cougar

4.

Remove the bolt from the upper


from pillar.

5.

Remove the bolt from the lower


assembly.

6. With seat in full forward position,

remove center anchor cover by

spreading sides and lifting off cover.

7. Remove the bolt attaching the buckle

ends.

8. Pull the buckle through the seat

assembly.

Installation


steps.

Torque all attaching bolts to 22-32


assure proper operation of retractors.

Pinto/Bobcat and Mustang (All

Models) Granada/Monarch (Two-

Door Models)

Removal

1. Remove the outboa rd front seat belt-

to-sill attaching bolt and rubber

washer (Fig. 9, View AA).

2. Unsnap the Guide Cover at the upper

attachment and remove the Seat Belt

Guide attaching bolt. (Fig. 9, View

BB).

3.

Remove the rear seat cushion and

back (refer to Part 41-14 and 41-20).

4. For Pinto, Bobcat and Mustang,

remove the quarter trim panel. On

M u s t a n g G h i a a n d G r a n a d a /

Monarch remove the roof side rear

trim panel before the quarter trim

panel. (Refer to Part 45-03.) (Fig. 9,

Views

CC—1,

2, 3, 4 and 5.)

5. Disengage the front seat belt opening

bezel from the opening in the quarter

trim panel for the standard Mustang,

Pinto and Bobcat. Remove the belt

from the exit slit in the bezel and

pa ne l . For M us ta ng G hia a nd

G r a n a d a / M o n a r c h m o d e ls ,

disengage the belt from the exit slit in

the roof side rear trim panel.

6. Remove the quarter panel mounted

retractor attaching bolt and remove

the outboard front seat belt assembly

from the vehicle. (Fig. 9, Views DD —

1, 2, and 3.)

NOTE: Pinto and Bobcat station

wagons outboard front seat belt sill

attaching end, boot, guide, tongue

and stop must be threaded through

the inside quarter panel from the top

after removing the retractor.

7.

RH Inboard Front Seat Belt and

Buckle removal procedure is: With

the seat in the forward position to

provide access, lift or slide the lower

end of the buckle end boot, remove

the front seat belt and buckle

assembly attaching bolt and remove

the assembly from the vehicle. (Fig.

9, Views EE—1 and 2.)

8. LH Inboard Front Seat Belt and

Buckle Assembly: With the seat

forward, disconnect the seat belt

warning buzzer wiring connector at

the lower end of the LH buckle end

boot, lift or slide (as applicable) the

lower end, remove the attaching bolt

and remove the assembly from the

vehicle.

Installation

To re-assemble, reverse the preceding


ft-lbs and cycle the system several times

to assure proper operation of the

retractor.

Granada/Monarch Four-Door

Models—Front

Removal

1. Remove the outboa rd front seat belt-

to-floor attaching bolt (Fig. 10, View

AA).

2. Unsnap the "D " Ring Guide Cover

at the upper attachment and remove

the belt guide attaching bolt (Fig. 10,

View BB).

3.

Remove the Center Pillar trim (Refer

to Part 45-03) and disengage the belt

from the exit slot in the center

body pillar inside finish panel (Fig.

10,

View CC).

4. Remove the center pillar mourned

retractor attaching bolt and remove

the outboard front seat belt assem bly

from the vehicle (Fig. 10, View DD).

5. RH Inboard Front Seat Belt and


forward, lift the lower end of

the

boot



41-50-8


4 1 -

PINTO-BOBCAT-MUSTANG (ALL)

GRANADA-MONARCH (2 DOOR)

386227


GRANADA-MONARCH (2 DOOR)

60262

V I E W - B B

PINTO-BOBCAT (2- AND 3-DOOR)

V I E W - C C

1

MUSTANG (ALL EX CEPT GHIA) GRANADA-MONARCH (2-DOOR)

V I E W - C C 2

V I E W - C C

3

PINTO-BOBCAT (STATION WAGON)

G R O M M

602A14

SLEEVE

337215

V I E W - C C

4

MUSTANG (GHIA) PINTO-BOBCAT (ALL)

VIEW - CC

5

MUSTANG (ALL)

386277

VIEW

V I E W - D D 2

GRANADA-MONARCH (2-DOOR)


GRANADA-MONARCH (2-DOOR

GRANADA MONARCH (2-DOOR

WITH BENCH SEAT)

WITH BUCKET SEATS)

VIEW-DD

3

L.H. BELT HAS

WIRE AND CONN.

SEALER

(.19

FLIGHT BENCH

V I E W - E E 2

N2

F IG . 9 Front Outboard Seat Belts—Pinto, Bobcat and Mustang (All Models); Monarch and Granada (2 Doors)




41-50-9

386227

FLIGHT BENCH SHOWN

V I E W - B B

60262

VIEW CC

V I E W - E E 1

ESB-M4G32-A -

SEALER (.19DIA.)

VIEW- EE

2

VIEW FF

ESB-M4G32-A -

SEALER (.19 DIA.)

BUCKET

FLIGHT BENCH

N2900A

10 Front Outboard Seat Belts—Granada and Monarch (Four Doors)



41-50-10


41-50

and remove the front seat belt and

buckle assembly attaching bolt.

Remove assembly from vehicle (Fig.

10,

View EE—1 and 2).

6. LH Inboard Front Seat Belt and


forward, disconnect the seat belt

warning wiring connector at the

lower end of the boot. Remove the

attaching bolt. Remove the assembly

from the vehicle.

Installation



ft-lbs. Cycle the system several times to


MarkV

NOTE: Fig. 11 Views A, B, C show

the Front Seat Belt and Shoulder Belt

Inboard and Outboard Locations. Tool

T70P2100B should be used for Removal

and Installatioil. Refer to Group 45 for

Trim Removal.

Removal

1. Remove the shoulder belt retractor

cover attaching screws (2).

2.

Remove the shoulder belt retractor

attaching screws (2). Lower Assy, to

rear floor (Fig. 11).

3. Unsnap "footman's loop".

4.

Remove the plug from the front of the

lap belt retractor cover. (Driver's side

only.)

5.

Disconnect the driver's side seat belt

electrical connector from left lap belt

retractor.

6. Remove the plug from the side of the

lap belt retractor.

7. Remove the one bolt from th e lap belt

retractor assembly and remove the

retractor assembly.

8. With the seat in the full forward

position, remove the center anchor

cover by spreading the sides and

lifting off the cover.

9. Remove the bolt attaching the buckle

ends.

10.

Pull the buckle ends through the seat

assembly.

Installation



ft.-lbs.

and cycle the system several

times to insure proper operation of

the retractor.

2-Door Ford and Lincoln

Continental

1. Unsnap the cover on upper "D " ring


bolt (Figs. 12 and 13).

2.

Remove quarter trim panels, Part 43-

05.

3.

Lincoln Continental Only—Remove

the four (4) screws retaining the seat

belt guide.

4. Remove the bolt from the " B "

retractor and remove the retra

from the pillar.

5.

Unsnap the drive r's side front c

from the retractor on top of sill

disconnect electrical connector.

6. Unsnap the other cover on

retractor assembly, remove

at taching bol t and remove

retractor assembly.

7.

Remove the seat belt loop reta

,

from seat assembly.

8. With the seat in full forward posi

remove the center anchor cove

spreading sides and lifting off co

9. Remove bolt attaching buckle en

10. Pull buckle through seat assemb

11. Thread the center belt through

seat cushion bezel and insert.

12. Position the center belt assem

install the attaching bolt, tighte

specification and install the ce

anchor cover.

13.

Install the lower retractor (on

bolt) and tighten to specification

14.

Connect the driver's side elec

connector to the retractor assem

and install the access covers.

15.

Ins ta l l the " B " p i l lar re t ra

assembly and tighten to specifica

16.

Lincoln Continental Only—In

the seat belt guide with four

retaining screws.

17.

Install quarter trim panels.

V I E W - A A

V I E W - B B

VIEW CC V I E W - C C 1

R18

F IG . 11 Seat Belt Assembly Mark V



41-50-11


41-50-11

L.H. SIDE SHOWN, R.H. SIDE TYPICAL

VIEW C VIEW D

R1913B

FIG.

12 Front Seat Belt Assemblies—2-Door Ford

VIEW A

V I E W B

R1914 3

FIG. 13 Front Seat Belt Assemblies—Lincoln Continental



41-50-12


4 1 - 5 0

18. Install the shoulder harness and bolt

to the "B " p i l lar and " D " r ing

a t t a c h m e n t a n d t i g h t e n t o

specification. Make sure there is no

twist in the webbing.

19.

Install seat belt loop retainer to top of

seat assembly.

REAR SEAT BELT RETRACTOR

ASSEMBLY

2-Door Maverick, Comet, Pinto,

Bobcat and Mustang

1. Remove the left scuff plate assembly.

2.

Remove the front seat assembly as

outlined in Part

41-01.

3. Remove the retractor cover-to-

quarter trim panel (one (1) screw).

4.

Remove the driver's side access hole

covers on the retractor assembly,

disconnect the electrical connector.

Remove the retractor assembly (three

(3) bolts).

5.


back assembly as shown in Part 41-14

or P a r t 41 -20 (w h ichever i s

applicable).

6. Remove the seat belt bezel from the

quarter trim panel (Fig. 14).

7. Remove the quarter trim panel. See

Part

45-03.

8. Remove the retractor assembly (one

(1) bolt).

9. Position the retractor assembly,

install the retaining bolt and tighten

to specification.

10.

Position the quarter trim panel, insert

buckle end through the quarter trim

panel hole and install the bezel to

retain the buckle end. Then, secure

the quarter panel.

11. Install the rear seat back and cushion

assembly.

12.

Install the retractor assembly (three

(3) bolts) and tighten to specification.

Connect the wire to the driver's side

retractor and install the access hole

covers.

13. Install the pillar-to-quarter trim panel

cover (one (1) screw).

14.

Install the scuff plate.

4-Door Maverick and Comet

1. Remove the rear seat cushion and

back assembly as outlined in Part 41-

14.

2.

Remove the quarter trim panel seat

belt bezel.

3. Remove the sill panel scuff plate.

4.

Remove the quarter trim panel (Part

45-03) and remove the retractor

assembly (one (1) bolt, Fig. 15).

5. Position the retractor assembly,

install the attaching bolt and tighten

to specification.

6. Place the quarter trim panel

position, insert the tongue

through the quarter trim panel

and install the bezel to retain

buckle end.

7.

Install the quarter trim panel

scuff plate.

8. Install the rear back and cus

assembly.

Al l Except Maver ick and Com

(2-Door Models) Pinto, Bobca

and Mustang

To remove the rear seat belt retr

and/or seat belt assembly it wil

necessary to remove the rear seat cus

and back assembly (Fig. 16). Ref

Part 41-14. Then, remove the seat

and/or retractor bolt and remove

assembly.

Remember, torque the attaching

to specification when reinstalling.

Granada, Mo narch

1. Remove the rear seat cushion

back assembly as outlined in Par

14.

2.

Position the retractor assem

install the attaching bolts and tig

to specification. The anchor tabs

to be positioned according to ge

specifications.


SEAT AND SHOULDER BELTS

The seat belts and shoulder belts are

factory installed in their proper locations.

If the belts are removed for any reason,

they should be installed as shown in Figs.

3 through 16. Sealer should be placed

around all seat belt anchor bolt holes in

the floor pan. Tighten the anchor bolts

to specification, shown at the end of this

Part.

SEAT BELT WITH NO ANCHOR

PLATE THREAD DAMAGE

1. Remove the damaged bolt for the

anchor reinforcement and discard.

2.

Install a new bolt with the same part

number as indicated at the end of this

Part and tighten to specification.

SEAT AND SHOULDER HARNESS

BELT WITH DAMAGED ANCHOR

PLATE THREADS

1. Remove the broken or stripped bolt

and discard.

2.

Drill out the internal threads in the

seat belt anchor plate with a 27/64

inch drill. (Shoulder belt 13/32 inch

drill.)

3. Re-thread the anchor plate with a 1/

2-13 tap (seat belt).

R1

FIG. 14 Rear Seat Belt Assemblies—Maverick and Comet 2 Door—Mustan

Pinto and Bobcat



41-50-13


41-50-13

4. Blow out the chips.

5. Ins ta l l the a t tachment parts in the

sequence shown in Figs. 3 throu gh 19,

whichever is applicable. Tighten the

replacement bolt to specification, as

shown at the end of this Part. Original

parts are to be replaced with the

repair parts indicated in the seat belt

parts replacement charts at the end of

this Part . Unless specif ied in the

chart, use original parts.

6. When rep airing a mu ltiple belt and

attachment, install nut (382599-5100)

to the bolt in the tunnel area from the

underside of the floor pan. Tighten to

specification, shown at the end of this

Part.

CLEANING

Seat and Shoulder Belt Webbing

Clean the belt webbing with any mild

soap solution recommended for cleaning

upholstery or carpets; follow instruc tions

provided with soap. Do not bleach or re-

dye the webbing because it may weaken

it.

FIG . 15 Rear Seat Belt Assemblies—Maverick an d Co me t—4-D oor



41-50-14


41-50

ALL STATION W AGONS

ALL SEDANS AND HARDTOPS

EXCEPT GRANADA AND MONARCH

GRANADA AND MONARCH

VIEW A

15

C

V I E W B

SEAT BACK

SEAT CUSHION

V I E W D

VIEW - E

VIEW - F

R

F IG .

16 Rear Seat Belt Assemblies—Typical—Except Maverick, Comet, Mustang, Pinto and Bobcat



41-50-15


41-5015

SPECIFICATIONS

PARTS REPLACEMENT CHART - SEAT AND SHOULDER BELT WITH DAMAGED WELD NUT ANCHOR PLATE THREADS

ORIGIN AL PARTS - SEAT BELT

Part No.

386273-S100

386274-S100

D2AB-65612A16-AA

382629-S100

382583-S100

3862702-S100

386276-S100

386277-S100

0 C o d e

Letter

IA

IB

-

•x-

-

IF

IL

IK

Part Name

Bolt - 7/16-20 x 1.38 Pan Head Tapping

Bolt - 7/16-20 x 1.75 Pan Head Tapping

(.50 Shoulder)

Spacer - Se rrated 1/2 x .30

Washer - .463A443 I.D. Plate

(1.80 Dia. .190 Thick)

Washer-1/2 Serrated (.18 Thick)

Bolt -

7/16-20

x .88 Pan Head Tapping

Bolt -

7/16-20

x 1.75 Pan Shoulder Tapping

(.75 Shoulder)

Bolt - 7/16-20 x 1.38 Pan Shoulder Tapping

(.50 Shoulder)

ORIGINAL PARTS - SHOULDER BELT

Part No.

386278-ST00

0 C o d e

Letter

ID

Part Name

Bolt -3 /8 -1 6 x 1.50 Pan Head Tapping

REPLACEMENT PARTS - SEAT BELT

Part No.

383531-S36

383753-S36

382553-S100

382522-S100

382533-S100

383437-S36

383754-S36

385709-S36

0Code

Letter

X

Y

-

-

-

W

z

T

Part Name

Bolt -

1/2-13

x 1.38 Pan Locking

Bol t -

1/2-13

x 1.75 Pan Locking

(.50 Shoulder)

Washer 9/16 Flat To Be Used

With Repair of 386274-S100

Bolt Only When Required

Washer- 1/2 Flat

(1.30 Dia. .190 Thick)

Washer- 1/2 Flat (.25 Thick)

B o lt - 1/2 x 13 Pan Locking

Bo l t -1 /2- 13 x2 .25 Pan Locking

(.88 Shoulder)

B o l t -

1/2-13

x 1.38 Pan Head

Shoulder Locking

REPLACEMENT PARTS - SHOULDER BELT

Part No.

3862 74-S100

©Code

Letter

IC

Part Name

Bolt - 7.16-20 x 1.75 Pan Head Tapping

© Ide ntificatio n letter on top of bolt head or face of spacer.

Note:

Bolt torqu e must be maintained at 20-30 ft-lbs. Replacement parts - 2 2-32 ft-lbs.

C R 1 I 1 2 H



41-60-1

Seat Trim

4 1 - 6 0

SUBJECT

Seat

G ENERAL INF O RM AT IO N

REM O VAL AND INST AL L AT IO N

Back Cover - Bench Typ e Fro nt Seat

Back Cover - Bucket and/or Sp li t

Bench Front Seat

Back Cover

—

Rear Seat

Center Arm Rest - Front Se at . .

Trim

PAGE

. . 6 0 -1

. . 6 0 -2

60-1

. . 60-2

60-2

SUBJECT

P A R T

41-60

PAGE

REMOVAL AND INSTALLATION (Con t 'd . )

Center Ar m Rest Cover - Fro nt Seat 60-2

Center Ar m Rest Cover - Rear Seat 60-2

Cushion Cover - Bench Typ e Fro nt Seat 60-2

Cushion Cover - Bucke t and Sp lit

Bench Fro nt Seat - Rf)-i

Cushion Cover -

High Back Cover

Rear Seat

- Bucke t Seat

60-2

60-2

CR2020-A

GENERAL INFORMATION

The following seat trim removal and

installation procedures generally apply to

all car lines.

If some of the steps do not apply to

the particular vehicle being serviced,

proceed to the next step and review the

appropriate illustrations shown. Unless

otherwise noted, the illustrations shown

in this section are

typical of all bucket,

bench and split bench (front seat

assemblies), arm rests (front and rear),

and rear seat cushion and back

assemblies.

See appropriate Figs. 1 through 21.

Seat trim replacement requires remo

and installation of seat components s

as seat tracks, seat assemblies and h

restraints. Refer to the applicable s

manual parts in Group 41 for th

procedures.


CUSHION COVER—BUCKET AND

SPLIT BENCH FRONT SEAT

1. Remove the seat and track assembly

from the vehicle. Refer to Group 41.

2. Remove the seat back latch handle

assembly.

3. Remove the seat cushion shield(s)

attaching screws, and separate the

shield(s) from the cushion.

4.

R e m o v e th e a r m r e s t - t o - s e a t

attaching covers and remove the

retaining bolts.

5. Remove the seat back-to-seat cushion

retainers and pins and remove the seat

back from the seat cushion.

6. Remove the seat track-to-seat cushion

screws and washers and remove the

seat track assemblies.

7.

Cut the hog r ings retaining the

cushion cover.

8. Remove the cover from the seat

cushion assembly and transfer the

tiedown and bolster wires to their

listings in the new cover assembly.

On units equipped with laterally

pleated and plain trim bucket (Pinto)

cushion covers, apply trim cement

(Part No. 19C525 or equivalent)

between the cover and the pad. This

will prevent wrinkling and buckling

of covers when installed in service.

9. Position the cover over the pad and

spring assembly and fold the cover

into position to install the hog rings

and/or plastic retainer(s) to the seat

cushion assembly. Then stretch the

cover and smooth out any wrinkles at

the same time the hog rings are being

installed.

10. Position the seat track assemblie

the seat cushion and install

a t taching screws and washe

Tighten to specification shown in

appropriate Figs. (Group 41).

11. Assemble the seat back and arm

to the cushion assembly.

12. Install the seat cushion shield(s)

seat back latch handle assembly.

13. Position the seat and track assem

in the vehicle and install the s

t r a c k- to - f loor a t t a c h ing bo

Tighten to specification shown in

appropriate Figs. (Group 41).

BACK COVER-BUCKET AND/OR

SPLIT BENCH FRONT SEAT

1.

Tilt the seat back forward, remove

seat back pivot covers and remove



41-60-2 Seat Trim

41-60-2

bolts and/or pins and retainers from

the seat back assembly pivot arm.

2.

Remove the seat back latch handle

and escutcheon.

3. Remove the seat back assembly (lift

outboard side and pull seat back out

of inboard pin socket), and place on

clean bench.

4.

Remove the seat back trim robe

panel, moulding and shields (retained

by trim clips and/or tabs and screws)

from the seat back (if so equipped).

5. Cut the hog rings and /or disengage

the plastic retainers from the seat

back frame assembly flange and

remove the cover.

6. Transfer all bolster tie-down wires to

their l is tings in the new cover

assembly.

7. Install the cover assembly.

8. Install the hog rings that retain the

cover or attach the plastic retainers to

the frame assembly flange.

9. Install the seat back trim panel, shield

and mouldings to the seat back

assembly.

10.

Install the seat back latch handle and

escutcheon.

11. Position the seat back assembly to the

seat cushion and install the retaining

bolts, pins and retainers and the pivot

covers.

12. Check the seat back latch operation

to be sure that the seat back assembly

holds in the locked position.

HIGH BACK COVER-BUCKET SEAT

To replace the Pinto/Bobcat high

back cover (bucket seat), follow the

procedures outlined for Back Cover

Bucket and Split Bench in this Section

and refer to the illustrations shown. The

removal and installation procedures are

typical.

CUSHION COVER-BENCH TYPE

FRONT SEAT

Remove the seat and track assembly

from the vehicle as outlined in the

applicable seat section (Group 41).

Remove the seat back from the cushion.

To replace the cushion cover, follow the

cushion cover removal and installation

procedures under Rear Seat Cushion and

Front Seat Arm Rest Removal and

Ins ta l la t ion in th is Sect ion . The

procedures are typical.

BACK COVER-BENCH TYPE

FRONT SEAT

Remove the seat and track assembly

from the vehicle as outlined in the

applicable seat section (Group 41).

Remove the seat back from the cushion.

To replace the seat back cover, follow the

S ea t Back Cover Remova l and

Installation procedures in this Section.

The procedures are typical.

CENTER A R M REST-FRONT SEAT

The front seat center arm rest on the

Lincoln Continental requires removal of

the hog rings retaining the arm rest cover

to the seat cushion assembly. Cut the hog

rings from underneath the front seat

cushion assembly. Then, lift the flap and

remove the screw retaining the arm rest

assembly to the seat cushion. Remove the

arm rest assembly.

On the LTD II, Cougar, Thunderbird

and Continental Mark

V,

remove the arm

rest shield(s) to gain access to the bolts

attaching the arm rest to the seat cushion

assembly . Then, remove the two

attaching bolts and remove the arm rest

assembly.

On the Ford and Mercury, remove

the hog ring(s) retaining the flap

assembly to gain access to the retaining

nuts. Remove the four nuts retaining the

back and strainer assembly to the seat

back frame assembly and remove the arm

rest.

CENTER ARM REST COVER-

FRONT SEAT

Disengage the hog rings and the cover

from the retainers (staples) on Lincoln

Continental. Then, remove the arm rest

cover.

The arm rest cover on the LTD II,

Granada, Monarch , Cougar , Ford ,

Mercury, Thunderbird and Continental

Mark V, is retained with a zipper. Unzip

the zipper and remove the arm rest cover

assembly.

CUSHION COVER-REAR SEAT

1.

Remove the rear seat cushion from

the vehicle. See Group 41.

2.

Disengage the button assemblies from

their respective retainers and remove

the buttons. The retainers will be

damaged upon removal and should be

discarded.

3.

Cut the hog rings from the cushion

cover and/or disengage the plastic

retainers from the seat cushion flange

and remove the cover.

4.

Transfer all bolster tie-down wires to

their respective listings in the new

cover assembly.

5. Position the cover over the cushion

assembly. Secure the plastic retainers

to the seat flange assembly (if so

equipped).

6. Install the necessary hog rings,

buttons and (new) retainers and

install the cushion assembly into the

vehicle.

BACK COVER-REAR SEAT

1.


rear seat back assembly from the

vehicle, and remove the center arm

rest (if so equipped) from the rear seat

back as outlined in the removal

procedure under Center Arm Rest

Cover-Rear Seat.

2.

Disengage the button assemblies from

their respective retainers on the: rear

side of the seat back and remove the

buttons.

3. With the front side down on a bench,

cut the hog rings that retain the cover

to the spr ing assembly and/or

disengage the plastic retainers from

the seat cushion flange assembl

y .

4.

Remove the cover from the seat back

assembly.

5. Transfer all bolster tie-down wires to

their respective listings in the; new

cover assembly.

6. Position the cover over the cushion

assembly.

Position the plastic retainers) over

the spring flange assembly.

7. Install the necessary hog rings,

buttons and (new) retainers and

install the rear arm rest to the seat

back assembly (if so equipped).

8. Install the seat back and seat cushion

into the vehicle.

CENTER A R M REST COVER-REAR

SEAT


rear seat back assembly from the

vehicle as outlined in Group 41.

2. Cut the retaining hog rings and

remove the rear cover from the arm

rest opening in the seat back.

3. Cut the hog rings that attach the arm

rest flap to the rear seat back.

4.

Remove the four bolts that attach the

arm rest link and vertical strainer

assembly to the rear seat back and

remove the arm rest assembly.

5.

Remove the flap-to-arm rest staples,

the cover-to-arm rest staples and slip

the cover off the pad and base

assembly.

6. Slip the new cover over the pad and

base assembly and install the arm rest

staples and hog rings.

7.

Assemble the center arm rest to the

rear seat back and install the four

ve r t i ca l s t r a i ne r - to - s ea t back

attaching screws.

8. Fasten the arm rest flap to the rear

seat back with hog rings.

9. Install the rear seat back assembly

and the rear seat cushion in the

vehicle.



41-60-3

Seat Trim

41-60

CENTER ARM REST

ASSEMBLY

SEAT BACK

ASSEMBLY

BUSHING

654A28

y

VIEW B

SEAT CUSHION

ASSEMBLY

SHIELD

654A82

BACK ASSEMBLY

SEAT BACK FRAME

REINFORCEMENT

61046-7

qrRFW

38 4

8

7i

VIEW B CUSHION

4 DOOR BENCH ASSEMBLY

VIEW A

2 DOOR BENCH R1631

FIG. 1 Front Seat Back and Center Arm Rest

2-and 4-Door

Flight Bench—LTD II and Cougar

BACK ASSEMBLY

ARM REST ASSEMBLY

PIN

386637

R1453-C

F IG .

2 Front Seat Back and Center Arm Rest Split Bench—Thunderbird,

Continental Mark V, LTD II and Cougar



41-60-4

Seat Trim

41-60-4

NU T

WASHER

A R M R E S T

SEAT

CUSHION

V I E W - B

R1930-B

FIG.

3 Front Seat Back and Center Arm Rest—Flight-Bench and Split-Bench—Ford and Mercury

COVER-61634-5

VIEW A

R1765-E

FIG. 4 Front Seat Back and Cushion Assembly—Pinto, Bobcat and Mustang



41-60-5

Seat Trim 41-60

BACK ASSEMBLY

PIN

353467

CUSHION ASSEMBLY

SPACER

386576

VIEW A

V I E W C

R1766-B

FIG .

5 Front Seat Back-to-Cushion and Latching Mechanism—2-Door Bench—Maverick and Comet

C

) HOG RINGS - 5 REQ UIRED

HOG RINGS - 4 R EQUIRED

(J J HOG RINGS - 1 REQUIRED

D ) HOG RINGS - 3 REQUIRED

V I E W B

V I E W B

VIEW A

FIG .

6 Front Seat Cushion Cover Installation—Split Bench—Thunderbird and Continental Mark V Shown— Typical



41-60-6

Seat Trim

41-60-6

HOG RINGS

4 REQUIRED

VIEW D

HOG RINGS

2 REQUIRED

EACH FRONT

LOWER CORNER

V I E W - A

HOG RINGS

4 REQUIRED

VIEW-B

SLIT

IN

COVER

FOR FRONT SEAT

BACK LATCH BEZEL

AND KNOB

V I E W - C

V I E W - E

VIEW - F

HOG RINGS

4 REQUIRED

R1931-A

FIG. 7 Front Bucket Seat Cushion and Seat Back Installation—Maverick Comet Granada and Monarch—Typical



4140-7

Seat Trim

41-60-

HOG RINGS - 25 REQUIRE D

AROUND FRAME ASSEMBLY

V I E W C

BUCKET

V I E W B

PLASTIC RETAINER

PART OF 62900

COVER ASSEMBLY

4 OR. BENCH

VIEW A

2 DR. BENCH

2 DR. BENCH

BENCH

4 DR. BENCH

R1659-C

F IG .

8. Front Seat Cushion Cover Installation—Bucket and Bench Seat—LTD II, Thunderbird and C ougar— Typical



41-60-8

Seat Trim

41-60-8

PAD ASSEMBLE

VIEW B

W I R E - 6 3 3 6 5

BUCKET SEAT

HOG R IN G - 1 REQUIRED

HOG RING -

1 REQUIRED

COVER ASSEMBL

V

- 6 4 4 1 6 - 7

BENCH SEAT

R1456-F

F IG . 9 Front Seat Back Cover Installation—Bench and Bucket—LTD ll

#

Thunderbird and Cougar



41-60-9

Seat Trim

41-60

TIE-DOWN WIRE

1 REQ'D. EACH SEAT

PA D

VIEW AA

HOG RING 1 REQ'D. EACH

SIDE OF WELT

VIEW BB

TIE-DOWN WIRE

TIE-DOWN WIRE

2 REQ'D. EACH SEAT

COVER

COVER

HOG RING 1 REQ'D. EACH

SIDE OF WELT

CUSHION LUXURY TRIM

TRIM PANEL

TIE-DOWN WIRE

2 REQ'D

SEAT BACK ASSEMBLY TO CUSHION ASSEMBLY

COVER

COVER

SEAT BACK STANDARD TRIM

VIEW EE

VIEW FF

SEAT BACK LUXURY TRIM

FRAME

PA D

COVER

HOG RING

1 EACH SIDE

VIEW HH

R159

F IG . 10 Front Seat Assembly—Mustang, Bobcat and Pinto



41-60-10

Seat Trim

41-60-10

TIE-DOWN WIRE - 1 REQ'D. EACH SEAT

.COVER

VIEW AA

HOG RING - 1

REQ'D. EACH SIDE

BACK ASSEMBLY

COVER - 61694

SCUFF PLATE -60060

CUSHION ASSEMBLY

V I E W C C

VIEW DD

FRAME ASSEMBLY - 61015

SEAT BACK PANEL - 61 632

(PINTO ONLY)

STANDARD TRIM

V IE W E E VIEW FF

VIEW GG

F IG . 11 Front Seat Assembly—Pinto and Bobcat



41-60-11

Seat Trim

41-60

\

SPLIT BENCH

VIEW A

CONTINENTAL MARK V

NON-RECLINER SHOWN

R.H. RECLINER S IMILAR

SEAT CUSHION

FRAME

SIDE SHIELD

FLIGHT BENCH SHOWN

SPLIT BENCH SIMILAR

PANEL -

61657-7

REAR SHIELD WITHOUT

SIDE SHIELD - FUL L BENCH

LTD I I , THUNDERBIRD

SWITCH INSTAL LATION (L.H. SIDE) FOR ALL MODELS FORD-MERCURY

SWITCH AND HOUSING

ASSEMBLY- 14B711

SWITCH INSTA LLATION (R.H. SIDE)

LTD I I , COUGAR AND TH UNDERBIRD

R 1 4 5 5 H

F IG .

12 Seat Shields—LTD II, Cougar, Ford, Mercury, Thunderbird and Continental Mark V



41-60-12

Seat Trim

41-60-12

c

HOG RINGS - 5 REQUIRED

EACH SIDE

COVER ASSEMBLY

HOG RINGS-13 REQUIRE

ALONG TO P

TOWN CA R

VIEW A


ALONG TOP


OG R INGS-15 REQUIRED

ALONG BOTTOM

LINCOLN CONTINENTAL

HOG RINGS-13 REQUIRED

ALONG BOTTOM

Q

rTTr-tzii^

HOG R INGS-8REQUIRED

EACH SIDE

HOG RINGS - 17 REQUIRED, FRONT

B J HOG R INGS -5 REQUIRED, EACH SICE

HOG RINGS -5 REQUIRED, REAR

HOG RINGS -8 REQUIRED



HOG R INGS-1 3 REQUIRED

ON TOP


EACH SIDE

o

, o

o

O _;

o ,

{•

°

r .f

. 0

M

0 I

THUNDERBIRD

HOG RINGS-

4 REQ'D.

HOG RINGS-

4 REQ'D.

HOG RING S-5 REQUIRED

ON BOTTOM

VIEW A

HOG RINGS - 1 1 REQUIRED

ON TOP


EACH SIDE

M A R K IV

HOG RINGS - 1 3 REQUIRED

HOG RINGS - 7 REQUIRED HO G RINGS - 7 REQUIRED

V I E W C

THUNDERBIRD-CONTINENTA L MARK IV MODEL 65

R 1 4 5 9 E

FIG.

13 Rear Seat Cover Installation—Lincoln Continental—Typical



41-60-13

Seat Trim

41-60-


ON TOP

HOG RINGS - 8 R EQUIRE D

WIRE ON EACH SIDE

<^

1

\

. j

i, *

...\. 8t

L WIRE

\ 63341

^ ft

1

-

—> ' i i '

— ^

— - (

i •

HOG RING

VIEW A

HOG RINGS - 11 REQUIRED ON TOP

HOG RINGS - 8 REQUIRED EACH SIDE \

PANEL AND EXTENSION ASSEMBLY

STATION WAGON

HOG RINGS - 9 REQUIRED ON BOTTOM

HOG RINGS-7 REQUIRED

EACH SIDE


ALONG FRONT


ALONG FRONT

HOG RING S-5 REQUIRED

EACH SIDE i


ALONG BACK

MODEL 7 1 MODELS 53-65


ALONG BACK

R145

F IG .

14 Rear Seat Cover Installation—LTD II, Cougar, Thunderbird Shown— Others Typical



41-60-14 Seat Trim

41-60-14

HOG RINGS

3 REQUIRED

EACH WIRE

HOG RINGS

18 REQUIRED

ALONG REAR

R1932-B

F IG .

15 Rear Seat Cushion and Seat Back Cover Instal lat ion—Granada and Monarch



41-60-15

Seat Trim

41-60-

HOG RINGS

4 REQUIRED

EACH SIDE

LUX URY TR IM

HOG RINGS

5 REQUIRED - PINTO AND BOBCAT

6 REQUIRED - MUSTANG

EACH SIDE

HOG RINGS

1 REQUIRED

EACH SIDE

ALONG FRONT

HOG RINGS

17 REQUIRED - MUSTANG


ALONG FRONT

HOG RINGS


23 REQUIRED - M USTANG

ALONG BACK

TRIM COVER

HOG RIN

VIEW A R1598-B

FIG . 16 Rear Seat Cushion Cover Installation—Mustang, Bobcat and Pinto—

Typical

SHIELD

TRIM PANEL

60762

CL

'

P

h ™

S S T

V1EWB

371904

LINCOLN CONTINENTAL

FRONT SEAT

BACK SPACER

(RECLINER) 62702

VIEW A

R1808D

FIG .

17 Front Seat Back—Trim Panel Installation—Typical



41-60-16

Seat Trim

41-60-16

PRING ASSEMBLY

VIEW BB

SPLIT BENCH

SPRING ASSE MBLY

BUSHING

SPLIT BENCH

R 933-B

FIG. 18 Front Seat Arm Rest Installation—Lincoln Continental



41-60-17

Seat Trim

41-60

ADHESIVE (USE IS OPTIONAL)

ADHESIVE (USE IS OPTIONAL)

COVER ASSEMBLY

2 DOOR BENCH

FLAP ASSEMBLY

4-DOOR BENCH

R1934-A

F IG .

19 Front Seat Center Arm Rest Installation—Ford and Mercury



41-60-18

Seat Trim

41-60-18

FLIGHT BENCH

SPLIT BENCH

R1935-A

FIG.

20 Front Seat Center Arm Rest Cover Installation — LTD II, Cougar, Lincoln, Ford, Thunderbird and Continental

Mark V

COVER ASSEMBLY

67244

LINK AND VERTICAL

STRAINER ASSEMBLY

67210

STAPLES

'ADHESIVE

BASE ASSEMBLY

67204

R1768-A

FIG. 21 Rear Seat Center Arm Rest Installation—Lincoln Continental Shown—

Typical



42-00-1 Window Glass and Mechanisms

42-0

WINDOW GLASS

AND MECHANISMS

G R O U P

(70000)

PART TITL E

Dual U-Run Front Door Window Mechanism

Dual U-Run Rear Door Window Mechanism .

Guide and Run Sliding Quarter Window

Mechanism

Mini-Vent Window Mechanism

Pivot Type Quarter Window

Single Guide Quarter Window Mechanism

Single Tubular Run Front Door Window

Mechanism

PART NO.

. . . . 42 -03

42-21

. . . . 42-34

42-08

. 42-33

42-35

. . . . 42-07

PART TITL E

Single Tubular

Run

Rear Do or W indow

Mechanism

Stationary Quarter Window Glass

Tailgate Window Glass and Mechanism

— Dual Action Gate

Window Glass and Mechanisms

General Service

PART NO

42-

42-3

42-4

42-

CR2003-A

Window Glass and Mechanisms

General

P A R T

42-01

SUBJECT PAGE


TESTING

Power Window Motor Test

01-2

Power Wind ow Switch Tests 01-2

SUBJECT PAGE


Power Window Relay 01-3

Power Window Switch

01-4

Power Window Switch Connector Wire 01-

CR2021-A

GENERAL INFORMATION

The door window mechanism should

be well lubricated to provide ease of

operation. The window glass mechanism

should be lubricated whenever the glass

channel or window regulator is removed

or excessive effort is required to operate

the windows. To lubricate a door window

mechanism, apply an even coating of

Polyethylene grease (19584) or

equivalent to the window regu

rollers, shafts and the entire length

roller guides as illustrated by the s

areas in Fig.l.



42-01-2

Window Glass and Mechanisms General Service

42-01-2

APPLY AN EVEN COATING OF POLYETHYLENE GREASE C4AZ-19584-A TO ALL WINDOW

REGULATOR ROLLERS, SHAFTS AND THE ENTIRE LENGTH OF ROLLER GUIDES AS

ILLUSTRATED BY THE SHADED AREAS

FIG. 1 Window Mechanism Lubrication Points

N1607-D

TESTING

P OW E R W I N D O W M O T O R

TEST—PERMANENT MAGNET

TYPE

To test the current draw of a power

window motor, remove the motor and

drive assembly from the vehicle. Refer to

the specific part of Group 42 for the

removal procedure.

Test Procedure

1. Connect an external power source

(power-pac or a fully charged ba ttery)

to the motor with an ammeter in

series as shown in Fig. 2.

2. Operate the motor and observe the

current draw. The current draw for

the no-load test should not exceed

specification (at end of this part) and

should not fluctuate. Reversal of the

motor wire connections will reverse

the direction of motor rotation.

Replace the motor if the current draw

exceeds specification.

POWER W INDOW SWITCH TESTS

Master Switch—With Quarter

Windows

Testing of the power window master

switch should be performed with the

switch removed from the vehicle. Use a

self-powered test light or an ohmmeter.

N2-70-B

FIG. 2 Power Window Motor Current Draw Test—Permanent Magnet Motor

Test

Procedure

1. Clip one test lead probe on pin No.

3 (Fig. 3) which is grounded.

2. With all switches in the neutral

position, pins No. 4 through 11

should have continuity to pin No. 3.

3. Push any one or all four window

switches forward (toward front of car

when in installed position). All odd

numbered pins of the switch(es)

pushed forward should loose

continuity to pin No. 3.

4.

Push any or all four window switches

rearward (toward rear of car when in

in s ta l l ed pos i t ion ) . A l l even

6.

numbered pins (4 through 11) of the

switch(es) pushed rearward should

loose continuity to pin No. 3.

Remove the test lead from pin No. 3

and connect it to pin No. 2 (hot feed

pin).

With all switches in the neutral

position, only pin No. 1 should have


Push any one or all four switches

forward and hold in that position. All

odd numbered pins of switches

pus hed fo rw ard s hou ld have


Pull any one or all four switches

rearward and hold in that position.



42-01-3

W indow Glass and Mechanisms Ge neral Service

42-0

All even numbered pins of switches

pu l l ed r ea rw ard s hou ld have


8. If any one switch does not test as

stated, replace the complete switch

assembly.

Single Switch—AH Models With

Power Windows

The Thunderbird , LTD II and

Cougar 2-door models use two of the

single switches as a master switch instead

of the multiple master switch. They

should be tested in the same way as the

standard single switch.

Test

Procedure

1. Use a self-powered test light or an

ohmmeter, to test the power window

switch.

2.

With the switch in the neutral

position, there should be continuity

between terminals 1 and 3, 2 and 5,

and 4 and 6. (Fig. 4).

3. With the switch toggle pushed

downward, there should be continuity


and 3 . Te rm ina l 6 s hou ld be


terminal.

4. With the toggle switch pushed

upward, there should be continuity


and 6 . Te rm ina l 1 s hou ld be


terminal.

5.

If the switch does not test as stated,

replace the switch.

Maste r Swi tch—Wi thou t

Quar te r Windows

The quarter window switches we

leted from the rear seat area and from

left front multiple switch and hou

Lincoln Continental, Thunderbird, C

nental Mark V and Mercury. Refer to

7 for test procedures.

The Granada and Monarch

switches are shown in Fig. 8 and th

procedures are shown in Figs. 3 an

LEFT REAR

LOCK-OUT SWITCH

PUSH UP FOR LOCK_

OUT OPERATION

RIGHT REAR

1 LOCK-OUT SWITCH TERMINAL

2 HOT FEED WHEN IGNITION SWITCH IS "O N'

3 GROUND TERMINA L

4 & 5 MOTOR TERMINALS - I EFT REAR

6 & 7 MOTOR TE RM INA LS -LE FT FRONT

8 & 9 MOTOR TER MINA LS-R IGHT FRONT

10 & 11 MOTOR TERMINALS - RIGHT REAR

LEFT FRONT

SWITCHES SHOWN

IN NEUTRAL

POSITION

RIGHT FRONT

N2313-A

SINGLE POWER WINDOW SW ITCH TEST

© POWER FEED, OR GROUND FROM DRIV

SWITCH (ALLOWS OPERATION OF

INDIVIDUAL WINDOWS FROM L. F. DOO

(2) HOT FEED FOR SINGLE SWITCH (BUS BA

TO PIN NO. 5)

@ MOTOR TERM INAL - UP

0 MOTOR TERMINA L - DOWN

© HOT FEED

© POWER FEED. OR GROUND FROM DRIVE

SWITCH (ALLOWS OPERATION OF

INDIVIDUAL WINDOWS FROM L. F. DOO

N246

FIG. 3 Power Window Master Switch Pin Connections and Locations—4 Door

Models—Lincoln, Ford, Mercury, LTD II, Cougar, Granada and Monarch

FIG. 4 Power Window Single Sw

Pin Locations—All Models


POWER W IND OW RELAY

Thunderbird, LTD II and Cougar

Removal

1. Disconnect the ground cable from th e

battery.

2.

Remove one screw attaching the relay

to the left-hand cowl, behind the trim

panel.

3. Disconnect the wires from the relay

and remove the relay.

Installation

1. Connect the wires to the relay.

2.

Position the relay to the L.H. cowl on

LTD II and Cougar and install the

one attaching screw.

3. Connect the battery ground cable,

and cheek the operation of the power

window.

Granada and Monarch

1. Disconnect the battery ground

and locate the relay on the R.H.

panel.

2. Disconnect the connector from

relay and remove the retaining sc

Remove the relay.



42-01-4

W indow Glass and Mechanisms Gen eral Service

42-01-4

3. Install the relay to the R.H. end panel

and connect the multiple connector.

4.

Connect the battery ground cable.

Ford and Mercury

1. Disconnect the battery ground cable

and locate the relay at the # 1

crossmember, under the driver's seat.

2.

Disconnect the connector from the

relay and remove the retaining

screws. Remove the relay.

3. In sta ll the relay to the No. 1

crossmember and connect the

multiple connector.

4.

Connect the battery ground cable.

Lincoln Continental

1.

Locate the relay on the headlamp

switch cover.

2. Disconnect the multiple connector

and remove the relay retaining

screws. Remove the relay.

3. Install the relay on the head lamp

switch cover and connect the multiple

connector.

P OWE R W INDO W S WITCH

Ford,

Mercury, Lincoln

Continental and Continental

M a r k V

1. Remove the screw from the front end

of the bezel and lift the bezel and

switch away from the arm rest (Fig.

5).

2. Remove the bezel and nut from the

mirror remote control (left front door

only).

3.

Remove two nuts (screws for Mark V

and Lincoln) from the bezel studs and

separate the switch(es) from the bezel.

4.

Pull the switch from the switch

connector.

5.

Position the switch to the connector

and press together firmly.

6. Position the switch(es) to the bezel

and install the two retaining (screws

for Mark V and Lincoln) nuts.

7. Install the bezel and nut on the

outside mirror remote control.

8. Position the switch and bezel to the

arm rest and install the retaining

screw.

LTD I I , Thunderbird, Granada,

Monarch and Cougar

1. Remove the switch bezel retaining

screw from the bottom side of the

HOUSING

14A335

ARM REST

CONNECTOR

FIG. 5 Typical Arm Rest Mounted Power Window Switch Installation—1977

Ford and Mercury

switch. Then, pivot the lower edge of

the bezel out and up to remove the

bezel.

2. The switch is held in place by the

electrical contact pins. To remove the

switch, carefully pry the switch from

t h e c o n n e c t o r w i t h a s m a l l

screwdriver.

3. Position the switch to the connector

and press firmly into place.

4.

Install the bezel on the switch and

install the bezel retaining screw.

5.

Inspect the rubber water seal and

replace if damaged. Then install the

water seal on the switch housing.

6. Install the switch in the vehicle.

P OWE R W INDO W S WITCH

CONNECTOR WIRE REMOVAL

I f replacement of the switch

connector or a wire leading to the

connector is necessary, the wire(s) can be

removed from the connector without

disassembling the connector.

To remove a wire from the connector,

insert a needle-like tool in the edge of the

pin hole (Fig. 6), and bend the terminal

in. Then, pull the w ire and terminal from

the connector. To install the terminal in

the connector, open the terminal and

insert it into the wire hole.

N2H6-A

FIG. 6 Power Window Switch

Connector Wire Terminal

Removal



42-01-5

Window Glass and Mechanisms General Service

42-

STANDARD MARK V LEFT HAND HOUSING SHOWN

R.P.O. HOUSING SIMILAR

POWER DOOR

LOCK SWITCH

POWER WINDOW SWITCH

MULTIPLE - MARK V

2-DR. MODELS-ONLY

LEFT HAND POWER WINDOW HOUSING

SHOWN FOR 2-DOOR FORD, MERCURY

THUNDERBIRD AND COUGAR XR-7

POWER WINDOW

SWITCH-MULTIPLE

LINCOLN

POWER WINDOW SWITCH - MULTIPLE

FORD, MERCURY, THUNDERBIRD, COUGAR XR-7

LEFT HAND HOUSING SHO

2-DOOR LINCOLN ONLY

MULTIPLE POWER WINDOW SWITCH TEST -

THUNDERBIRD AND LINCOLN CONTINENTAL

CONNECT ONE SIDE OF AN OHMMETER OR TEST

LIGHT TO TERMINALS (BATTERY TERMINAL)

WINDOW SWITCH

POSITION

NEUTRAL

BOTH SWITCHES

FORWARD

BOTH SWITCHES

REARWARD

CONTINUITY BETWEEN

TERMINALS

#2 ONLY

# 2

5-7

# 2 & 4 - 6

CONNECT ONE SIDE OF AN OHMMETER OR

LIGHT TO TERMINALS (GROUND TERMI

WINDOW SWITCH

POSITION

NEUTRAL

BOTH SWITCHES

FORWARD

BOTH SWITCHES

REARWARD

CONTINUITY BETW

TERMINALS

# 3 & 4-5-6-7

#3&4-6

•#3

&

5-7

•THE LOCKOUT SWITCH WILL HAVE CONTINUITY BETWEEN TERMINALS-8M AND#2 WHEN THE SWITC

THE CENTER POSITIONS.

MULTIPLE POWER WINDOW SWITCH TEST

FORD AND MERCURY

o

CONNECT ONE SIDE OF AN OHMMETER OR TEST

LIGHT TO TERMINALS (BATTERY TERMINAL)

WINDOW SWITCH

POSITION

NEUTRAL

BOTH SWITCHES

FORWARD

BOTH SWITCHES

REARWARD

CONTINUITY BETWEEN

TERMINALS

#2 ONLY

#2

5-7

* t 2 & 4 - 6

CONNECT ONE SIDE OF AN OHMMETER OR

LIGHT TO TERMINAL#3 (GROUND TERMIN

WINDOW SWITCH

POSITION

NEUTRAL

BOTH SWITCHES

FORWARD

BOTH SWITCHES

REARWARD

CONTINUITY BETW

TERMINALS

4t3

& 4-5-6-7

4*3 8.4-6

# 3

&

5-7

•TERMI NAL REMAINS IN THE MULTIPLE SWITCH ASSEMBLY BUT IS NOT ELECTRICALLY CONNECTE

NOT TEST FOR CONTINUITY).

R

FIG. 7

Power W indo w M aster Switch

Pin

Connections

and

Locations Thunderbird, Lincoln Continental, Continental M

V, Ford, Mercury and Cougar XR7



42-01-6

W indow Glass and Mechanisms Ge neral Service 42-011-6

SWITCH ASSY.

14540

HOUSING

14A355

if

V 1

4 DOOR

GROUND

SCREW

GROUND

SCREW

SWITCH

14529

FIG.

8

Power W indow Master Switch—LTD

II,

Cougar, Gran ada

and

Monarch

R1969-B

SPECIFICATIONS

WINDOW MOTOR CURRENT ORAW

No Load

.

5 amperes or less at 12.8 v olts

CN2433-A



42-03-1

Dual

U-Run

Front Door Win dow Mechanism

42-

Dual U-Run Front Door

Window Mechanism

P A R T

42-03

SUBJECT

ADJUSTMENTS

03-1


Belt Weatherstrip

PAGE SUBJECT PA

REMOVAL

AND

INSTALLA TION (Cont'd.)

Glass 0

Glass Run 0

03-4 Windo w Regulator 0

ADJUSTMENTS

Maverick and Comet

To obtain proper alignment of the

glass runs to the door frame, raise the

glass to the up position. Loosen the front

and rear run lower retaining screws

(Items A and B, Fig. 1). Lower the glass

until the top edge of the glass is

approximately 4 inches above the belt

line. Then, tighten the run retainer

attaching screws (Items A and B) to

specification. Cycle the window up and

down to assure a good window fit. Then,

tighten the run retaining screws.

Pinto and Bobcat

To obtain proper alignment of the

glass to the door glass runs and the door

frame follow the adjustments in the order

given.

1. Cycle the window to the full up

position.

2. Remove the door trim panel and

watershield.

3. Loosen the upper and lower guide

attaching screws (Item A l & A2).

4. Loosen the glass run adjusting screw

(Item B).

5. Position the glass firmly into the

upper rear corner and rear edge of the

CR202

door window frame run. Hold

in this position and tighten the

guide attaching screw and the

upper guide attaching screw (Ite

& A2).

6. Assure that the glass is i

outboard position within the gla

and tighten the bracket ass

glass run adjusting screw (Item

7. Lower the door glass so the to

of glass is flush with the doo

opening. Position the door w

upper front stop assembly Ite

to the quadrant and tighten sec

N2310-A

FIG. 1 Front Door Window Mechanism Adjustment—Maverick and Comet



2-03-2

Dual U-Run Front Door W indow Mechanism

42-03-2

ITEM B

NUT AND WASHER

A S S E M B L Y

383278

ITEM C

S£REW AND WASHER

A S S E M B L Y

57-187

I T E M

C

SCREW AND WASHER

A S S E M B L Y

57487

ITEM B

N U T A N D WA S H E R

A S S E M B L Y

383278

2 Front Door Window Mechanism Adjustment—Pinto and Bobcat

N 2 1 7 E - E

Note: It is not necessary to remove

the stop assembly (21742) when

installing glass or door window

regulator.

8. Cycle the glass and check for binds.

If no binds are found install the

watershield and door trim panel.


GLASS

Maverick and Comet

Removal

1. R e m o v e t h e t r i m p a n e l a n d

watershield from the door.

2. Lower the glass until the glass

retainers (Figs. 3 and 4) are visible at

the access holes in the door inner

panel.

3. Remove the front and rear glass

retainers by pushing the center pin

from the retainer with a small drift

punch (Figs. 3 and 4). Support the

glass and pry the retainer from the

drive arm bracket and glass by

inserting a screwdriver behind the

glass retainer flange.

Remove the front run lower attaching

screw.

. Remove the rear run lower attaching

screw.

downward and lift the glass out of the

door from the outside.

Installation

1. Insert the glass into the door front

end first. Then, tip the glass into the

normal position.

2. Position the drive arm bracket to the

glass and push the glass rear retainer

into the hole. Then, install the glass

retainer pin by pushing it into the

retainer hole until the end of the pin

is flush with the retainer flange (Figs.

3 and 4).

3. Install the glass front retainer using

the same method as the rear retainer.

4. With the glass positioned in the front

and rear runs, install the front run

retainer and rear run retainer lower

attaching screws.

5.

Adjust the window mechanism as

outlined in the Adjustment Section.

6. Install the watershield and door trim

panel.

Pinto and Bobcat

Removal



2. Lower the glass until the bracket

rivets to the glass are visible at the

access hole in the door inner panel.

3. Remove the center pins of the two

rivets attaching the door glass to the

glass bracket with a drift punch. Then

remove the

rivets

by drilling the head

from the rivet with a 1/4 inch drill.

DO NOT ATTEMPT TO PRY

THE RIVETS OUT AS DAMAGE

TO THE GLASS AND GLASS

BRACKET COULD RESULT.

4. Push the (2)

rivets

from the glass and

glass bracket and lift the glass up and

out of the door.

Installation

1. Install the Spacer (263A82) and

Retainer A ssy. (234A46) into the two

1/2 inch dia. holes in the Door Glass

(21410-1) and install the glass

through the door belt opening (Install

glass front end first).

2. Position the glass to the door glass

bracket and install (2) l/4"-20 x 1"

bolts 384925-S36 & (2) l/4"-20 nut

and washer assemblies (45334-S2) to

attach the glass to glass bracket.

Tighten to 6-11 ft-lb torque.


panel.

W INDOW REGULATOR

Maverick and Comet

Removal


watershield.

2. Support the glass and remove the

screw attaching the window regulator

equalizer arm to the door inner panel

(Fig. 3). On Pinto and Bobcat models,

remove two equalizer arm bracket

retaining nuts , and remove the

bracket (Fig. 4).

3. Remove four window regulator

attaching screws on Maverick and

Comet.

4.

Disengage the window regulator from

the glass channel bracket, and remove

the regulator through the lower

access hole.

Installation

1. Place the regulator in the door, and

engage the regulator arm rollers in the

glass channel bracket.

2.

Position the window regulator to the

door inner panel and install the

attaching screws. On Pinto and

Bobcat, use 1/4-20 x 1/2 inch screw

and washer assemblies to attach the

regulator to the inner panel.

3. Position the regulator equalizer ami

to the door inner panel and install the

attaching screw.



42-03-3

Dual U-Run Front Door W indo w Mechanism

42-0

BELT INSIDE

WEATHERSTRIP

6221436-7 , BELT OUTSIDE

»>& WEATHER STRIP

6221452-3

DOOR FRAME

GLASS RUN

V |

GLASS CHANNE L

RETAINER-62234A46

GLASS CHANNEL-6223276

WINDOW REGULATOR-6227000..

GLASS-6221410

REAR RUN RETAINER-62222A00

N17

F IG .

3 Front Door Window Mechanism—Maverick and Comet

VIEW A

NU T & WASHER

(45334)

SCREW & WASHER

ASSEMBLY (57487-S2)

DOOR GLASS

BRACKET ASSEMBLY

(23276-7)

V I E W C

DOOR INNER

PANEL (REF.)

SCREW & WASHER

ASSEMBLY (57487-S2)

GLASS RUN

ADJUSTMENT

BRACKET

(214A54-5)

.RUN &

BRACKET

ASSEMBLY (223A72-3)

SCREW & WASHER

ASSEMBLY (57487

N

F IG .

4 Front Door W indow Mechanism—Pinto and Bobcat



42-03-4


42-03-4

4.

Install the watershield and door trim

panel.

Pinto and Bobcat

Removal


watershield and support the glass in

the up position.

2.

Remove the center pin from the (3)

regulator attaching rivets with a drift

punch. Then, drill the head from each

rivet using a 1/4 inch drill and

remove the rivet.

3. Disengage the regulator arm from the

glass bracket, and remove the

regulator from the door.

Installation

1. Position the regulator in the door and

insert the roller into the glass bracket

channel.

2.

Position the regulator to the inner

panel and install (3) l/4 -20 x 1/2

screw and washer assemblies (Part

57487-S2) to attach the regulator to

the inner panel. Tighten the screws

securely with (3) l/4 -20 nut and

washer assemblies (45334-S2).

3.

Check the operation of the window

mechanism and install the


GLASS

RUN

Maverick

and

Comet

1. Remove the window glass from the

door.

2.

Pull the glass run from the front run

retainer and door glass frame. Then,

pull the run from the rear run retainer

(Fig. 5).

3. Position the glass run to the run

recess at the rear corner of the glass

frame. Insert the glass run into the

recess and into the front and rear

retainers.

4. Install the window glass in the door

and adjust as outlined in the

Adjustment Section.

Pinto and Bobcat

Removal


watershield.

2.

Support the glass in the up position.

3. Remove the (2) rivets attaching the

glass to the glass bracket. Remove the

center pin from the rivet with a drift

punch. Then drill the head from each

rivet using a 1/4 inch drill and

remove the rivet.

4.

Remove the (2) screw and washer

assemblies attaching the glass run to

the inner panel. Tilt the upper portion

of the run rearward to disengage the

window bracket from the regulator

arm roller.

5.

Remove the run and bracket assembly

and the glass bracket from the door

access hole.

Installation

1. Assemble the glass bracket, and the

glass run adjusting bracket on the run

and bracket assy, and lubricate the

run and roller/guides with a thin

coating of Polyethylene Grease

(C4AZ-19558-A). Assure that ali the

rollers and guides are evenly coated

with Polyethylene Grease prior to

installing.

2.

Install the run and bracket assembly,

glass bracket and glass run adjusting

bracket through the access hole in the

door inner panel and position the

glass bracket guide on the regulator

arm roller.

3. Loose assemble the run and bracket

assembly upper and lower attaching

screws to the door inner panel.

4. Remove the glass support and install

the glass to the glass bracket using (2)

l/4 -20 x 1 Bolt Hex Head (384925-

S36).

5. Tighten upper and lower run :ind

bracket assembly screws.

6. Adjust the glass as outlined in the

adjustment section of this procedure.

7. Install watershield and door trim

panel.

BELT WEATHERSTRIP

1. Lower the window.

2.

Pry the weatherstrip retainers out of

the retainer holes in the glass opening

flange (Fig. 6), and remove the

weatherstrip. Use care not to chip the

paint at the glass opening flange.

3. To install, position the weatherstrip

to the door and push the retainers

firmly into the holes.

FRONT

RUN

RETAINER

NUT AND WASHER 21-1A32-3

ASSEMBLY

SCREW

AND

WASHER

ASSEMBLY

VIEW A

VIEW B

N2180

FIG. 5 Door Glass Run—Typical



42-03-5


42-0

OUTSIDE

BELT

WEATHERSTRIP

VIEW

A

GLASS

INSIDE BELT

WEATHERSTRIP

21436-7

OUTSIDE

BELT

WEATHERSTRIP

21452-3

RETAINER

.

,

(PART OF

/ / WEATHER-

Pinto and Bobcat STRIP)

RETAINER

(PART

OF

WEATHERSTRIP)

WEATHERSTRIP

21452

N2

FIG.

6 Door Belt Weatherstrip

SPECIFICATIONS

DUAL

U-RUN

FRONT DOOR WINDOW MECHANISM TORQUE SPECIFICATIONS

Description

Glass

Run

Retainer Attac hing Screws

Window Regulator Attaching Screws

-

2-Qobr

4-Door

Equalizer Arm

to

Door Inner Panel

Torque

Maverick, Comet

6-11 ft-lbs

6-11 ft-lbs

3-7 ft-lbs

6-11 ft-lbs

Pinto, Bobcat

6-11 ft-lbs

6-11

ft-lbs with

1/4x20x1/2

Inch Sc

6-11 ft-lbs

CN



42-07-1

Single Tubular Run Front Door W indo w Mechanism

4 2 - 0 7 - 1

Single Tubular Run Front Door

Window Mechanism

P A R T

42-07


ADJUSTMENTS

All Models Except Granada and Monarch 07-1

Granada and Monarch 07-1

REMOVAL AND INST ALLATION

Glass 07-2

Guide 07-2



Run 07-2

Window Drive 07-2

Window Mo tor 07-2

Window Regulator 07-2

SPECIFICATIONS 07-4

CR2023-A

ADJUSTMENTS

ALL MODELS EXCEPT GRANADA

AND MONARCH

Separate adjustment steps are given

for each adjustment so that a partial glass

adju stme nt can be performe d. If a

complete glass adjustment is required,

follow the ad justments in the order given.

All window mechanism adjustments

must be performed with the door trim

panel and w atershield removed. After the

adjustment(s) are completed, install the

watershield and trim panel.

Glass Position—Fore and Aft

It is necessary to reposition the glass

in the opening if the glass has been

removed or if extreme door hinge

a d j u s t m e n t s a r e p e r f o r m e d . T o

reposition the glass, remove the trim

panel and watershield. Then, loosen the

upper attaching screw and upper guide

(Item A, Fig. 1), and reposition the glass.

Position the upper guide and tighten the

upper run attaching screw after glass is

moved to desired position.

Stabilizer Adjustment

The stabilizers are used to support th e

glass at the belt line. The trim panel must

be removed to adjust the stabilizers.

Then, with the glass in the up position,

push the front stabilizer firmly against

the glass surface and t ighten the

attaching screw (Item B, Fig. 1). Repeat

the procedure for the rear stabilizer.

Glass In-Out

The in-out adjustment is used to

obtain a good seal with the weatherstrip

at the top edge of the glass. This

adjustment is made by repositioning the

guides with respect to the glass bracket.

To adjust the in-out of the glass, loosen

the two lower guide attaching screws

(Items C , Fig. 1), and move the top edge

of the glass inward or outward as

required to obtain a good seal with the

UPPER FRONT STOP

STABIL IZER

/GLASS

/ BRACKET

UPPER GUIDE

LOWER STOP

N2305-D

FIG.

1 Single Tubular Run Front Door W indow Mechanism Adjustment— All

Except Granada and Monarch

weatherstrip; then, tighten the lower

guide attaching screws.

On the right

door, tighten the lower guide rear screw

first and then tighten the front screw.

After the guide attaching screws have

been tightened, again check the glass-to-

weatherstrip fit for a good seal. Readjust

the in and out tilt of the glass if a good

air tight seal is not achieved.

Upper

Stop

Adjustment

The upper stop adjustments are used

to limit the up travel of the glass to

maintain

a

constant g lass height when the

glass is raised to the full closed position.

The door trim panel must be removed to

adjust the up stops. To adjust the stops,

raise the window to the up position.

Check to be sure that there is no

interference when the door is

#

opened.

Then, position the up stop brackets down

against the glass stops, and tighten the

stop bracket attaching screw (Item D,

Fig. 1). Use this procedure for both the

front and rear upper stops.

Lower

Stop

Adjustment

The lower stop is used to control the

depth the glass can be lowered into the

door. To adjust the lower stop, remove

the door trim panel. Loosen the lower

stop retaining screw (Item E, Fig. 1), and

lower the glass until the top edge is flush

to 1/4 inch above the outer panel. Then,

lift the stop against the glass bracket and

tighten the retaining screw.

Granada and Monarch (Fig. 2

and 3)

1. Loosen attaching hardware until

upper and lower guide and rear



424)7-2 Single Tubular

Run

Front Door W indo w Mechanism

42-

retainer lower attachments are loose.

2.

Raise glass with window regu lator

into glass run. If necessary, position

glass manually forward and rearward

to obtain a proper sealed glass edge.

3. Tighten tube nut (top) to 6-11 ft-lbs

torque.

4. Tighten lower tube attaching bolt to

inner panel. Tighten lower guide bolts

(2).

5. Lower window half way and

lock side retainer attachment (

models only).


GLASS

Removal

1.

Remove

the

door trim panel

and

watershield.

2.

Remove one screw attaching each

glass stabilizer to the inner panel, and

remove the stabilizers (Fig. 4).

3. Remove the upper front and rear stop

brackets from the door inner panel

(Fig. 4).

4.

Remove the center pin from the rive ts

attaching the glass bracket to the

glass (Figs.

2, 3 and 4)

with

a

drift

punch. Then, remove the rivets by

drilling the head from the rivet with

a 1/4 inch drill. Do

not

attempt to

pry

the rivets

out as

damage

to the

window mechanism could result.

5. Push the rivets from the glass and

glass bracket. Move the glass forward

in the door until the rear upper stop

is aligned with the access notch in the

inner panel at the belt line. Lift the

rear

of the

glass

up and out of the

door. Then, move the glass rearward

until the front upper stop is aligned

with the access hole, and remove the

glass.

6. Remove

the

rivets from

the

upper

stops following the procedure given in

steps 4 and 5 for rivet removal. Then,

remove

the

stops from

the

glass.

Installation

1.

Position

the

upper stops

to the

glass

and install each stop on the glass with

a 1/4-20 x 1 inch hex bolt and a 1/4-

20 nut and washer assembly. Tighten

the nut to 6-11 ft-lb torque.

2.

Insert the glass into the door using the

access notch for clearance of the

upper stops.

3. Position the glass to the glass bracket

and install three 1/4-20 x 1 inch bolts

and three 1/4-20 nuts to attach the

glass

to

the glass bracket. T ighten

the

nut to 6-11 ft-lb torque.

4. Install

the

upper front

and

rear stop

brackets (Fig. 4).

5.

Install the glass stabilizers and adjust

the glass, stabilizers

and

upper stops

as out l ined in the A d jus tmen t

Section.


panel.

W IND OW REGULATOR

Removal


watershield and support glass in up

position.

2. If equipped with electric windows

(except Ford, Mercury, Meteor,

Thunderbird, Lincoln Continental

and Continental Mark V), remove

the center pin from the mo to r

bracket-to-inner panel attaching rivet

with a drift punch. Then, drill the

head from the rivet with a 1/4 inch

drill and remove the rivet. Disconnect

the motor wires

at the

connector.

3. Remove the center pin from the


punch. Then, drill the head from the

regulator attaching rivets with a 1/4

inch drill.

4.

Disengage the regulator arm from the

glass bracket , and remove the

regulator from

the

door.

5. If equipped with electric windows,

mount the regulator assembly in a

vise. Drill a 5/16 inch hole through

the regulator sector gear and the

regulator plate. Install a 1/4 inch bolt

and nut in the hole to prevent the

sector gear from moving when the

motor and drive assembly is removed.

Remove the motor assembly from

the

regulator and install it on a new

regulator.

Installation

1. Lubricate the window mechanism as

outlined in Part 42-01.

2. Install

nut and

retainer assemblies

on

the regulator mounting plate and

motor support bracket at the rivet

attaching holes.

3. Position the regulator in the door and

insert

the

roller into

the

glass bracket

channel.

4.

Position the regulator to the inner

panel and install 1/4-20 x 1/2 inch

screw and washer assemblies to attach

the regulator to the inner panel.

Tighten the screws securely.

5.

If equipped with electric windows,

install a 1/4-20 x 1/2 inch screw and

washer assembly to attach the motor

bracket

to the

inner panel (except

F o r d , M e r c u r y , T h u n d e r b i r d ,

Lincoln Continental and Continental

Mark

V).

Connect the motor wires at

the connector.

6. Check the operation of the window

m e c h a n i s m ,

and

i n s t a l l

the


W I N D O W M O T O R A N D / O R

DRIVE

Removal

1. Remove the

watershield.

t r i m p a n e l and

2.

Remove any door mounted

speakers,

(if

so equipped).

3.

All

models except Ford, Me

Thunderbird, Lincoln Conti

and Continental Mark V have

punched in the door panel for

and dr ive removal .

On

m

without access holes, use the d

located on the inner door pa

drill three 3/4 inch holes in th

for access to the motor and

attaching screws.

The holes should be drilled

glass in the U P position. The h

pilot drill should

be as

sh

possible, about

1/4

inch beyo

saw.

4. Disconnect

the

motor wires

multiple connector.

5.

Working through the 3/4 inch

remove the three motor and dr

regulator attaching screws.

remove the motor

and

drive fro

door.

Installation

1. Position the motor and drive

regulator and install the three

just snug-not tight.

2.

Connect the motor wires

connector and cycle the gl

assure gear engagement. Aft

gears are engaged, tighten th

motor

and

drive attaching scr

3. Install body tape over the drille

on Ford, Mercury, Thunde

Continental Mark V and L

Continental models.

4.

Ins ta l l the radio speaker

equipped and removed).

5.

Check the window operation.

install the watershield and trim

GUIDES A N D / O R RUN

Removal

1. Remove the door trim pane

watershield.

2. Support

the

glass

in the UP

po

3. Remove the two attaching s

from the upper and lower gui

4.

Remove the glass run uppe

lower attaching screw (Figs.

2

4) , and remove the run and

from the door.

5.

Remove the guides from the t

of the run.

Installation

1. Install the guides on the ru

lubricate the run as shown in P

01.




42-07-3

Position the run and guides into the 3. Po sition the gu ides to the glass

door, and install the run upper and brack et and install the attac hin g

lower attaching screws (Figs. 2, 3 and screws.

4). 4. Remove the glass support and adjust

the window mechanism as outlined in

the Adjustment Section of this Part.


panel.

RETAINER

SCREW & WASHER

ASSEMBLY

1UN & BHACKET ASSEMBL

SCREW & WASHER ASSEMBLY

VIEW Y ^

FIG.

2 Adjustment Points—Granada and Monarch Door (2-Door Models)

RUN ASSEMBLY

N2542 A

REGULATOR

LOWER

STOP

BRACKET

FIG. 3 Adjustment Points—Granada and Monarch Front Door (4-Door Models)



42-07-4


42-07

STOP BRACKET

21742

SEE VIEW A

F IG . 4 Typical Front Door Win dow Mechanism

SPECIFICATIONS

VIEW A

VIEW B

RIVET

VIEW C

WASHER RETAINER

RIVET

V I E W D

N2473

SINGLE TUBULAR RUN FRONT DOOR WINDOW MECHANISM TORQUE SPECIFICATIONS

Description

Glass Stop Attaching Screw

Run Attach ing Screws

Stabilizer Attach ing Screws

Upper Stop Bracket

Regulator-to-lnner Panel

Guide-to-Glass Bracket

Torque

6-11 ft-lbs

6-11 ft-lbs

6-11 ft-lbs

6-11 ft-lbs

6-11 ft-lbs

6-11 ft-lbs

CN2437-B



42-08-1

Power Mini-Vent Window

42-08-1


P A R T

42-08

SUBJECT PAGE

DESCRIPTION 08-1

ADJUSTMENTS- Lincoln Cont inental

Mam Glass 08-1

Vent Glass 08-3

ADJUSTMENTS - Thunderbird and Mark V

Main Glass 08-6

Mini-Vent 08-6

Vent Glass 08-6

SUBJECT PAGE

REMOVAL

AND

INSTALLATION

Drive 08-H3

Doo r Glass Assem bly

08-11

Door Window Guide

08-16

Door Window Run 08-16

Motor

08-16

Vent Glass Assembly

08-11

Vent Window Guide 08-12

SPECIFICATIONS

08-16

CR2024-A

DESCRIPTION

Thunderbird

and

Continental Mark

V mini-vent systems operate in the same

manner

as the

Lincoln Continental;

h o w e v e r ,

the

i n t e r n a l c o n t r o l

mechanisms

are

quite different.

The

adjus tments

for the

door glass

are

similar; however, the adjustment for the

mini-vent window assembly is entirely

different.

The mini-vent front door window

electric mechanism has a single tubular

run with

a

slidedown vent glass.

One

switch controls the operation of both

the

vent

and

main side glass. When

the

window switch

is

moved

to the

lower

position, the vent lowers into the door

first. When the vent is completely down,

the main glass lowers into

the

door.

The

glass

and

vent operates

in

reverse (glass

and then vent) when raising the window

The vent

or

main glass

may be

stopped

in any position between open and closed.

NOTE: To

ensure proper Mini-Vent

Window operation, remember to apply

the special mini-vent lubricant to all

areas shown

in

Fig.

19.

ADJUSTMENTS

LINCOLN CONTINENTAL O N L Y -

MAIN GLASS ADJUSTMENT

(REFER

TO

FIGS.

1

THROUGH

4)

The main glass

of the

system shifts

slightly as the vent reaches the end of its

cycle. Therefore, if you check the door

window adjustments with

the

vent

window down,

you

will find that they

change after

the

vent window

is

raised.

Always make sure that

the

vent window

is fully raised when checking

any

adjustment.

Fore and

Aft

Adjustment

Both fore

and aft and

equalizer

adjustments

are

used

in

combination

to

get

a

good

fit of

the door glass along

the

A-post (parallel to weatherstrip retainer)

and the top of the door glass. It is

i m p o r t a n t t h a t

any

fore

and aft

adjustment of the

run is

accompanied by

an upper guide ti l t adjustment

to

maintain a good it o the A-post.

Do not

try

to

adjust the glass parallel

to

the

B-

pillar.

When re-adjusting

the

system, with

the tilt or fore and aft, the rear up-stop

s hou ld

be

loos ened

and the

las t

component secured.

To adjust

the

glass forward

or

rearward, loosen the glass run upper

attaching screw (Fig. 1), and the rear up-

stop.

Then, position

the

glass forward

or

rearward as required, and tighten the

glass run upper attaching screw. To tilt

the glass forward

or

rearward, loosen

the

screws attach ing

the

upper guides

to the

guide plate (Fig. 1). Then, rock

or

tilt the

glass forward

or

rearward

as

necessary,

and tighten the attaching screws. Adjust

the rear up-stop

if

no other adjustments

are

to be

performed.

Glass In-Out Tilt

The in-out tilt adjustment

is

used

to

o b t a i n a g oo d s e a l a g a i n s t the

weatherstrip along the top edge of the

glass. This adjustment

can be

made

by

loosening

the

screws attaching

the

lower

plastic guide

to the

guide plate bracket

(Fig.

1).

Then, move

the

glass

top

edge

in or out to obtain a good seal with the

roof rail weatherstrip,

and

tightSn

the

guide attaching screws. The rear up-stop

should

be

loose during this adjustment.

Up Adjustment

With

the

main glass

in the

full

UP

position, cycle

the

vent glass until

the

vent window cap is raised above the door

belt line. Loosen the regulator arm roller

attachment and both up-stops. Manually

lift the door glass bracket assembly un til

the

top

edge

of

the door glass seats into

the weatherstrip sufficiently

to

obtain

a

good seal, especially at the upper rear

c o r n e r of the g la s s . T igh ten all

attachments

to

6-11 ft-lbs torque, [f the

UP position of the glass must be re-

adjusted, both door glass stops must

be

loose

and the up or

down adjustment

made with the regulator arm roller only.

Upper Stop Adjustment

Raise the glass to the UP position,

checking to be sure that the top eclge of

the glass contacts the weatherstrip

sufficiently

to

provide

a

good seal. Then,

position

the

upper front stop bracket

down against

the

glass stop

and

tighten

the attaching screw. Position

the

upper

rear stop down against

the

glass bracket

and tighten

the

attaching screw.


The stabilizers are used to support the

glass

at the door belt line. To adjust„ raise

the glass to the full UP position. Loosen

the stabilizer attaching screw

and

rotate

the stabilizer against

the

glass. Tighten

the stabilizer attaching screws.

Down Stop Adjustment

The down stop should be adjusted

so

that

the

main glass

is

between flush

and



STABILIZER

RET AI NER

BRACKET - VENT

WINDOW

STOP - VENT

WINDOW

RI VET

VIEW

VIEW

VIEW

REGULATOR

STOP LOWER

RUN AND BRACKET

ASSEMBLY

F I G . 1 Mini -Vent Window

S/stem

Lincoln Continental 4-Door Shown—2-Door Typica l

N2515 B



42-08-3


42-08-3

IN-OUT (VENT WINDOW)

FRONT UPSTOP

UP ADJUSTMENT ROLLER ON REGULATOR ARM

(DOOR GLASS)

VENT UPSTOP

UP ADJUSTMENT

VENT GUIDE

ADJUSTMENT SCREW

STABIL IZERS

REAR UPSTOl

:

DOWN STOP

MODEL 53 SHOWN

(MODEL 60 SAME

EXCEPT REGULATOR

& GLASS)

IN-OUT (TOP EDGE OF GLASS)

ADJUSTMENT

FIG. 2 Door Glass Adjustments—Lincoln Continental

N25 16-A

1/4 inch above the belt w eatherstrip with

the window in the full DOWN position.

Front Door Vent W indow Guide

Adjustment

The front guide is held in position by

a retainer attached to the door hinge

pillar by a screw. To adjust the front

guide, loosen the screw and lower the

door window and vent glasses. The front

guide locates itself in the adjustment slot.

Before tightening the retainer screw

check the vent g lass for proper

installation into the front guide.

VENT GLASS ADJUSTMENT

There are two basic vent window

adjustments; an in-out adjustment and

an up-stop adjustment.

In-Out Adjustment

To adjust the vent window in or out

at the belt l ine, f irs t remove the

weatherstrip end cap from the front edge

of the door. With the weatherstrip end

cap removed, insert a 7/16 inch open end

wrench through the access opening in the

door and adjust the acorn-head adjusting

bolt as necessary. Turning the adjusting

bolt in or out will move the mini-vent in

and out. The vent assembly should be

adjusted so that a parallel dimension is

obtained between the door outside belt

and the vent glass assembly. However, in

some instances, it may be necessary to

position the vent glass inboard to secure

a good seal to the A-post.

This is the only adjustment that can

be performed on a mini-vent window

system without removing the trim panel.

If the vent is adjusted inboard wii:h the

acorn bolt, make sure that the vent glass

raises full UP when cycled. If the vent

does not go full UP, remove the trim

panel and adjust the vent up-stop.

Up-Stop Adjustme nt

The vent up-stop can be adjusted up

or down through an access hole in the

door inner panel. The up-stop should be

adjusted so that the vent glass is flush

with the leading top edge of the door

glass. The division bar cap will extend

slightly above the two pieces of glass

when they are flush.

Re-check the in-out adjustment after

adjusting the up-stop. If a main glass re-

adjustment is performed, the vent up-



42-08-4 Power Mini-Vent Window

42-08

LOOSEN SCREW AT

REGULATOR ARM ROLLER

TO ADJUST DOOR GLASS

UP OR DOWN

FORE AND AFT ADJUSTMENT

'GLASS TILT ADJUSTMENT

DOOR GLASS BRACKET

GLASS iN-OUT

ADJUSTMENT

RAISE DOOR GLASS AT GLASS

BRACKET TO OBTAIN A SEAL TO

ROOF RAIL W/STRIP

FIG. 3 Door Glass Adjustments—Lincoln Continental



42-08-5

Power Mini-Vent W indow 42-08-5

VENT GLASS

VENT WINDOW STOP ASSEMBLY

VENT WINDOW STABILIZER ASSEMBLY

RETAINER FRONT DOOR

VENT WINDOW GUIDE.

ASSURE THAT VENT

GLASS IS INSTALLED

WITHIN "C" CHANNEL

OF GUIDE

BRACKET ASSEMBLY DIVISION

BAR OUTER

BRACKET ASSEMBLY DIVISION

BAR INNER

REGULATOR ASSEMBLY

DO NOT TIGHTEN RETAINER

VIEW A .

ASSEMBLY GUIDE SCREW AND

WASHER ASSEMBLY UNTIL VENT

WINDOW AND DOOR GLASS IS

CYCLED TO FULL DOWN

POSITION

N25-

8-A

FIG. 4

Mini-Vent Glass Adjustment—Lincoln Continental



42-08-6


42-08-

stop may have to be re-positioned to

maintain flushne ss to the m ain glass.

THUNDERBIRD AND

CONTINENTAL MARK V MAIN

AND VENT GLASS ASSEMBLY

ADJUSTMENTS (REFER TO FIGS. 5

THRU 8)

The door trim panel and watershield

m u s t b e r e m o v e d p r i o r t o a n y

adjustment.

Fore and Aft Adjustment

The fore and aft adjustment of the

entire door glass and m ini-vent assembly

can be made by loosening the front vent

channel attachment and the 3 bolts in the

glass bracket (Fig. 6). Then, position the

glass fore or aft as required.

It will also be necessary to adjust the

equalizer assembly to obtain a proper

glass-to-weatherstrip relationship.

NOTE:

If sluggish o r binding window

operation develops, loosen the front vent

channel upper attachment lock nut and

cycle the system. The vent channel may

not be properly set with the tube upper

channel.

Equalizer Adjustment

This adjustment pertains to the

relationship of the glass-to-weatherstrip

at the roof rail and the windshield "A"

post.

If the glass system is "tilted" in the

opening, where the forward or rearward

ends of the glass are low to its respective

weatherstrip, the system can be rotated

in the opening by loosening the upper

plastic guide attachments on the main

glass brackets, and rocking the glass on

the tubular run (Fig. 7).

Flipper Arm Adjustment

An adjustable "flipper arm" at the

end of the main glass drive arm is

provided to establish the full up position

of the main glass assembly.

If you find, after you have adjusted

the equalizer, that you are unable to get

the top edge of the glass into the

weatherstrip, check the "up-stops" to

make sure they are not improperly

positioned. Next, loosen the (2) bolts

retaining the flipper arm to the drive arm,

and adjust the flipper arm upward to

obtain the needed height (Fig. 7).

CAUTION: This is a very critical

adjustment. Improper adjustment could

cause sluggish or slow operation of the

entire system. Allow from 1/8" to 3 /16 "

of slot opening above the bolt washer for

proper set (see Fig. 7).

In-Out Adjustment

Make the "in-out" adjustment by

loosening the screws attaching the lower

plastic guide to the guide plate bracket

and moving the window assembly in or

out at the roof rail weatherstrip. The

glass should be off the stops to make this

adjustment (Fig. 8).


There are two stabilizers on the main

glass assembly (Fig. 8). One stabilizer is

mounted forward of the tube and one

rearward.

Raise the window to the full-up

position, loosen the retaining bolt on the

stabilizer and slide in or out to a finger

tight fit to the glass.

MINI-VENT ADJUSTMENTS

Refer to Figs. 9 thru 12

There are three adjustments for the

mini-vent assembly; an up-stop, in-out

and a vent full-up adjustment.

Also, it's important that the lower

mini-vent channel blade attachment be

properly positioned in the fork retainer.

Vent-Up-Stop-Adjustment

1. To obtain a parallel fit of the leading

edge of the mini-vent glass to the

main glass assembly, loosen the vent

up-stop attachment and position up

or down as required (Fig. 9).

In-Out Adjustment

1.

To adjust the in-out relationship

the mini-vent glass to the main gla

assembly, loosen the mini-ve

channel upper adjustable attachme

lock nut (Fig. 10).

2. Using a 9/32 " Allen wrench, turn

adjustable screw right (inboard)

left (outboard) to obtain a paral

relationship of the mini-vent glass

the main glass assembly.

NO TE: It's a good idea to sight do

the glass assemblies from the rear of

door, to make sure th at the mini-vent a

main glass assemblies are parallel.

This will prevent improper inboa

outboard channel adjustment that c

cause the mini-vent to be out of line w

the main glass assembly. This conditi

may bind the vent brackets and result

a mini-vent that will lower, but not ra

Vent Full-Up Position

Adjustment

1. Loosen the two bolts retaining t

vent arm cam plate on the regulat

assembly and position the moveab

cam plate to the lowest side of t

attaching slots on the door inn

panel (Fig. 11).

2. If you are unable to get the mini-ve

assembly raised to the full-up positi

by adjusting the stops and the ca

plate, you may have to elongate t

lower adjustment slot in the do

inner panel at the regulator cam pla

attachment.

Channel Blade Attachment

Position

The lower mini-vent channel bla

attachment must be properly position

between the two fork rubber prongs. T

prongs are designed with a specifi

clearance between them, to allow t

lower channel to "float" during wind

operation (Fig. 12). If not proper

positioned, the mini-vent may bind-u

causing it to lower but not raise.



42-08-7

Power Mini-Vent W indow

42-08-7

OUTER VENT

WINDOW

DIVISION BAR

VENT WINDOW

STABILIZER

DOOR WINDOW

STOP AS SEMBLY

N2714-A

FIG. 5 Mini-Vent W indo w System— Thunderbird and Continental Ma rk V




42-08

(7) LOOSEN THE FRONT

VENT CHANNEL ATTACHMENT

AND THE 3 BOLTS IN THE

GLASS BRACKET

(2) POSITION THE

GLASS FORE OR

AFT AS REQUIRED.

F IG .

6 Main and Vent Glass Fore-Aft Adjustment—Thunderbird and Continental Mark V

EQUALIZER ADJUSTMENT

LOOSEN FRONT VENT

CHANNEL

ATTACHMENT.

(7) LOOSEN THE UPPER

GUIDE ATTACHMENTS.

0 CHECK FOR

PROPER POSITION

OF UP STOPS.

(3) "ROCK" THE GLASS

SYSTEM IN THE OPENING

TO OBTAIN A PARALLEL

RELATIONSHIP OF THE

TOP EDGE OF THE GLASS

TO THE WEATHERSTRIP.

(2) LOOSEN 2

BOLTS RETAINING

FLIPPER ARM.

FLIPPER ARM ADJUSTMENT

(3) DROP DOOR GLASS TO THIS

HEIGHT AND USE SCREWDRIVER

AS LEVER TO SWING REG. ROLLER

PIVOT AND SET.

ALLOW 1/8" TO 3/16" MAX. OF

SLOT OPENING ABOVE BOLT

WASHER FOR PROPER SET.

N2716

FIG. 7 Main and Vent Glass—Equalizer Adjustment and Flipper Arm Adjustment—Thunderbird and Continental Mark V



42-08-9

Power Mini-Vent Window 42-08-9

STABILIZER ADJUSTMENT

LOOSEN THE RETAINING BOLT AND SLIDE THE

STABILIZER IN OR OUT TO OBTAIN A FINGER

TIGHT FIT TO THE GLASS.

IN-OUT ADJUSTMENT

LOOSEN THE 2 BOLTS THAT RETAIN LOWER

GUIDE ATTACHM ENTS. TILT THE UPPER

EDGE OF THE GLASS INBOARD OR

OUTBOARD AS REQUIRED.

N2717-A

F IG . 8 Main and Vent Glass Stabil izer Adjustment and In-Out Adjustment—Thunderbird and Continental Mark V

LOOSEN UPPER STOP ATTACHMENT

AND POSITION STOP AS REQUIRED

TO OBTAIN A FLUSH FIT BETWEEN

EDGE OF MINI-VENT AND MAIN

GLASS.

M2718-A

F IG . 9 Mini-Vent Up Stop Adjustment—Thunderbird and Continental Mark V



42-08-10

Power Mini-Vent W indow 42-08-

LOOSEN LOCK NUT USING A 9/32 " A LLEN

WRENCH, TURN THE ADJUSTING SCREW TO

THE LEFT TO MOVE THE FRONT OF THE

VENT OUTBOARD. TURN THE ADJUSTABLE

SCREW RIGHT TO MOVE VE NT INBOARD.

N271

FIG. 10 Mini-Vent In-Out Adjustment—Thunderbird and Continental Mark V

LOOSEN LOCK NUT USING A 9/3 2" ALLEN

WRENCH, TURN THE ADJUSTING SCREW TO

THE LEFT TO MOVE THE FRONT OF THE

VENT OUTBOARD. TURN THE ADJUSTABLE

SCREW RIGHT TO MOVE VENT INBOARD.

N27

F IG .

11 Mini-Vent Full Up Position Adjustment—Thunderbird and Continental Mark V




42-08-11

THE BLADE MUST BE POSITIONED

BETWEEN THE 2 PRONGS ON THE

LOWER ATTACHMENT. IF THE

BLADE IS OUTBOARD OR

INBOARD OF THE "F ORK", THE

VENT WILL NOT OPERATE.

PRONGS ON

LOWER CHANNEL

ATTACHMENT

LOWER

CHANNEL

ATTACHMENT

V E N T

' C H A N N E . L

LOWER CHANNEL

ATTACHMENT

DOOR INNER

PANEL

\ 2721 A

F IG .

12 Mini-Vent Channel Blade Attachment


DOOR AND VENT GLASS

ASSEMBLY

The door and vent glass are to be

removed from the vehicle as a single unit.

Refer to Figs. 1, 13 and 14.

Removal


watershield.

2.

Remove the screws attaching the

weatherstrip end-caps at the rear and

front end of the door.

3. Remove the door outs ide bel t

moulding. (Loosen the door glass

down-stops to gain access to the screw

attachments).

4.

Loosen the stabilizer attaching screws

and remove the stabilizers.

5.

Remove the front and rear upper stop

brackets.

6. Cycle the vent to the full down

position and remove the vent roller

from the vent guide. Also lower the

door glass sufficiently to remove its

attaching rivets from the bracket

(approximately 3 inches).

7.

Remove the three (3) door glass-to-

glass bracket retaining rivets. When

removing the rivets, first knock out

the center pin or mandrel of the rivet

with a drift punch or similar tool.

REMOVE W/STRIP

END CAP (4 SCREWS)

DOOR OUTSIDE BELT MOULDING

(7-9 SCREWS)

REMOVE W/STRIP

END CAP (4 SCREWS)

NOTE:

BELT MOULDING REMOVAL AIDED

BY HAVING GLASS IN FULL DOWN

POSITION WITH DOWN STOP LOOSE

OR REMOVED.

F IG . 13 Door and Vent Glass Removal

N:?519-A



42-08-12

Power Mini-Vent W indow

42-08-1

Then, drill out the remainder of the

rivet using

a 1/4

inch drill. DO

NOT

ATTEMPT TO BREAK OR PRY

OUT THE RIVET, AS THIS WILL

BREAK THE

GLASS.

8. Rotate and lift the door glass and vent

up

and out at the

rear

of

the door,

as

an assembly.

Installation

Refer

to

Figs.

15 and 16.

The vent

and

door glass

are pre-

assembled

and

installed

as a

unit,

as

shown in Fig. 15. Sliding efforts must also

be checked prior to installation, as shown

in Fig. 16.

1. Lower the vent glass prior to loading,

so that

the

vent

cap is 3 to 4

inches

above

the

vent brackets. Be sure that

the vent glass

is

positioned within

the

front w indow guide retainer assembly

and that the vent roller is in the C-

channel

of

the vent window bracket.

2. Feed the regulator roller into the glass

bracket C-channel

and

assemble

the

door glass

to the

regulator glass

bracket using three (3) 1/4-20 x 1

inch bolts, nuts

and

washers

to

replace

the

original rivets. Drop

the

regulator

arm

approximately

one to

two inches

for

clearance,

and

use

one

bolt

as a

drift

to

assure proper glass

position when installing the other two

bolts to the

glass.

Run

the glass

to the

full

UP

p o s i t i o n

to

c o m p l e t e

installation. Torque the bolts to 6-11

ft-lbs.

3.

Install

the

door outside moulding.

4. Install

the

front

and

rear up-stop

brackets.

5. Install

the

two stabilizers (leave loose

until

the

glass adjustment

is

made).

6. Install the weatherstrip front and rear

end-caps.

7. Adjust

the

system following

the

procedures under Adjustment.

8. Install

the

w atershield

and the

door

trim panel.

W IND OW REGULATOR

Removal

Refer

to

Figs.

1, 17 and 18.

1. Remove

the

glass

and

vent from

the

door,

as

outlined

in

this Section.

2. Remove the door glass

run

upper and

lower attaching screws,

and

remove

the run , glass bracket and guides from

the door.

Do not loosen the upper and

lower guides on the bracket.

3.

Disconnect

the

regulator motor wires

at

the

connector.

4. Using

a

drift punch, remove

the

center

pin

from

the

four

(4)

rivets

attaching

the

door

and

regulator

reinforcement

and the

nine

(9)

rivets

attaching

the

regulator

and

motor

support

to the

door inner panel.

REAR GL

UPSTOP

REMOVE

THE

DOOR GLASS

AND

MINI-VENT GLASS

AS

A UNIT. GUIDE

THE

REAR GLASS UPSTOP THROUGH

THE OPENING AT THE REAR OF THE DOOR AS SHOWN

(NOTE: THE

DOOR W/STRIP

END

CAPS

AND

DOOR OUTER

BELT MOULDING MUST

BE

REMOVED

FOR

ADEQUATE

CLEARANCE FOR GLASS REM OVAL)

N252

FIG . 14

Removing Door

and

Mini-Vent Glass

5.

Finish removing

the

thirteen

(13)

rivets with

a 1/4

inch drill.

6. Remove

the

reinforcement plate from

the door inner panel.

7. Remove

the

regulator from

the

door

through

the

upper rear opening,

motor

end

first.

8. Remove

the

rivets

and

drillings from

inside the door.

9. Mount

the

regulator

in a

vise. Drill

a 5/16 inch diameter hole through

the

r e gu la to r s e c to r ge a r

and the

regulator plate. Install

a 1/4

inch bolt

and

nut in the

hole

to

prevent

the

sector gear from moving when

the

m otor

and

dr ive

are

r e m ove d .

R e m o v e

the

m o t o r

and

d r i v e

assembly.

Installation

1. Position

the

regulator

arm as

shown

in

Fig.

17 and insert the regulator into

the large access hole

in the

door

upside down, gradually turning

the

regulator

to the

upright position

as it

is installed.

2. Install five (5) 1/4-20 x 1/2 inch

screw

and

washer assemblies into

the

five holes across

the top of

regulator

and through

the

door inner panel.

I ns t a l l

the

m a tc h ing nu t s

and

washers,

but do not

tighten.

3.

Connect

the

regulator motor wires

and cycle the regulator quadrant gear

as required,

to

install

the

remaining

four (4)

1/4-20 x 1/2

inch screw

a

washer assemblies. Tighten

all

n

(9) attaching screws

to 6-11

ft-

torque.

All nine screw and was

assemblies must be installed with

head of the screw on the regulato

motor support panel side of the d

panel. This will prevent

the

scr

thread from interferring with lin

gears,

etc.

4. Install the door and window regul

reinforcement using four (4)

1/4-2

5/8

inch screw and washer assemb

for retention.

5. Install

the run,

glass bracket

guides

in the

door.

6. Install

the

glass

and

vent assem

into

the

door.

7. Adjust

the

window mechanism

outlined

in

the Adjustment section

this Part.

VENT W IND OW GUIDE

Removal

1. Remove

the

vent glass

and

door g

from

the

door

as an

assembly.

2. Using

a

punch

and 1/4

inch d

remove

the

rivet attaching

the

gu

to

the

door panel.

3.

Remove

the

guide adjusting sc

located

on the

hinge face

of

the d

4. Remove

the

guide.




42-08-13

FABRICATE A SHIM 3/64"

THICK 1/8 " WIDE X 8 " LONG

AND INSERT BETWEEN DOOR

GLASS AND DIV. BAR RUN AS

SHOWN

VENT GLASS (REF I

TIGHTEN TO

6-11 FT. LBS.

TORQUE

AND REMOVE

SHIM

1. SEE ILLUS TRA TION NO. 1 FOR ASSEMBLY OF DIV. BAR BRKTS., BUSHINGS, & SPACERS & VENT .

2. HOLD VEN T GLASS TO DOOR GLASS AS SHOWN AND INSERT SHIM .

3. TIGHTE N BRA CKET SCREWS TO 6-11 FT. LBS. TORQU E.

4. SLIDE VENT GLASS DOWN & REMOVE SHIM.

5. SLIDE VE NT GLASS UP & DOWN TO CHECK FOR BINDS.

6. LUBRICATE DIV. BAR AND BRACKETS WITH MINI-VENT LUBE (D3AZ-1955 3-A).

N; 521-B

F IG . 15 Pre-Assembling Door and Mini-Vent Glass



42-08-14


42-08-1

MINI-VENT GLASS

ASSURE THAT GLASS

BRACKETS ARE TIGHT

(6-11 FT. LBS. TORQUE)

THE VENT WINDOW ASSY. MUST SLIDE

IN

BOTH

DIRECTIONS WITH A MAXIMUM OF 14 LBS. FORCE

FOR THE FULL LENGTH OF THE DOOR GLASS . THE

WINDOW ASSY. IS TO

BE

HELD

IN

POSITION SHOWN

WHEN THE SLIDING EFFORTS ARE CHECKED.

MINI-VENT LUBE (D3AZ-19553-A) IS TO BE APPLIED

TO BRACKETS AND VENT DIV.

BAR

WHICH REDUCES

SLIDING EFFORTS.

PUSH GAUGE'

N2522

FIG. 16

Checking Sliding Efforts—Mini-Vent



42-08-15


42-08-15

POSITION THE REGULAT OR ARMS AS SHOWN AND INSERT

THE REGULATOR THROUGH THE ACCESS HOLE IN THE DOOR

INNER PANEL UPSIDE DOWN

AND

GRADUALLY TURN

TO

UPRIGHT POSITION DURING INSTALLATION

FIG. 17 Inserting Wind ow Regulator Into Door—Lincoln

POSITION REGULATOR ARMS

TO

INNER PANEL AS SHOWN

AND INSTALL (9) SCREW & WASHER ASSEMBLIES (PART

57487-S2) TO ATTACH THE REGULATOR TO THE DOOR

INNER PANEL. NOTE: ALL (9) SCREW AND WASHER

ASSEMBLIES MUST BE INSTALLED W ITH THE HEAD OF

THE SCREW ON THE REGULATOR AND MOTOR SUPPORT

PANEL SIDE OF THE DOOR INNER PA NEL.

N2524 A

FIG. 18 Installing Window Regulator—Lincoln



42-08-16 Power Mini-Vent W indow

42-08

Installation

1. Position the vent window guide in the

door and attach to the inner panel

using a 1/4-20 x 1/2 inch screw and

washer assembly and a matching nut

and washer.

2. Install the vent guide adjusting screw

into the hinge face of the door. Do not

tighten this screw until the glass

installation is complete and the entire

glass system is cycled to the down

position.

3.

Ins ta l l

the

vent

and

door glass

assembly and adjust the system.

DOOR W INDOW

RUN

AND/OR

GUIDE

Removal


watershield.

2.

Remove the three (3) glass-to-glass

bracket retaining rivets.

3. Support the glass and remove the run

upper and lower attaching screws.

4. Disengage

the

glass from

the

glass

bracket and remove the run, glass

bracket and guide from the door

as

an

assembly.

MINI-VENT W INDOW ASSY. (REF.)

5. Remove the run from the guides, and

the guide from the glass bracket.

Installation

1. Assemble the glass bracket,guide and

glass run.

2.

Position the glass run in the door and

install the two attaching screws after

feeding

the

regulator roller into

the

glass bracket C-channel.

3.

Position

the

glass-to-glass bracket

and assemble with three (3) 1/4-20 x

1 inch bolts and matching nuts and

washers.

The

regulator

arm can be

moved to gain access to the attaching

p o i n t s . T i g h t e n the n u t s to

Specification.

4. Adjust the run and guide as outlined

in the Adjustment Section of this

Part.

5.

Install the w atershield and the door

trim panel.

DRIVE AND/OR MOTOR

Removal


watershield.

USE HAND PUMP TYPE

APPLICATOR. ASSURE

THAT CONTAINER IS

PROPERLY CLEANED

BEFORE FILLING WITH

D3AZ-19553-A WINDOW

LUBE.

2.

Drill a 3/4 inch diameter hole

dimple located near the bottom

of the door opposite the wi

motor drive.

The

hole

saw

should

be as

short

as

possible,

1/4

inch beyond

the saw.

3. Disconnect the motor wires a

connector.

4. Working through the two ex

holes and the drilled hole, remov

three 3) motor and drive-to-reg

attaching screws. Separate

the

m

and drive from the regulator

remove the motor and drive from

door.

Installation

1. Position the motor and drive i

door and to the regulator. Insta

three attaching screws just snug

tight.

2.

Connect the motor wires a

connector and cylce the glass

sure of gear engagement. Whe

gears

are

engaged, tighten

the

motor

and

drive attaching screw

3. Install the w atershield and the

trim panel.

CYCLE THE VENT GLASS DOWN TO POSITION

SHOWN

AND

APPLY SILICONE FLUID P ART

NO

D3AZ-19553-ATOTHE D IVISION BAR AT THE

(5) LOCATIONS INDICATED BY ARROWS IN

VIEW

"A".

• APPLY LUBRICANT

AT THESE LOCATIONS

INNER

&

OUTER VENT WINDOW BRACKETS

(REF).

VIEW

A

FIG. 19 Mini-Vent W indow Lubrication

.

NOTE: AFTER APPLYING SILICONE, CYCLE TH

VENT WINDOW 3-4 COMPLETE CYCLES

ASSURE THA T THE SILICONE REACHES

ALL CONTACT POINTS.

N2

SPECIFICATIONS

Description

Glass Stop Attaching S cr e w 0

Run Attaching Screws

Stabilizer Attaching Screws

Regulator Arm Roller Attachment

Upper Stop Bracket

Torque

6-11 ft-lb

6-11 ft-lb

6-11 ft-lb

6-11 ft-lb

6-11 ft-lb

Description

Motor Bracket-to-Motor

Motor Bracket and/or Regulator to-Inner PanelQ


Glass-to-Glass B ra ck etQ

Torqu

13-32 m

6-11 f

6-11 f

6-11 f

Q R i v e t e d in Production

CN 2



42-21-1

Dual U-Run Rear Door Window Mechanism

42-211-1

Dual

U-Run

Rear Door

Window Mechanism

P A R T

42-21

SUBJECT PAGE

ADJUSTMENTS 21-1


Glass 21-1

Glass Run 21-2

SUBJECT

PAGE


Regulator

21-2

SPECIFICATIONS 21-3

CR2025 A

ADJUSTMENTS


watershield.

2. Loosen the window mechanism

adjusting screws (Items A, B, C, and

D, Fig. 1).

3.

Raise the glass to the UP position.

Then, tighten the front run retainer

attaching screw (Item A) and the

equalizer arm attaching screw (Item

B) to specification.

4.

Lower the glass until the top edge is

approximately 4 inches above the belt

line.

Then, tighten the front run

retainer lower attaching screw (Item

C) to specification.

5.

Position the rear run retainer and

division bar firmly against the glass,

and tighten the attaching screw (Item

D) to specification.

6. Check the window mechanism

operation. Then, install the


N2:t29-A

FIG.

1 Rear Door Window Mechanism Adjustment—Maverick and Comet

REMOVAL

AND

INSTALLATION

GLASS

Removal


watershield.

2. Remove the front run retainer upper

and lower attaching screws (Fig. 2).

Then, pull the retainer from the run

and lay the retainer in the bottom of

the door.

3. Remove the rear run retainer lower

attaching screw.

4. Lower the glass and remove the rear

run retainer and division bar upper

attaching screw (Fig. 2).

5. Loosen the rear run retainer and

division bar from the stationary glass

weatherstrip.

6. Remove the stationary glass from the

door.

7.

Remove the rear run retainer and

division bar from the door.

8. Remove the glass front and rear



punch (Fig. 3). Support the glass and

pry the retainer from the drive arm

bracket and glass by inserting a

screwdriver behind the glass retainer

flange.

Installation

1. Position the glass in the door and to

the regulator arm bracket. Install the

two bracket-to-glass retainers (Fig.

3) . Then, insert the center pin into

each retainer until it is flush with the

retainer flange.

2.

Lower the glass and insert the rear

run retainer and division bar in the

door.

3. Apply silicone lubricant (D3AZ-

19553-A) or equivalent to i:he



4 2 -2 1 -2 Dual U-Run Rear Door Window Mechanism

4 2 - 2

stationary glass weatherstrip. Install

the glass and weatherstrip in the door.

Then, move the run retainer and

division bar into position and install

the upper attaching screw.

4. Install the front run retainer.

5.

Install the front and rear runs in the

retainers.

6. Install the rear run retainer lower

attaching screw. Then, adjust the

window mechanism as outlined in the

Adjustment Section.


panel.

REGULATOR

Removal

1.

Remove the door trim panel and

watershield.

2.

Remove the front and rear glass



punch (Fig. 3). Support the glass and

pry the retainer from the drive arm

bracket and glass by inserting a

screwdriver behind the glass retainer

flange.

3. Remove the screw attaching the

regulator equalizer arm to the door

inner panel.

4.

Remove four regulator attaching

screws, and remove the regulator

from the door.

Installation

1. Position the regulator to the door

inner panel and install the attaching

screws.

2.

Position the equalizer arm to the door

inner panel and install the attaching

screw.

3. Position the regulator arm bracket to

the regulator arm and the glass. Push

the glass rear retainer into the

Then, install the glass retainer p

pushing it into the retainer hole

the end of the pin is flush wit

retainer flange (Fig.3). Instal

front retainer the same way.

4.

Adjust the window mechanis

outlined in the Adjustment Sec

5. Install the watershield and door

panel.

GLASS RUN

Removal

1.

R e m o v e t h e t r i m p a n e l


2.

Remove the front run ret

attaching screws (Fig. 2), and re

the run from the retainer.

3.

Remove the rear run retainer

attaching screw (Fig. 2).

SCREW 376129-S2

(8-20 LB FT TORQUE)

WEATHERSTRIP 26928

SCREW AND WASHER

382682-S100

(6-11 LB FT TORQUE)

SCREW AND WASHER

57485-S2

(3-7 LB FT TORQUE)

N2

FIG. 2 Rear Door Window Mechanism—Maverick and Comet



42-21-3

Dual U-Run Rear Door Window Mechanism

42-21-3

4. Lower the glass and remove the rear

run retainer and division bar upper

attaching screw.

5. Loosen the stationary glass from the

division bar, and remove the glass

from the door.

6. Pull the glass run from the door.

Installation

1. Position the glass run to the door and

press firmly into the door frame.

2. Apply s ilicon lubricant to the

stationary glass weatherstrip, and

install the glass and weatherstrip in

the door.

3. Move the rear run retainer and

division bar into position and install

the upper attaching screw (Fig. 2).

4. Press the run firmly into the rear run

retainer.

5. Install the front run retainer and

insert the run into the retainer.

6. Install the rear run retainer lower

attaching screw.

7. Adjust the window mechanism as



panel.

BUTTON RETAINER

GLASS RETA INER REMOVAL

PUSH BUTTON C UT

WITH DRIFT PU^ CH

PRY RETAINER CU T

WITH SCREWDRIV \R

GLASS RETAINER INSTALLA TION

PUSH RETAINER

IN

FIRML'

PUSH BUTTON IN UNTIL

FLUSH WITH RET AINE R SCREWDRIV

i R

______ \

\

N242.S-A

FIG.

3 Glass Retainer Removal and

Installation

SPECIFICATIONS

DUAL U RUN REAR DOOR WINDOW MECHANISM TORQUE SPECIFICATIONS

Description

Rear Run Lower

Rear Run Upper

Front Run

Equalizer Arm

Window Regulator

Torque

3-7 ft-lb

6-11 ft-lb

6-11 ft-lb

8-20 in-lb

6-11 ft-lb

CN2443-B



42-24-1

Single Tubular Run Rear Door W indo w Mechanism

42-2

Single Tubular Run Rear Door

Window Mechanism

P A R T

42-24

SUBJECT

PAGE SUBJECT

PAG

ADJUSTMENTS 24-1


Glass

Guides

Regulator

24-2

24-2

24-2


Run 24-

Window Drive 24-

Window Motor 24-

SPECIFICATIONS 24-

ADJUSTMENTS

Thunderbird, LTD II, Cougar,

Ford, Mercury, and

Lincoln Continental



adjustm ent can be performed. If a


follow the adjustments

in

the o rder given.


must be performed with the door trim

panel and watershield removed. After the

adjustment(s) are completed, install the


Glass Position— ore

and Aft


in the opening if the glass has been

removed or if extreme door hinge

a d j u s t m e n t s a r e p e r f o r m e d . T o

reposition the glass, loosen the run upper

attaching screw (Item A, Fig. 1), and

reposition the glass. Tighten the screw

after glass is moved to desired position.


The stabilizers are used to support the

glass at the belt line. The trim panel must

be removed to adjust the stabilizers.

Then, with the glass in the UP position,

push the front stabilizer firmly against

the glass surface and tighten the

attaching screw (Item B, Fig. 1). Repeat

the procedure for the rear stabilizer.

Glass

In Out

The in-out adjustment is used to

obtain a good seal with the weatherstrip

at the top edge of the glass. This

adjustment is made by repositioning the

lower guide with respect to the glass

bracket. To adjust the in-out of the glass,

loosen the two guide lower attaching

screws (Item C, Fig. 1), and move the top

edge of the glass inward or outward as

required to obtain a good seal with the

weatherstrip. Then, tighten the guide

attaching screws to 6-11 ft-lbs torque.

Upper Stop

Adjustment

The upper stop adjustment is used to

limit the up travel of the glass to maintain

a constant glass height when the glass is

CR2026

UPPER REAR STO

N2

FIG. 1 Single Tubular Run Rear Door Window Mechanism Adjustment

raised to the full closed position. The

door trim panel must be removed to

adjust the up stops. To adjust the stops,

raise the window to the UP position.

Check to be sure that there is no

interference when the door is opened.

Then, position the up stop brackets down

against the glass stops, and tighten the

stop bracket attaching screw (Item D,

Fig. 1). Use this procedure for both the

front and rear upper stops.

Lower Stop Adjustment

The lower stop is used to control the

depth the glass can be lowered into the

door. To adjust the lower stop, remove

the door trim panel. Loosen the lower

stop retaining screw (Item E, Fig. 1)

lower the glass until the top edge is

to 1/4 inch above the outer panel. T

lift the stop against the glass bracke

tighten the retaining screw.

GRANADA AND MONARCH

1. Secure upper and lower division

attachment after it is positioned a

rearward as possible (Fig. 2).

2.

Run glass into frame to the ful

position.

3.

Secure nut and washer assemb

top of run assembly. Torque to

ft-lbs.



42-24-2

Single Tubular Run Rear Door Window Mechanism

42-24-2

4. Secure nut and washer assembly at

bottom of run assembly. Torque to 6-

11 ft-lbs.

5. Run glass down and up to check for

binding.

6. If binding occurs, loosen bottom

attachment of

tube,

run glass to 1 inch

from UP position. Adjust bottom

attachment inboard or outboard (in

opposite direction of binds) to remove

binds. Secure all attachments.


GLASS

Removal


watershield.

2. Remove the upstops from the door

inner panel.

3.

Support the glass and remove the

glass-to-glass bracket attaching rivets.

Remove the center pin from the rivets

with a drift punch. Drill the head

from each rivet with a 1/4 inch drill.

Remove the rivets and glass-to-glass

bracket. (See Figs. 2, 3, 4 and 5.)

4.

Loosen the front and rear stabilizer

attaching screws, and move the

stabilizers away from the glass. (Figs.

3, 4 and 5.)

5. Remove the glass support and remove

the glass from the door.

Installation

1. Position the glass in the door, and

position the glass bracket to the glass.

Install

1/4-20x1

inch hex head bolts

and 1/4-20 hex nuts to attach the

glass bracket to the glass. Tighten the

bolts and nuts to specification. (See

specifications at end of this Part.)

2. Install the upper front and rear stops

on the inner panel with attaching

bolts with

1/4-20x1

inch hex head

bolts and 1/4-20 hex nuts. Tighten

the bolts and nuts to specification.

3. Adjust the glass to fit the opening and

adjust the stabilizers as outlined in

the Adjustment Section.

4. Install the watershield and trim panel

on the door.

W IND OW REGULATOR

Removal


watershield and support the glass in

the UP position.

2.

If equipped with electric windows

(except Ford, Mercury, Thunderbird,


Mark V), remove the center pin from

the motor bracket to inner panel

attaching rivet with a drift punch.

Then drill the head from the rivet

with a 1/4 inch drill and remove the

rivet. Disconnect the motor wires at

the connector.

3.

Remove the center pin from the


punch. Then drill the head from the

regulator attaching rivets with a 1/4

inch drill.

4.

Disengage the regulator arm from the

glass bracke t , and remove the

regulator from the door.

5. If equipped with power windows,



the regulator sector gear and the

regulator plate. Install a 1/4 inch bolt

and nut in the hole to prevent the

sector gear from moving when the

motor and drive assembly is removed.

Remove the motor and drive from the

regulator. Install the motor and drive

on a new regulator.

Installation

1. Lubricate the window mechanism as

outlined in Part 42-01.

2. Install nut and retainer assemblies on

the regulator mounting plate and

motor support bracket at the rivet

attaching holes.

3.

Position the window regulator into

the door and insert the regulator arm

roller into the glass bracket channel.

4. Position the regulato r to the inner

panel, and install 1/4-20x1/2 inch


the regulator to the inner panel.

Tighten the screws securely.


install a 1/4-20x1/2 inch screw and

washer assembly to attach the motor

bracket to the inner panel (except

Ford, Mercury, Thunderbird,

Lincoln Continental and Conti-

nental M ark V ). Con nect the

motor wires at the connector.

6. Check the operation of the window

m e c ha n i sm . T he n , i ns t a l l t he

watershield and trim panel on the

door.

W I N D O W M O T O R A N D / O R

DRIVE

Removal

1. Re m ove th e t r im pa ne l a nd

watershield.

2. Disconnect the moto r wires at the

multiple connector.

3.

All models except Ford, Mercury,

Thunderbird, Lincoln Continental

and Continental Mark V have holes

punched in the door panel for motor

and drive removal. On models

without access holes, use the dimples

located on the inner door panel to

drill three 3/4 inch holes in the door

for access to the motor and drive

attaching screws. The holes should be

drilled with the glass in the UP

position. The hole saw pilot drill

should be as short as possible, about

1/4 inch beyond the saw.

4. Working through the 3/4 inch holes,

remove the three motor and drive-to-

regulator attaching screws. Remove

the motor and drive from the dcor.

Installation

1.

Position the motor and drive to the

regulator and install the three screws

just snug—not tight.

2. Connect the motor wires at the

connector and cycle the glass to

assure gear engagement. After the

gears are engaged, tighten the three

motor and drive attaching screws.

3.

Check the window operation and

install body tape over the drilled hole

( For d , M e r c ur y , T hunde r b i r d ,


M a r k V ) . T h e n , i n s t a l l t h e


RUN AND/OR GUIDES

Removal

1. Re m ove the t r im pa n e l a n d


2. Support the glass and remove four

screws attaching the upper and lower

guides to the glass bracket (Figs. 2, 3,

4 and 5).

3.

Remove the run upper and lower

attaching screws, and remove the run

and guides from the door.

4. Remove the guides from the run

(Figs.

2, 3, 4 and 5).

Installation

1. Assemble the guides on the run

making sure they are in the correct

order (Figs. 2, 3, 4 and 5).

2. Position the run in the door and the

guides to the glass bracket.

3.

Install the run upper and lower

attaching screws, and the guide

attaching screws.

4.

Adjust the run and guides as outli led

in the Adjustment Section.

5. Install the watershield and door t rim

panel.



GLASS RUN

SCREW

WEATHER STRIP

RETAINER AND

DIVISION BAR

NUT AND WASHER

ASSEMBLY

SPACER

SCREW AND WASHER

ASSEMBLY

DOOR WINDOW

BRACKET

VIEW

SCREW AND WASHER IN-OUT

ADJUSTMENT

FIG. 2 Adjustment Points—Granada and Monarch Rear Door

N



42-24-4

Single Tubular Run Rear Door W indow Mechanism

42-24-4

RETAINER

BUTTON STABILIZER

(ON GLASS)

BUTTON STABILIZER

(ON OUTER REINFORCEMENT)

STOP

RIVET

UPPER STOP

BRACKET

SCREW RIVE T

VIEW JQ ELECTRIC

REGULATOR

DOOR WINDOW

BRACKET

UP STOP BRACK ET

SCREW

DOWN STOP ^

MO

-f

OR

BRACKET

TUBULAR

WINDOW RUN

ASSEMBLY

NUT AND

WASHER ASSEMBLY

N25" 3-A

F IG . 3 Rear Door Wind ow Mechanism—Lincoln

LOWER STOP

FIG. 4 Rear Door Wind ow Mechanism—T hunderbird, LTD II and Cougar



42-24-5

Single Tubular

Run

Rear Door W indow Mechanism

42-2

G L A S S

B R A C K E T

2 6 3 A 5 2 - 3

LOWER GUIDE

2 2 2 A 9 2

LOWER

S T O P

21758

R-JN

Z63A70-1

VIEW D

RETAINER

VIEW

A

GLASS

WA

RIVET

RIVET

VI

RUN

RUN

RUN BRACKET

INNER

PANEL

VIEW C

VIEW

D

N

F IG . 5 Rear Door Window Mechanism—Ford and Mercury



42-24-6

Single Tubular Run Rear Door W indow Mechanism

42-24-6

SPECIFICATIONS

SINGLE TUBULAR RUN REAR OOOR WINDOW MECHANISM TORQUE SPECIFICATIONS

Description

Glass Stop Attach ing Screw ©

Run Attaching Screws

Stabilizer Attaching Screws

Upper Stop Bracket

Motor Bracket-to-Motor

Motor Bracket and/or Regulator-to-lnner Panel ©


Glass-to-Glass Brac ket ©

Torque

6-11 ft-lb

6-11 ft-lb

6-11 ft-lb

6-11 ft-lb

13-32 in-lb

6-11 ft-lb

6-11 ft-lb

6-11 ft-lb

© Rivets are used in prod uction .

CN2445-B



42-33-1


42-3

Pivot Ty pe Quarter W indow

P A R T

42-33

SUBJECT PAGE

REMOVAL

AND

I NS TA LLA TI ON

Glass 33-1

Hinge

33-3

Latch 33-3

SUBJECT

PAG


Quarter Window Assembly 33

Weatherstrip 33

CR2027


Refer to Part 43-01

for

fixed Quarter

Windows.

GLASS

Maverick and Comet

Removal

1. Pry off the latch bracket cover (Fig.

1).

2.

Remove the latch bracket retaining

screws.

Peel back the w ea th er s t rip to gain

access to the window hinge retaining

screws (Fig. 1). Remove the retaining

screws

and

remove

the

glass from

the

vehicle.

Push the pin attaching the latch

to the

la tch retainer (Fig. 1) with a drift

punch.

R emo v e the r e ta in er nut from the

l a t c h r e t a i n e r , and r e m o v e the

retainer

and

bushings from

the

glass.

Installation

1. Install the latch on the glass.

Po s i t io n

the

w in d o w g las s

in the

window opening and install the glass

hinge retaining screws.

Instal l the latch bracket retain ing

screws.

Install the latch bracke t cover.

3.

4.

5.

2.

3.

4.

Pinto and Bobcat (Except

Wagon)

Removal

1. Remove the latch trim cover (Fig. 2).

2.

R e m o v e

two

sc r ews a t tach in g

the

latch to the roof side.

3.

With

an

assistant, press

on

each side

of the hinge, and pull the hinge from

the body. Repeat this procedure for

the other hinge.

4. Push the hinge pin from each hinge

with a small d iameter rod inserted

through the hole in the bottom of the

hinge. Then, remove

the

hinges from

the glass frame.

W INDO W GLASS

ASSEMBLY 6229706-7

LATCH RETAINER-302A02

BUSHINP-302A02

RETAINER NUT

LATCH BRACKET

COVER 6230584

FIG. 1 Quarter W indow Installation—Mav erick and Comet

5. Remove pin from the latch bolt and

latch. Remove the latch from the bolt.

6. Remove the latch bolt and nut from

the glass.

Installation

1. Install

the

latch bolt

and nut on the

glass.

2.

Position latch

to the

latch bolt

and

install the pin.

3.

Position the hinges to the glass and

install the hinge pins. The larg

in the h inge must be on top

installed.

4. Position the glass and hinges

body. Press the hinges firml

place.

5. Position the latch to the roof s

and install

the two

attaching s

6. Install the latch trim cover.



42-33-2


42-33-2

VENT LATCH

WEATHERSTRIP

VIEW A

-—GLASS

WEATHERSTRIP

VIEWB

WEATHERSTRIP

B-PILLAR

MOULDING

VIEWC

QUARTER

WINDOW

ASSEMBLY

HINGE

B-PILLAR WEATHERS"RIP

VIE W P N21 75-B

FIG . 2 Quarter Vent Wind ow— Pinto and Bobcat (Except Wag on)

•QUARTER PANEL

I

VIEW A N2478-B

FIG.

3 Pinto and Bobcat Station Wa gon Quarter W indow



42-33-3


42-

Pinto and Bobcat Wa gon

Removal

1. Mark the position of the latch on the

body. Then, remove three screws

attaching the latch to the body (Fig.

3).

2. With an assistant, depress each side

of the hinge, and pull the hinge from

the body. Repeat this procedure for

the other hinge.

3.

Push the hinge pin from each hinge

with a small diameter rod inserted

through the hole in the bottom of the

hinge. Then, remove the hinges from

the glass frame.

4. Remove the latch from the glass.

Installation

1. Install the latch on the glass.

2. Position the hinges to the glass and

install the hinge pins. The large hole

in the hinge must be on the top when

installed.

3.

Position the hinges to the body and

press them firmly into place.

4. Position the latch to the body in the

exact same location as it was before

being removed. Failure to properly

position the latch could result in glass

failure.

5. Install the three latch attaching

screws.

WEATHERSTRIP

Maver ick , Comet, P in to and

Bobcat

1.

Remove the vent window assembly.

2. Pull the weatherstrip from the vent

window opening.

3.

Clean all adhesive from the qua rter

window opening flange.

4. Apply a bead of adhesive (19552) to

the entire window opening on the

outside of the window opening flange.

5. Apply a soap solution to the inner

side of the window opening flange.

6. Install the weatherstrip in the window

opening making sure the weatherstrip

is seated over the flange.

7. Install the vent window assembly and

clean all excess adhesive and soap

solution from the window opening

area.

HINGE

M aver ick an d Co m et

Removal

1. Pry off the latch bracket cover (Fig.

1).

GLASS WINDOW ASSEMBLY

N

FIG. 4 Quarter Window—Mustang 3-Door Model

2. Remove the two la tch bracke t

retaining screws.

3.

Peel back the weatherstrip to gain

access to the window hinge attaching

screws (Fig. 1). Remove the hinge

attaching screws and remove the glass

and hinge from the vehicle.

4.

Remove the moulding and hinge

assembly from the glass.

Installation

1. Install the moulding and hinge

assembly on the glass.

2.

Position the glass in the opening and

install the hinge attaching screws.

3.

Position the latch to the body and

install the two attaching screws.

4. Install the cover on the latch bracket.

LATCH

1. Remove the latch trim cover (Fig. 1

and 2).

2. Remove two screws attaching the

latch to the roof side.

3.

Remove the pin from the latch

retainer and latch at the glass. Then,

remove the latch from the retainer.

4.

Position the latch to the retainer and

install the pin.

5. Position the latch to the roof side, and


6. Install the latch trim cover.

QUARTER WI ND O W ASSEMB

M u s t a n g

The Mustang 3-Door Model qu

window is replaced as a wi

assembly (Fig. 4 ).

Removal

1. Remove the window upper reta

screws (3).

2. Remove the window front ret

screws (3).

3.

Remove the window lower ret

bolts (2).

4. R e m o v e t h e q u a r t e r w i n

assembly.

Installation

1.

P o s i t i o n t h e q u a r t e r w i n

assembly and install the wi

lower retaining screws (2) hand

2. Install the window front ret

screws (3).

3. Install the window upper reta

screws (3).

4.

Position the qua rter window, m

certain that it is properly seate

5. Tighten the screws and torqu

window lower retaining bolts

6-11 ft-lbs.



42-34-1

Guide and Run Sliding Quarter Windo w Mechanism

42-34-1

Guide and Run Sliding Quarter

Window Mechanism

P A R T

42-34

SUBJECT

ADJUSTMENTS

34-1


Glass

PAGE SUBJECT PAGE

REMOVAL

AND

INSTA LLATIO N (Cont 'd.)

Guide 34-3

Regulator

34-2

34-2 Run 34-3

ADJUSTMENTS

Separate adjustment steps

are

given


adjustment

can be

performed.

If a

complete glass adjustment

is

required,

follow the adjustments in the order given.

All adjustments should be made after the

door glass is properly adjusted and must

be performed with

the

trim panel

and

w a te r sh i e ld r e m ove d . A f t e r the

adjustment(s)

are

completed, check

the

glass

for

air and w ater leaks and readjust

if necessary. Then, install the watershield

and quarter trim panel.

Weatherstrip lubricant or water can

be used

to

inspect

for

proper sealing

of

glass against a weatherstrip. When the

weatherstrip

is

wet, the area that contacts

the glass will be dark black. Any area not

contacting the glass will be a dull grey.

Always check

the

glass

for

good sealing

against the weatherstrip after adjusting

the window mechanism.

Glass Position

—

Up and Down

The glass up and down adjustment is

used

to

obtain

a

good seal with

the

roof

w e a t h e r s t r i p on s l i d i n g g l a s s

mechanisms.

To

adjust, move

the

glass

to

the

closed position. Loosen

the

guide

front and rear attaching screws (Item A,

Fig.

1).

Move

the

glass

up or

down,

as

necessary, to position the top edge of the

glass into

the

weatherstrip pocket.

The

glass front edge at the weatherstrip

should

be

parallel

to the

door glass rear

edge when properly positioned. Then,

tighten

the

guide attaching screws.

Glass Stop Adjustments

The glass stop adjustment is used to

limit

the

forward travel

of the

glass

to

maintain a constant position

to the

door

glass when the quarter glass is closed. To

adjust, loosen the stops attaching screws

(Items B and C, Fig. 1). Move the quarter

CR2028-A

GUIDE FRONT BRACKET

A

I.

//UPPER FRONT STOP

LOWER FRONT STOP

GUIDE ASSEMBLY

Vt

REAR STOP

ATTACHING

BOLT

" * - . .

%

. . / ^ R U N R EA R B RA CK ET N 17 6-C

FIG.

1

Quarter Window Mechanism Adjustment—Typical

glass to

the

door glass to obtain a good

seal position

at

the

weatherstrip. With

the glass

in

position, move

the

upper

front stop rearward against the glass and

tighten the attachin g screw (Item B).

Move

the

lower front stop rearward

agains t the glass and t ighten the

attaching screw (Item C). Cycle the glass

and check

to be

sure

the

stops

are

properly adjusted so that binding does

not exist between

the

door

and

quarter

glass when the door is opened and closed.

Glass In-Out Position

The in-out adjustment

is

used

:o

match the quarter glass to the contour of

the door glass,

and

obtain

a

good seal

at

the glass weatherstrip.

To

adjust, loosen

the glass run front and rear bracket

attaching screws (Items D and E, Fig.

I).

Move the lower edge of the quarter glass

in

or out as

necessary

for

proper

alignment with

the

door glass. Then,

tighten the run attaching screws (Items

D

and E).



42-34-2

Guide and Run Sliding Quarter Window Mechanism

42-3


GLASS

Removal

1. Remove the pressure relief

valve

from

the quarter lock pillar.

2 . Remove four screws attach ing the

dust seal to the quarter pillar at the

belt line, and remove the seal.

3 .

Remove the quarter trim panel and

watershield.

4 .

Remove two screws attaching the

glass run and brackets to the inner

panel (Fig. 2).

5 .

Remove two screws attaching the

guide and brackets to the inner panel,

and remove the rear stop from the

guide (Fig. 2).

6. Remove two nuts retaining the drive

arm bracket to the glass. Then, lower

the glass and slide the guide

off

the

glass rollers and remove the guide

through the pressure relief valve

opening in the quarter lock pillar. It

may be necessary to jiggle the guide

for removal.

7 .

Remove the glass from the quarter.

Installation

1.

Transfer the glass hardware to the

new glass.

2 .

Position the glass in the quarter.

3 .

Lubrica te the guide as outlined in

Part

42-01.

4 . Install the guide in the quarte r

through the pressure relief valve

opening in the quarter lock pillar.

Insert the glass rollers into the guide

and install the guide bracket to inner

panel rear attaching screw F i g . 2 ) . Be

sure the glass bracket rollers are

properly inserted into the guide.

5 .

Position the drive arm bracket to the

window regulator and the glass

bracket studs. Then, install the

retaining nuts.

6. Install the guide front bracket-to-

inner panel attaching screw (Fig. 2).

Install the rear stop on the guide in

the location shown in

F i g . 2 .

This stop

must be installed in the specified

location.

7 .

Position the glass run and brackets to

the glass and inner panel, and install

the two attaching screws snug.

8. Adjust the quarter glass as outlined


9. Install the watershield and quarter

trim panel.

1 0 .

Install the quarter pillar dust seal and

the pressure relief valve.

REGULATOR

Removal

1. Remove the quarter trim panel and

watershield.

2 .

Remove the center pin from th

rivets attaching the regulator

inner panel with a drift punch.

drill out the rivets with a 1/4

drill.

3 . Disconnect the regulator motor

at the connector if equipped

power w indows.

4 .

Disengage the window regulato

from the drive arm bracket

remove the regulator from

quarter.

5 .

If equipped with power win

remove the m otor and drive ass

from the regulator.

Installation

1.

Install the motor and drive ass

on the window regulator. Insta

nut and retainer assemblies o

regulator mounting plate a

attaching holes.

2 .

Position the window regulator

drive arm bracket and the inner

3 .

Install four screw and w

assemblies to attach the wi

regulator to the inner panel. T

the bolts securely.

4 .

Connect the window regulator

wires at the harness connec

equipped with power windows

GUIDE FRONT' f:*

:

"--tt

BRACKET

GLASS 29700-1

IF REMOVED, REPLACE WITH

SCREW NO. 57487 -S2' \

AND NUT NO. 378622-S2 -

UPPER FRONT STOP

--.--.

;

. 30600-1?/

DRIVE ARM BRACKET

30014-5

STOP ATT ACHING SCREW

HOLE WITH OPERA WINDOW

STOP ATT ACHING SCREW

HOLE WITHOUT OPERA WINDOW

W I N D O W J

R E G U L A T O R

30306- 7

\

• • *E L EC T RI C W I N D O W R E G U L A T O R

. . : y .

v

.

v

G U I D E

. IF REMOVED, REPLACE

\\ \ SCREW AND NUT

\

57487-S2 & 378622-S2

ACEWTh - X ^ X

-

NO. 'S :.-

... i £>?

622-S2

" * - - • - - ; . - > - . . . . • "

*••?

111

*U N

REAR BRACKE i

/ 30574

GLA

GLASS ROLLE R

VIEW

A

N

F I G . 2 Quarter W indow Mechanism—Thunderbird and Continental Mark V



42-34-3 Guide

and Run

Sliding Quarter W indow Mechanism

42-34-3

5.

C h e c k the w i n d o w for p r o p e r

o p e r a t i o n . T h e n , i n s t a l l the

watershield and quarter trim panel.

GUIDE

Removal

1.

Remo ve the pressure relief valve from

the quarter lock pillar.

2.

Remove four screws a t taching the

dust seal

to the

quarter lock pillar

at

the belt line, and remove the seal.

3.

Remove

the

quar ter trim panel

and

watershield.

4.

R e m o v e two s c rews a t t ach ing the

guide and brackets to the inner panel

(Fig. 2).

5. Remove

the

rear stop from

the

guide

(Fig. 2).

6. Remove

two

nuts retaining

the

drive

a rm bracke t to the glass (Fig. 2).

Then, lift the glass up and out of the

run. Lower the glass and slide the

guide off the glass rollers and remove

the guide through the pressure relief

valve opening. It may be necessary to

jiggle

the

guide

for

removal.

7 . Remove the b r a c k e t s , s t o p , and

bumper from the guide.

Installation

1. Assemble the b racke t s , s top , and

bumper to the guide (Fig. 2).

2.

L ubr ica te the guide as out l ined in

Part

42-01.

3.

Ins e r t

the

gu ide in to

the

q u a r t e r

t h r o u g h the pres sure re l ief va lve

opening. Insert

the

glass rollers into

the guide and position the guide to the

quarter inner panel.

4.

Position the drive arm bracket to the

glass, and install the two re ta ining

nuts.

5.

Install the two screws attaching the

guide bracket

to the

inner panel.

6. Install the rear stop on the guide in

the location shown in Fig. 2.

This stop

must be installed in the specified

location.

7.

Adjust th e guide and upper front stop

a s o u t l i n e d in the A d j u s t m e n t

Section.

8. Install the watershield, qu arter trim

panel, quarte r pillar dust seal, and the

pressure relief valve.

RUN

Removal

1. Remove the qua rter trim panel and

watershield.

2.

Remove the glass run front bracket

a n d r e a r b r a c k e t - t o - i n n e r p a n e l

attaching screws,

and

remove

the run

(Fig. 2).

3.

Remove

the

brackets from

the run.

Installation

1. Position the front and rear brackets

to the g la s s run, and ins ta l l ihe

attaching screws.

2.

Position the run to the inner panel

an d

the

bottom edge

of the

glass.

3.

Install the glass run brackets to-inner

panel attaching screws.

4.

Adjust the glass run as required.

5.

Install the w atershie ld and qua r te r

trim panel.



42-35-1


42-35

Single Guide Quarter

Window Mechanism

P A R T

42-35

SUBJECT PAGE

ADJUSTMENTS 35-1


Glass 35-2

Guide

35-2

SUBJECT PAGE


(Cont'd.)

Motor and/or Drive

35-

Regulator

35-

Weatherstrip

35-

ADJUSTMENTS

BELT IN-OUT ADJUSTMENT

To adjust, loosen the guide to inner

panel upper two attaching screws (Fig.

1).

Move the glass inboard or outboard

as necessary to align with the door glass

at the belt line. Then, tighten the guide

two upper attaching screws.

GLASS TILT ADJUSTMENT

To adjust, loosen the quarter window

guide lower bracket- to- inner panel

attaching screw (Fig. 1). Then, tilt the

glass, to obtain a parallel fit between the

quarter glass and the door glass, and

tighten the guide lower bracket-to-inner

panel attaching screw.

GLASS IN-OUT TILT ADJUSTMENT

To adjust the in-out tilt of the top of

the glass, loosen the guide-to-lower

bracket attaching screw (Fig. 1). Move

the lower end of the guide inboard or

outboard as necessary to align the top

edge of the quarter glass with the door

glass. Then, tighten the glide-to-lower

bracket attaching screw.

UP-STOP ADJUSTMENT

Loosen the two up-stop screws (Fig.

1), and raise the glass until a good seal

CR2029-A

is obtained between the quarter glass

the door glass and roof rail weatherst

Position the front up-stop firmly aga

the glass bracket and t ighten

attaching screw.

DOWN-STOP ADJUSTMENT

Loosen the down stop attach

screw (Fig. 1). Lower the glass until

top edge is flush with the bottom of

glass opening. Then, position the do

stop up against the glass roller a

tighten the stop attaching screw.

N 24

FIG.

1 Quarter Window Mechanism Adjustment—Mercury



42-35-2

Single Guide Qu arter W indow Mechanism

42-35-2


GLASS AND/OR GUIDE

Removal


watershield.

2.

Remove the front and rear upper

stops (Fig. 2).

3.

Mark the location of the three guide

attaching screws (Fig. 2), and remove

the three screws.

4.

Disengage the regulator arm roller

from the glass bracket channel, and

lift the glass and bracket up and out

of the quarter.

5.

To remove the guide, tilt the top of

the guide rearward and remove the

guide through the quarter lower

opening.

6. If the glass is to be replaced, remove

the weatherstrip and glass bracket

from the glass.

Installation

2.

4.

Install the glass bracket on the glass

as shown in Fig. 2. Tighten the roller

retaining nuts to 40-80 in-lb. torque.

Install the weatherstrip on the front

edge of the glass.

Install the guide in the quarter, if it

was removed.

Insert the glass into the quarter

engaging the glass bracket rollers into

the guide.

WINDOW

REGULATOR

30306-7

5.

Insert the regulator arm roller into

the glass bracket channel, and install

the three guide attaching screws.

6. Align the guide to the position

marked during disassembly and

tighten the guide attaching screws.

7. Install the front and rear upper stops,

and adjust them as outlined in the

adjustment section.

8. Install the watershield and quarter

trim panel.

REGULATOR

Removal


watershield.

2.

Mark the location of the three guide


the screws.

3. Disconnect the regulator motor leads

at the connector if equipped with

electric windows.

4.

Remove the center pin from the

regulator attaching rivets with a

center punch. Support the glass and

drill the rivets out with a 1/4 inch

drill.

5.

Disengage the regulator arms from

the glass bracket channel and the

equalizer bracket, and remove the

regulator from the quarter.



GLASS

29710-1

GLASS BRACKET

305A02-3


the sector gear and the regulator

plate. Install a 1/4 inch bolt and nut

through the hole to prevent the sector

gear from moving when the motor

and drive assembly is removed.

Remove the three motor and drive

attaching screws, and remove the

motor and drive from the regulator.

Install the motor and drive on the

new regulator.

Installation

1. Install nut and retainer assemblies on

the regulator mounting plate at the

rivet attaching holes.

2.

Position the window regulator into

the quarter and engage the regulator

arm rollers into the equalizer bracket

and the glass bracket channel.

3. Position the regulator to the inner

panel and install 1/4-20 x 1/2 inch


the regulator to the inner panel

4.

Connect the regulator motor leads at

the connector, if equipped with

electric windows.

5. Position the guide to the inner panel

and install the three attaching sc rews.

Align the guide to the position

marked during disassembly and

tighten the three attaching screws.

. EQUALIZER

vf ARM BRACKET

^ 303A08

VIEW D

VIEW C

GUIDE

VIEW D

GLASS

HUT AND WASHER

ASSEMBLY

384847-S2

VIEW A

GLASS

NUT AND WASHER

ASSEMBLY-384847-S2

VIEW B

VIEW E

WEATHERSTRIP

30146-7 N23 23-B

FIG.

2 Quarter Window Mechanism—Mercury



42-35-3


42-35

6. Check the window operation and

install the watershield and quarter

trim panel.

MOTOR AND/OR DRIVE

Removal


watershield.

2. Locate two dril l dimples in the


3. Raise the glass to the UP position and

drill two 3/4 inch holes in the inner

panel with a hole saw. The hole saw

pilot drill should be as short as

possible, about 1/4 inch beyond the

saw.

4. Disconnect the motor lead wires at

the connector.

5.

Remove three motor and drive

attaching screws and remove the

motor and drive from the regulator.

Installation

1.

Position the motor and drive to the

regulator and install the three screws


2. Connect the motor wires at the

connector and cycle the glass to

assure gear engagement . Then,

tighten the three motor and dr

attaching screws.

3.

Install body tape over the two

inch drilled holes.

4. Install the watershield and quar

trim panel.

QUARTER W IND OW

WEATHERSTRIP

The weatherstrip is held on the gl

by the r e t a ine r . T o r e p l a c e

weatherstrip, slide it up and out of

retainer. Lubricate the new weathers

before sliding it into the retainer.



42-38-1

Stationary Quarter Window

42-38-1

Stationary Quarter W indow

P A R T

42-38

SUBJECT PAGE

SUBJECT PAGE

ADJUSTMENTS

Continental Mark V 38-2

Thu nde rbird , LTD II and Cougar 38-1


Mercury Model 65 38-3

Thu nde rbird and Continental Mark V 38-3

ADJUSTMENTS

Thunderbird, LTD II and Cougar

Minor inboard/outboard adjustment

of the stationary quarter window-to-door

glass can be done by removing the

pressure relief valve from the lock pillar,

to gain access to the quarter window glass

bracket retaining screw. Loosening the

glass bracket retaining screw allows

inboard/outboard movement of the front

edge of the quarter

glass,

so that a proper

seal at the door glass is obtained (Fig. 1).

GLASS IN-OUT ADJUSTMENT

To adjust, loosen the two screws

attaching the guide assembly to the

quarter inner panel. Move the glass

inboard or o utboard as necessary, to align

with the door glass at the belt. Then,

tighten the guide attaching screws.

QUARTER WINDOW

GLASS ASSY.

O U T

SCREW QUARTE R

WINDOW BRACKET

(7) REMOVE PRESSURE RELIEF VALVE

(2 SCREWS)

(2) LOOSEN QUARTER WINDOW

BRACKET RETAINING SCREW

(3) ADJUST QUARTER WINDOW GLASS

ASSY.

INBOARD/OUTBOARD AS REQUIRED

FIG.

1 Stationary Quarter W indow Glass Adjustme nt Procedure—Thunderbird,

LTD II and Cougar

CR2030-A

GLASS FORE-AFT TILT

ADJUSTMENT

To adjust, loosen the quarter window

guide lower bracket- to- inner panel

attaching screw. Then, tilt the glass as

required to obtain a parallel fit between

the quarter glass and the door glass.

Tighten the lower bracket attaching

screw.

GLASS IN-OUT TILT ADJUSTMENT

To adjust the in-out tilt of the :op of

the glass, loosen the guide-to-lower

bracket attaching screw and move the

lower end of the guide inboa-d or

outboard as necessary, to align the top

edge of the quarter glass with the door

glass. Then, tighten the guide-to- lower

bracket attaching screw.

GLASS UP-DO W N ADJUSTMENT

Loosen the front and rear up-stop

screws and hex flanged nut and ra^se the

glass until a good seal is ob tained between

the quarter glass, door glass and the roof

rail weatherstrip. Tighten the hex fl anged

nut and then, position the front and rear

up-stops firmly against the glass bracket

and tighten the attaching screws.

GLASS IN-OUT AND FORE-AFT

ADJUSTMENTS

1. To adjust, loosen the two screw and

washers attaching the bracket :o the

inner panel at the belt line.

2. Loosen the sc rew and washer

attaching the bottom of the bracket to

the support assembly.

3. Make the necessary fore-aft and in-

out adjustments assuring that the

door and quarter glass is at a parallel

fit with approximately 2 3/16" to 1/

4" margin.



42-38-2 Stationary Quarter Window

42-38

4. Tighten the three screws and

washers to 6-11 ft-lbs torque.

GLASS FORE-AFT TILT

ADJUSTMENT

1. To adjust, loosen the three screws

and washers attaching the bracket

to the glass.

2. Make the necessary fore-aft tilt

adjustment, assuring that the door

and quarter glass is at a parallel fit

with approximately a 3/16" to 1/4"

margin.

3. Tighten the three screws and

washers to 6-11 ft-lbs torque.

GLASS UP-DO W N ADJUSTMENT

1. To adjust, loosen the three nuts

attaching the glass to the bracket.

2. Raise or lower the quarte r glass to

obtain a proper seal between the glass

and the roof rail weatherstrip, by

adjusting the nut securing the glass

retainer-to-tab on the quarter glass

bracket.

3. Tighten the three nuts to 6-11 ft-lbs

torque.

Continental Mark V

While the following adjustments can

be made separately to correct specific

condit ions, complete adjustment is

performed in the following sequence. All

adjustments must be performed after the

door glass is properly adjusted and with

the trim panel, watershield and sound

insulator removed.

GLASS UP -DO W N AN D FORE-AFT

TILT ADJUSTMENTS

1. Loosen the two screw and washer

assemblies at taching the quarter

window glass bracket upper support

assembly to the quarter inner panel

(Fig. 2).

2. Loosen the one screw and washer

assembly a t taching the quar te r

s

window glass bracket lower support

assembly to the quarter inner panel.

3. Manually, raise or lower the quarter

window to obtain a seal condition into

t h e p o c k e t o f t h e r o o f r a i l

weatherstrip.

4.

Make sure that the door and qua

glass is at a parallel f i t w

approximately 3/16" to 1/4" mar

5. Tighten the three screw and wa

assemblies to 6-11 ft-lbs torque.

GLASS FORE-AFT AND IN-OUT

TILT ADJUSTMENTS

1. Loosen the two screw and was

assemblies attaching the qua

window glass bracket upper sup

assembly to the quarter inner pa

(Fig. 2).

2. Loosen the one screw and wa

assembly a t taching the qua

window glass bracket assembly to

quarter window glass bracket lo

support assembly.

3.

Make the necessary fore-aft and

out tilt adjustments assuring that

door and quarter glass is at a para

fit with approximately a 3/16" to

4"

margin.

4.

Tighten the three attaching screw

washer assemblies to 6-11 ft

torque.

GLASS

6O297A68

BRACKET

60305A04

(2 PLACES)

SCREW

55907

VIEW A

R. H. SIDE SHOWN

GLASS

FLUSH + - .06

VIEW B

VIEW C

BUTYL TAPE

M3G95

GLASS

BEND TABS

AT ASSY.

6 PLACES

N2782-B

FIG. 2 Stationary Quarter Window Installation—Thunderbird



42-38-3


42-38-3


QUARTER W IND OW ASSEMBLY

Mercury Model 65

Removal

1.

Remove the rear seat cushion, quarter

arm rest, roof s ide inner rear

moulding, quarter trim panel and

watershield.

2. Remove the two screws and wash-

ers attaching the bracket to the

inner panel at the belt line.

3. Remove the three nuts and washers

attaching the bracket to the glass.

4.

Using caution so the quarter glass and

bracket do not fall, remove the

r e m a i n i n g s c r e w a n d w a s h e r

attaching the support assembly to the


5.

Separate the glass from the bracket

and remove the glass between the

inner and outer quarter panels at the

belt line.

6. Remove the bracket and support

assembly through the access hole in

the inner panel.

7. Then, remove the weatherstrip and

glass-to-bracket a ttachments from the

glass.

Installation

1. Install the mounting tape, retainer

and weatherstrip on the front edge of

the glass.

2.

Install one bolt, washer, bushing and

teenut into each of the three holes in

the glass and tighten 6-11 ft-lbs

torque.

3. Install one spring nut to the support

assembly.

4.

Install two spring nuts at the two

holes in the top flange of the bracket.

5.

Attach the support assembly to the

bracket with one screw and washer.

6. Then, install the bracket and support

assembly through the access hole in

the quarter inner panel and assemble

the lower support attachment to the

inner panel with one screw and

washer (loosely). .

7.

Install the window assembly between

the inner and outer quarter panels (at

the belt line) and insert the three studs

on the window assembly into the

bracket slots.

8. Insert the threaded end of the retainer

through the hole in the tab on the

glass bracket and engage the hole in

the retainer on to the lower stud of the

three hole pattern of the glass.

9. Assemble the retainer loosely, with

the two nuts and washers.

10.

Assemble the upper two attachments

of the bracket to the inner panel (at

the belt line) with two screws and

washers (loosely).

11. Refer to the Adjustment Procedures

and adjust the window as required.

12.

Install the water shield, quarter trim

panel, roof side inner moulding, arm

rest and rear seat cushion assembly.

Thunderbird And Continental

Mark V

Removal

1. Remove the rear seat cushion

assembly, quarter arm rest, quarter

t r im panel (upper and lower) ,

watershield, sound insulator, roof

side inner m ouldings (front and rear),

shoulder strap (at roof rail) and the

roof side rear trim panel.

2.

Remove the four screws attaching the

quarter lock pillar-to-window frame

seal assembly to the quarter lock

pillar (Fig. 2).

3. Remove the one screw attaching the

bottom end of the quarter glass at belt

inside weatherstrip assembly to the

quarter panel assembly.

4.

Remove the tapping screws (6-

Thunderbird, 7-Continental Mark V)

attaching the rear roof quarter

window housing and the glass at belt

inside weatherstrip assembly.

5.

Remove the two screw and washer

assemblies attaching the quarter

window glass bracket assembly to the

quarter window glass bracket upper

support assembly (Fig. 2).

6. Remove one screw and washer

assembly attaching the quarter


quarter window glass bracket lower

support assembly and carefully lower

the window assembly to rest at the

bottom of the quarter panel.

7. Remove the

five

screws attaching the

quarter window outside moulding

assembly to the quarter panel (Fig. 3).

8. Rem ove the w indow b rac ke t

assembly through the opening

between the inner and outer quarter

panels at the belt line.

9. Remove the one screw and washer

assembly attaching the quarter


bracket assembly retainer (Fig. 2).

10. W ith the window assembly on a work

bench, use a drift punch and remove

the center pin from the two rivets

attaching the glass to the bracket

assembly. Then, remove the rivets by

drilling them out with a 1/4" drill

(Fig. 2).

Installation

1.

Assemble and attach the quarter

window glass to the bracket assembly

with one spacer , one re ta iner

assembly, one l/4"-20 x 1" hex head

bolt and l/4"-20 nut and washer

assembly. Tighten to 6-11

f*-lbs

torque.

2.

Assemble the quarte r window glass

bracket assembly to the bracket

assembly retainer with one screw and

washer assembly and tighten to 6-11

ft-lbs torque.

3. Insert the quarter window assembly

into the opening between the inner

and outer quarter panels and care-

fully lower it to rest at the bottom

of the quarter panel.

4.

Attach the quarter window outside

moulding assembly to the quarter

panel with five screws.

5. Raise the window to the installed

position and loosely assemble the

lower attachment of the quarter


quarter window glass bracket lower

support assembly with one screw and

washer assembly (Fig. 2).

6. Loosely assemble the two upper

attachments of the quarter window

glass bracket assembly to the quarter

glass bracket upper support assembly

w i th tw o s c rew and w as he r

assemblies.

7. Refer to the Adjustment Procedures

(this Part) and adjust the window as

required.

8. Install the rear roof quarter window

housing and the quarte r window glass

at belt inside weatherstrip assembly

(attached to housing) with tapping

s c rew s (6 Thunderb i rd and 7

Continental Mark V).

9. Install the quarter lock pillar-to-

window frame seal assembly to the

quarter lock pillar with four screws

(Fig. 3).

10.

Ins ta l l the w atershie ld , sound

insulator, roof side rear trim panel,

shoulder strap (at roof rail), quarter

trim panels (upper and lower), roof

side inner m ouldings (front and rear),

quarter arm rest and rear seat cushion

assembly.

Other Models

See Figs. 4 through 7 for installation

on other models.



42-38-4


42-38

GLASS ASSEMBLY

- 6529740

MOULDING ASSEMBLY

- 65291A32

SEAL

TO FRONT OF BODY 65297A80 BUTYL TAPE

ESB-M3G95-A SPACER -

6629760

BUTYL TAPE

SEAL

ACKET

SCREW

BUTYL TAPE

MOULDING

SEAL

N2646-C

FIG.

3 Quarter Window Housing And

Moulding

Assembly

Installation—Thunderbird And Continental Mark V

WINDOW ASSY.

5329700

TO FRONT OF BODY

r BEND TABS

OVER FRAME

R.H. SIDE SHOWN L.H. TYPICAL

(INSIDE

OF

BODY SHOWN)

VIEW A

(R.P.O. VINYL ROOF)

TA B

(REF: TRIM PANEL)

VIEW

B

N28

FIG.

4 Quarter Window (RPO>—LTD II and Cougar



42-38-5


42-38-5

NUT & SEALER

-385411

TO FRONT OF BODY

WINDOW ASSY.

- 6529600

|

VIEW-A

N2(E81-A

FIG. 5

Quarter Window (Model 65L)—Cougar

VIEW A

FIGURE 1

BUTYL TAPE-

G95

EAL

.20 ± .06

VIEW C

N21J82 A

FIG. 6

Opera Window—Thunderbird



42-38-6 Stationary Quarter Window

42-38

20 ± .06

MOULDING -

65291A32

BUTYL TAPE

- MG395

WINDOW

VIEW - B

FIGURE -1

SCREW

55907

SPACER

WINDOW

FLUSH ± .06 ALON

FRONT AND BOTTO

EXISTING

E

DGE OF CERAMIC

SLOT PAINT LINE

VIEW

BRACKET

65305A04

WINDOW ASSY.

- 65297A68

R.H. SIDE SHOWN L.H. SIDE TYPICAL (INSIDE OF BODY SHOWN)

N28

FIG. 7 Quarter Window—LTD II and Cougar



42-41-1

Tailgate Window Glass

and

Mechanism—D ual Action G ate

42-41-1

Tailgate W indow Glass

and

Mechanism

-

Dual Action Gate

P A R T

42-41

SUBJECT PAGE

ADJUSTMENTS

41-1


Glass 41-3

Guide

41-3

SUBJECT PAGE

REM O VAL AND INSTALLA TION (Con t 'd . )

Motor and/or Drive

41-{i

Regulator

41-3

Ru n

41-4

ADJUSTMENTS

TAILGATE W IND OW

ADJUSTMENT

Ford

and

Mercury

Separate adjustment steps

are

given


a d j u s t m e n t can be p e r f o r m e d . If a

complete glass adjustment

is

required,


Al l w in d o w mech an ism ad ju s tmen ts

except the in-out tilt of the top edge of

the glass must be performed with the trim

p a n e l r e m o v e d . The i n - o u t t i l t

ad justment can be performed without

r e m o v i n g

the

t r im p an e l . A f te r

the

adjustment(s) are completed, operate the

w i n d o w

up and

d o w n

to see if the

mechanism is free of binds which cause

h a r d o p e r a t i n g e f f o r t s for m a n u a l

w i n d o w s

or

s lu g g i s h o p e r a t i o n

for

electric windows.

If

binding

is

found

to

exist, repeat the adjustmen t(s). Install the

tailgate trim panel (if removed) after the

adjustments are completed.

Glass Position— Full-Up

The tailgate glass should be properly

positioned within the glass opening to

CR2031-A

assure a good seal around the glass with

the weathers tr ip .

The top

edge

of the

glass should also

be

parallel

to

the top of

the glass opening when the glass is closed.

To adjust, loosen each upper stop bracket

attaching screw (Item A, Fig. 1), and

again check the glass fit. If the glass fit

is not as specif ied , loosen the four

window regulator attaching bolts (Item

B, Fig. 1). Move the glass un til th«.

s

top

edge of the glass is parallel to the glass

o p e n i n g , and t i g h t e n the r e g u l a t o r

attaching bolts. After

the

glass

has

been

posit ioned in the opening , m ove the

UPPER STOP

BRACKET

UPPER STOP

BRACKET

FIG.

1 Tailgate Window Mechanism Adjustment—Ford

and

Mercury



42-41-2

Tailgate Window Glass and Mechanism—Dual Action Gate

42-41

upper stop brackets down firmly against

the stops and tighten the attaching

screws.

Glass Position—Side-to-Side

The tailgate glass can be positioned

from side-to-side to obtain a good seal

overlap with the side weatherstrips. To

adjust, loosen the two lower right guide-

to-glass attaching screws (Item

C, Fig.

1).

Then, move the glass from side-to-side as

necessary to obtain a good glass overlap

with the weatherstrip on each side of the

glass. Tighten the guide attaching screws

after the glass has been moved to the

desired position.

Glass Tilt—In and Out

The top edge of the tailgate glass can

be tilted in or out to obtain a good seal

against the weatherstrip. To adjust,

loosen the glass run lower attaching

screws (Item D, Fig. 1). Then, move the

run lower ends forward or rearward as

necessary to move the glass top edge

against the weatherstrip to obtain a good

seal. Tighten the run lower attaching

screws after a good seal is obtained.

LTD II, Thunderbird and Cougar



adjustment can be performed. If a




must be performed with the tailgate trim

panel removed. After the adjustments)

are completed, operate the window up

and down to see if the mechanism is free

of binds which cause hard operating

efforts for manual windows or sluggish

operation for electric w indows. If binding

i s f o u n d t o e x i s t , r e p e a t t h e

adjustment(s). After adjustment, install

the tailgate trim panel.

Glass Position—Full-Up


top edge in the opening if the glass or

regulator has been removed or if extreme

t a i l g a t e h i n g e a d j u s t m e n t s a r e

performed. To reposition the glass,

loosen the four window regulator

attaching screws (Item C, F ig. 2) and the

upper stop bracket attaching screws

(Item D). Adjust the glass for a parallel

fit to the roof and a good seal along the

roof weatherstrip by repositioning the

window regulator. Then, tighten the four

regulator attaching screws. Position the

window upper stop b rackets firmly down

against the stops, and t ighten the

attaching screws (Item D).

Glass Position—Side-to-Side

It is necessary to reposition the g

from side-to-side in the opening if

glass has been removed or if extr

t a i l g a t e h i n g e a d j u s t m e n t s

performed. To adjust the glass from s

to-side, loosen the glass-to-glass bra

attaching screws (Item A, Fig. 2). M

the glass sideways to obtain a g

overlap seal with the weatherstrip

each side. Then, tighten the glass-to-g

bracket attaching screws (Item A).


The stabilizers are used to support

glass at the belt line. Loosen the stabi

attaching screw (Item E, Fig. 2),

push the stabilizer firmly against

glass surface. Then, tighten the attach

screw. Repeat the p rocedure for the o

stabilizer.

Glass In-Out

Tilt

The in-out tilt adjustment is use

ob ta in a good se a l a ga ins t

weatherstrip at the top edge of the gl

To adjust the in-out tilt, loosen the g

attaching screws (Item

B,

Fig. 2).

M

the top edge of the glass inward

outward, as required, to obtain an a

water tight seal against the weathers

Then, tighten the guide attaching scr

(Item B).

N24

FIG. 2 Tailgate Wind ow Mechanism Adjustment—LTD II, Thunderbird and Cougar



42-41-3

Tailgate Window Glass

and

Mechanism—Dual Action Gate

42-41-3

REMOVAL

AND

INSTALLATION

TAILGATE GLASS

Thunderb i rd ,

LTD II and

Cougar

Removal

1 . R emo v e

23

t a i l g a t e t r i m p a n e l

attaching screws and remove the trim

panel.

2.

R e m o v e

the

ta i lg a te in n er p an e l

access cover.

3.

L o w e r

the

t a i l g a t e

to the

d o w n

position and partially raise the glass.

4. Remove two screws attaching each

side of the glass to the glass bracket

(Fig. 3), and remove the bushings and

stops.

5. Slide the glass from the tailgate

Installation

1.

Position the glass into the tailgate and

to

the

g lass brackets .

Be

sure

the

spacers

are

placed between

the

glass

an d the glass bracket (Fig. 3).

2. Install the bushings, stops and glass-

to-g lass bracket at taching screws

(Fig.

3).

Tighten

the

glass attaching

screws

to

specification.

3. Adjust

the

glass from side-to-side.

4. Install the tailgate inner panel access

cover and tailgate trim panel.

Ford

and

Mercury

Removal

1. Remove

the

tailgate inside cover

and

watershield.

2. Remove the tailgate inner panel lower

access cover.

3. Lo wer

the

tai lgate

to the

D O W N

position, and raise the glass until the

glass brackets are accessible.

4.

Remove

the

center

pin

from

the

glass-

to-glass bracket rivets with

a

drift

punch. Then, drill the heads from the

r ivets with

a 1/4

inch dr i l l ,

and

remove the rivets.

5. Disconnect the wires from the rear

window defroster terminals ,

if so

equipped.

6. Slide

the

glass from

the

tailgate.

Installation

1. Position the glass into the tailgate and

to the g lass brackets . Be sure the

spacers are placed between the glass

an d

the

glass bracket

(Fig. 4).

2. Install 1/4-20 x 1 inch hex head bolts

an d 1/4-20 hex head nuts to attach

the glass bracket

to the

glass. Tighten

the bolts

and

nuts

to

specification.

3. A d j u s t

the

g l a s s

as

o u t l i n e d

in

A D J U S T M E N T S in this part.

4. Connect the wires to the rear window

defroster terminals,

if so

equipped.

5. Install the tailgate inner panel lower

access cover, and the watershield and

tailgate inside cover.

£ >- *—UPPER S10P REGULATOR

BRACKET 44000

422B36

GUIDE

422B15

BUSHING

2 5 7 5 4

42138

FIG.

3 Tailgate Window Mechanism—Thunderbird, LTD II, and Cougar

N2769-A

2. If equipped with an electric window

regulator, disconnect the motor wires

at

the

connector.

3. R emo v e fo u r r eg u la to r a t tach in g

screws and disengage the regulator

from

the

mounting b rackets. Slide

the

regulator

to one

side

to

disengage

the

regulator arm rollers from the glass

brackets ,

and

remove

the

regulator

through

the

access hole.

Installation

1. Position

the

regulator into

the

tailgate

and engage the rollers in the glass

bracket channels.

2.

P o s i t i o n

the

r e g u l a t o r

to the

mo u n t in g su r f ace

and

engage

the

c r a n k (if so e q u i p p e d ) w i t h the

window regulator.

3. I n s t a l l

the

w i n d o w r e g u l a t o r

attaching screws.

4. Connect the motor wires, if equipped

with

an

electric tailgate window.

5. Install the glass in the tailgate and

adjust the glass full-up and side-to-

side positions.

Ford

and

Mercury

Removal

REGULATOR

LTD II, Thund erbird and Cougar

Removal

1. Remove the glass from the tailgate.

1.

Remove the tailgate glass.

2. Remove

the

glass brackets from

the

regulator arm rollers.

3. Disconnect the motor wires at the

connector.

4. R emo v e fo ur reg u la to r a t tach in g

screws and remove the regulator from

the tailgate

(Fig. 4).

5. Drill a 5/16 inch hole through the

regulator sector gear and regulator

plate. Install

a 1/4

inch bolt

and nut

through

the

hole

to

prevent

the

sector

gear from moving when the mo to r

and drive assembly

is

removed from

th e r eg u la to r . R emo v e

the

m o t o r

assembly from the regulator.

Installation

1. Position

the

regulator

in the

tailgate

and install the attaching screws.

2. Connect the regulator motor wires at

the connector.

3. Install the tailgate glass.

GLASS RUN AND /OR GUIDE

LTD II, Thund erbird

and

Cougar

Removal

1. Remove

23

tailgate inside trim panel

attaching screws

and

remove

the

trim

panel.

2. R e m o v e the ta i lg a te in n er p an e l

access cover.

3. L o w e r

the

t a i l g a t e

to the

d o w n

position and partially raise the glass.

4. Remove two screws attaching sach

side

of the

glass

to the

glass bracket

(Fig. 3), and remove the bushing*, and

stops.



42-41-4

Tailgate Window Glass and Mechanism—Dual Action Gate

42-41

WINDOW REGULATOR

BACK WINDO

REG.

A RM

GUIDE

RIVET(6REQ'D

RETAINER

RIVET (6 REQ'D.)

N242

FIG. 4 Tailgate Window Mechanism—Ford and Mercury

5.

Remove the two s tabi l izer but tons

from the glass lower corners (Fig. 3).

Then, s l ide the glass out of the

tailgate.

6 . Remove the glass run upper and

lower attaching screws (Fig. 3), and

remove the run and guide from the

tailgate.

7.

Remove the guide and glass bracket

from the run.

8. Remove the glass bracket from the

guide.

Installation

1.

Install the glass bracket on the guide

and the guide on the run (Fig. 3).

2. Pos i t ion the run, guide and glass

bracket in the tailgate and engage the

glass bracket with the regulator arm.

3.

I n s t a l l t h e t w o g u i d e a t t a c h i n g

screws.

4. Position the glass in the tailgate and

to the glass brackets.

5.

Install two screws, stop, and bushing

attaching each side of the glass to the

brackets (Fig. 3).

6. Install the two stabilizer buttons (Fig.

3).

7. Adjust the tailgate glass as outlined


8. Install the inner panel access cover,

and the tailgate inside trim panel.

GLASS RUN

Ford and Mercury

Removal

1. Remove the tailgate inside cover and

watershield.

2.

Remove the glass from the tailgate as

outlined in this part.

3.

Remove the outs ide bel t moulding

and weatherstrip from the tailgate.

4.

Remove the run uppe r and lower

attaching screws and remove the run

and glass bracket from the tailga

(Fig. 4).

5.

Remove the glass bracket and guid

from the run.

6. To remove the guides, remove tw

screws attaching each guide to t

glass bracket.

Installation

1. Install the guides on the glass brack

if they were removed. Be sure to no

that the lower right guide is differe

from the other guides (Fig. 4).

2.

Install the glass bracket and guides

the run, and install the run in t

door.

3.

Install the weath erstrip and outs

belt moulding.

4.

Install the tailgate glass as outlined

this part.

5.

Install the tailgate watershield a

inside cover.



42-41-5

Tailgate Window Glass and Mechanism—Dual Action Gate 42-41-5

WINDOW MOTOR AND/OR

DRIVE

Removal

1.

Remove the tailgate inner panel and

watershield.

2. Disconnect the motor wires at the

connector.

3. Working through the access hole(s),

remove the three motor and drive-to-

regulator attaching screws. Remove

the motor and drive from the tailgate.

Installation

1. Position the mo tor and drive to the

window regulator , and instal l the

three screws


2. C o n n ec t th e mo to r w i r es a t th e

connector and cycle the g lais to

assure gear engagement. After the

gears are engaged, tighten the three

motor and drive attaching screws.

3. Check the window operation. Then,

install the watershield and tailgate

inner panel.



43-01-1

Stationary Window Glass

43-01

STATIONARY WINDOW GLASS

PART

T IT L E PART NO.

PART TITLE

GROUP

(70000)

PART NO.

Stationary Glass - Buty l Type

Seal

43-1

1 Station ary Glass - We atherstrip Typ e Seal 43-01

CR2004-A

Stationary Glass -

Weatherstrip Type Seal

P A R T

43-01

SUBJECT PAGE


Back Window Mouldings

01-1

Back Windo w - Wea therstrip

Typ e Seal 01-6

Opera Wind ow 01-9

SUBJECT PAGE

REM O VAL AND INST AL L A T IO N (Con t' d .)

Quarter Wind ow Mou ldings 01-1

Stationary Quarter Wind ow Glass 01-6

Windshield Mou ldings 01-1

Windshield - Wea therstrip Type Seal 01-1


Be f or e r e m oving the e x t e r io r

mouldings, it should be determined by

the types of retainer used whether a

respective door, quarter or luggage

compartment trim panel must first be

removed to provide access.

If a weld stud is distorted or broken

off, it can be replaced with a screw

(37956O-S1O1) or pop rivet as shown in

Fig. 23.

WINDSHIELD MOULDINGS

The windshield mouldings for the

Maverick, Comet, Pinto and Bobcat are

shown in Figs. 2 and 3. The mouldings

are retained with retainers set in the glass

opening and should be released from the

retainers with the tool shown in Fig. 1.

BACK W INDO W MOULDINGS

The back window mouldings are

shown in Figs. 4 throug h 11. If the

mouldings are retained with retainers set

in the glass opening, the m oulding should

be released with the tool shown in Fig.

1.

QUARTER W IND OW MOULDINGS

The s ta t ionary quar te r window

mouldings on the Pinto and Bobcat are

retained within the weatherstrip (Fig.

12). Refer to Quarter Window and Glass

Removal and Installation procedures

(this Section).

The mouldings for Mustang are

shown in Figs. 15 and 16. Granada and

Monarch are shown in Figs. 17 and 18.

CR2032-A

LTD II and Cougar mouldings a

shown in Figs. 19 and 20.

WINDSHIELD WEATHERSTRIP

TYPE SEAL

Removal

PVC tape is to be used on the pin

weld flange (Pinto and Bobcat), in pla

of sealer.

1. Remove the windshield wiper blad

and arms.

2.

Remove the side and top mouldi

using Tool T64P-42006 or equival

(Fig. 1).

3. Using Tool T64P-42006 or equival

(Fig. 1), remove the windshield low

moulding. Start at the center, th



43-01-2

Stationary Glass-Weatherstrip Type Seal

43-01-2

EXTERIOR

MOULDING

WEATHERSTRIP

FIG. 1 W indshield or Back Win dow M oulding—R emova l Tool

work outboard and remove each side

of the two-piece moulding.

4.

From inside the vehicle, push the

windshield glass from the body

opening.

5.

Remove the weatherstrip from the

glass or body opening.

Installation

1. Clean all sealer (butyl or PVC tape)

from the body opening. Check all

moulding retainers and replace any

that are loosened or damaged.

2. Apply butyl tape (.06 inch x

1 .00

inch

x 59.00 inch) along cowl top for

Maverick and Comet only.

3. Apply sheet metal primer to the body

glass opening flange (Maveric K and

Comet). Apply PVC tape to the body

glass opening flange (Pinto and

Bobcat).

4.

Position the weatherstrip on the

window glass.

5. Insert a draw cord in the pinch weld

opening of the weatherstrip all

around the weatherstrip (Figs. 13 and

14) and overlap the cord about 18

inches at the lower center of the glass.

M446-E Ta pe the en ds of the cor d to the glass.

6 . Pos i t i on the wind ow glass t o t he ; bod y

o p e n i n g .

UPPER MOULDING

03144-5

SIDE

M O U L D I N G

03136-7

M O U L D I N G

03148-9

SIDE

M O U L D I N G

03136-7

M O U L D I N G 0 3 1 4 8 - 9

RETAINER

SPACER

V EW-D

T O P M O U L D I N G

WEATHERSTRIP

03110

FIG. 2 Windshield and Exterior Moulding Instal lat ion—Maverick and Comet



43-01-3


43-01

SEALER-USING ATHIN

NOZZLE GUN, APPLY

AS

SHOWN

IN

VIEW

"F"

BETWEEN GLASS AND

WEATHER STRIP TO

DIMENSIONS SHOWN

IN FIGURE 2.

FIGURE-2

VIEW-A

MOULDING-WINDSHIELD

OUTSIDE SIDE 03136-7

MOULDING-WINDSHIELD

OUTSIDE TOP 03144-5

GLASS ASSEMBLY-

WINDSHIELD 03100

TO FRONT OF BODY

RETAINER-WINDSHIELD OUTSIDE

LOWER MOULDING END 03782-3

MOULDING-WINDSHIELD

OUTSIDE LOWER 03148-9

WEATHER STRIP ASSEM

WINDSHIELD 03110

FIGUR

RETAINER

42413 ' VIEW-B

VIEW-C

FOAM

TAPE

VIEW-D

VIEW-E

SEALER

VIE

SP

(SEE VIEW K)

SPACER

(SEE VIEW

K)

1,2

RETAINER

SEALER

V I E W G

1/8 TO 1/4

INCH

OVERLAP

SPA

VIEW K N21

FIG .

3

Windshield and Exterior Moulding Installation—Pinto and Bobcat



43-01-4 Stationary Glass-Weatherstrip Type Seal

43-01-4

OUTSIDE LOWER

MOULDING 42404-5

WEATHERSTRIP

42084 N1659-E

FIG.

4 Back Window and Exterior Mouldings - LTD II and Cougar XR7

MOULDING

42430-1

FIG.

5 Back Window and Exterior Mouldings—M averick and Comet 2-Door Shown—Ty pical 4-Door



43-01-5


43-0

MOULDING

GLASS

WEATHERSTRIP

MOULDING

RETAI

WEATHERSTRIP

VIEW-D

MOULDING

P.V.C.

TAPE

' / CEMEN T

VIEW A

MOULDING

WEATHERSTRIP

V I E W - C

.090

Ino

P.V.C. TAPE-

SEALER

VIEW

GLASS

WEATHERSTRIP

V I E W - F

RETAINER

VIEW-G

RIVET

V I E W - H

P.V.C. TAPE

N

F IG .

6 Back Win dow and Exterior Mould ing— Gra nada and Monarch

2-Door

Shown—Typical

4-Door



43-01-6


43-01-6

MOULDING ASSEMBLY

OUTSIDE

UPPER

423A00

FIG. 7 Back Window and Exterior Mouldings—Pinto and Bobcat 2-Door

7. With an assist ant applying hand 3.

pressure from the outside, pull the 4.

draw cord to pull the lip of the

weatherstrip over the body opening

flange. Draw the weatherstrip lip over

the lower flange, each side flange, and

then over the upper flange.

8 . Ins ta l l the windshield outs ide

mouldings as shown in Figs. 2 and 3. 5.

9. Install the wiper blades and arms

(Group 35) and test for water leaks. 6.

BACK WINDOW-WEATHERSTRIP

TYPE SEAL

Removal

1. Rem ove the w indo w ou t s ide

mouldings (Figs. 4 through 11).

2.

Remove the window interior garnish

mouldings, (if so equipped).

3. With an assistant, push the glass and

weathers t r ip f rom the window

opening.

4. Clean all sealer from the glass and/o r

•weatherstrip if either is to be

re-used.

5.

Clean all tape seal from the glass

opening flange.

Installation—All

Models Except Pinto

and Bobcat 3 Door and Station Wagon

1. Check a l l moulding re ta iners .

Replace or repair damaged retainers

to insure moulding retention. Replace

any missing or damaged weld studs

with a screw.

2.

Apply tape seal to the pinch weld

flange of body opening.

Position the w eatherstrip on the glass.

Insert a draw cord in the pinch weld

opening of the weatherstrip all

around the weatherstrip (Figs. 13 and

14),

and overlap the cord about 18

inches at the lower center of the glass.

Tape the ends of the cord to the inside

of the glass.

Position the window glass to the body

window opening.

With an assistant applying hand

pressure from the outside, pull the

draw cord to pull the lip of the

weathers t r ip over the window

o p e n i n g f l a n g e . D r a w t h e

weatherstrip lip over the lower flange,

each side flange and then over the

upper flange.

7. I n s t a l l t h e w i n d o w o u t s i d e

mouldings.

8. Install the window interior garnish

mouldings.

9. Test for water leaks. Apply sealer in

the glass groove of the weatherstrip,

if necessary.

Pinto and Bobcat 3 Door and Station

Wagon

1. Remove the moulding and clean the

weatherstrip area. Then, using a hand

tool (screwdriver, chisel, etc.), insert

an approximately 1/8 inch diameter

drawcord into the moulding cavity of

the weatherstrip. Start the cord at the

lower center edge of the weatherstrip

and continue pushing the cord around

N216'5 D

the entire perimeter (Fig 9). Leave a

minimum of

10

inches of cord trailing

at each end after completion.

2.

Apply a soap solution around the

entire moulding retaining lip on the

weatherstrip.

3. Assemble the right and left hand

sections of the mouldings to the

w ea the r s t r ip by p rog res s ive ly

positioning the retaining lip of the

m o u l d i n g u n d e r t h e r a i s e d

weatherstrip retaining lip. Adjust the

moulding as required to assure full

engagement of the retaining lip.

4.

Starting at the bottom of the glass,

pull the drawcord outboard over the

top of the moulding. Then, apply

hand pressure to the moulding as the

cord is being slowly pulled from the

weatherstrip.

5.

Visually check for full engagement of

the moulding to the weatherstrip and

repair any loose areas with a hand

tool.

6. Remove all excess soap solution from

the weatherstrip assembly.

STATIONARY QUARTER

W INDO W GLAS S

Pinto and Bobcat

Removal

1. Pry the weatherstrip inboard lip from

the forward edge of the glass; then

push the glass and weatherstrip from

the glass opening.



43-01-7


43-0

GLASS BACK WINDOW

P.V.C. TAPE

WEATHERSTRIP

42084

GLASS

VIEW A

P.V.C. TAPE

CEMEN

VIEW B

STRIKER

6443252

NUT& WASHE

- 45334

VIEW

NUT& WASHER

- 387353

SPACER

6440610

VIEW-D

FIG.

8 Back Windo w and Exterior Mouldings— Pinto and Bobcat 3-Door



43-01-8

Stationary Glass-Weatherstrip Type Seal 43-01-8

MOULDING-BACK WINDOW

OUTSIDE SIDE

USING A HAND TOOL, INSERT

DRAWCORD INTO THE

WEATHERSTRIP ASSY MOULDING CAVITY OF

BACK WINDOW THE WEATHER STRIP

SCREWDRIVER,

CHISEL, ETC.

LIFTGATE ASSY.

GLASS-BACK WINDOW

VIEW A- A TYPICAL SECTION WITH

MOULDING INSTALLED

DRAWCORD-APPROXIMATELY

1/8" DIAMETER.

N2556-A

FIG.

9 Back Window Outside Moulding Instal lation—Pinto and Bobcat—3-Door and Station Wagon

c

P.V.C. TAPE

WEATHERSTRIP'

42084

VIEW-A

VIEW-C

N1I72 -F

FIG. 10 Back Window and Exter ior Mouldings- LTD I I Ranchero

2. Remove the upper moulding from the

w e a t h e r s t r i p a n d r e m o v e t h e

weatherstrip from the glass.

Installation

1.

Clean any sealer or broken glass from

the weatherstrip.

2. Apply PVC tape to the glass opening

flange. Then, install the weatherstrip

on the glass and install the moulding

in the weatherstrip groove. (Fig. 12).

3.

Insert a draw cord in the pinch weld

opening of the weatherstr ip all

around the weatherstrip and overlap

the cord about 18 inches at the lower

center of the glass. Tape the ends of

the cord to the glass.

4. Position the quarte r glass to the body

opening, then apply hand pressure

from the outside and pull the draw

cord to pull the weatherstrip over the

body opening flange.

Mustang, Granada and Monarch

1. Re m ove the i n t e r io r ga r n i sh

mouldings (Group 45).

2.

3.


quarter window assembly to the rear

quarter (Figs. 15, 16, 17 and 18), and

remove the assembly from the

opening.

Position the glass to the opening, and

install the attaching screws.

4.

Install the interior garnish mouldings

(Group 45).

Mark V, Thunderbird, LTD II and

Cougar

Removal

1.

Remove the inside garnish moulding

and quarter trim panel (Group 45).

2.

Remove two bolts attaching the glass

bracket extension (Figs. 19 and 20)

to the quarter inner panel.

3.

Loosen the glass bracket-to-extension

bolts,

and remove the glass, bracket

and extension from the vehicle.

4. Place the glass on a bench and remove

the extension from the glass bracket.

5. Remove the center pin from the glass

bracket-to-glass rivets with a drift

punch. Then, drill the head from the

rivets with a

1/4-inch

drill, and

remove the rivets.



43-01-9


43-0

MOULDING

42492-3

WEATHERSTRIP

42006

NOTE

A

-

P VC FOA M TAPE

1 I A

X 1

12

X

INSTALLED ON THE PINCH WEL

FLANGE PRIOR

TO

INSTALLATI

OF W7STRIP. OVERLAP BUTT JO

AT CENTERLINE BY APPROX. 1

DO NOT STRETCH TAPE DURING

INSTALLATION. APPLY CEMENT

BETWEEN FLANGE

AND

TAPE-

LIFTGATE ASSEMBLY

40010

F IG . 11

Back Window

and

Exterior Mouldings—Pinto

and

Bobcat Station W ag on

6. Separate the glass bracket, spacers

and retainers from the glass.

7. Remove the front weatherstrip and

retainer from the glass.

GLASS

WEATHERSTRIP

'29732-3

V IE W -AA VIEW -BB

N2186-C

F IG . 12

Quarter Window

and

Mouldings Pinto

and

Bobcat

N

Installation

1. Install the front weatherstri

retainer on the glass using buty

1 3/4 inch wide tape, approxi

0.06 inch thick.

2.

Position the retainers and spac

the glass

and

snap them tog

(Figs. 19 and 20).

3. Position the glass bracket to th

and install

1/4-20 x

1 inch

he

bolts and 1/4-20 hex nuts to

the bracket to the glass. Tight

nuts

to

6-11 ft-lb. torque.

4.

Position the extension to the

bracket and install the a ttaching

finger tight.

5.

Pos i t ion the glass and b r

assembly in the quarter and

two

bolts to attach the assembly

inner panel. Tighten the bolts

ft-lb.

torque.

6. Position

the

glass snugly again

weatherstrip to obtain a goo

between the glass and weathe

Then, tighten

the

glass brack

extension attaching bolts to 3-

torque.

7.

Install

the

quarter trim pane

interior garnish moulding.

OP E RA WINDOW

Removal

1. From inside the vehicle, remo

interior garnish mouldings t



43-01-10


43-01-10

access to the quarter pillar trim

panels.


back assembly (Group 41).

3. Remove the quarter lower and upper

trim panel to gain access to the opera

window attaching screws (Figs. 17

and 18).

4. Remove the screws and opera

window assembly.

Installation

1.

Clean all sealer and foam tape from

t h e b o d y o p e n i n g a n d t h e

weatherstrip.

2. Apply foam tap e to the flat surface of

the weatherstrip.

3. Posit ion the window to the body

opening and instal l the at taching

screws.

4. Instal l the upper and lower tr im

panel, garnish mouldings and seat

back and cushion assembly.

Draw Cord

N1127-B

FIG.

13 Draw Cord Installation—Typical

N1128-C

FIG. 14 Draw Cord Installation—Typical

QUARTER WINDOW ASSEMBLY

29700-1

FIG.

15 Quarter W indow Insta llat ion—Mustang 2-Door



43-01-11


43-01

VIEW

A

N2498-

FIG.

16 Quarter Window Installation—Mustang

3-Door

SCREW

GLASS

MOULDING

MOULDING

G

N

FIG.

17 Stationary Quarter Window—Granada and M onarch-2-Door



43-01-12


43-01-12

SEAL

GLASS RET.

SEAL ASSY.

297A28

GLASS RETAINER

SEAL ASSEMBLY

VIEW - A

MOULDING

ASSEMBLY

VIEW - C

FIG. 18 Stationary Quarter Window—Granada and Monarch 2-Door



43-01-13


43-01

STABILIZER QUARTER

SCREW INNER PANEL

RETAINER

GLASS

BRACKET

N24

FIG.

19 Stationary Quarter Window—LTD II and Cougar



43-01-14


43-01-14

MOUL DING

MODEL 65K

MOUL DING

SCREW

5 REQ'D.

WEATHERSTRIP

SCREW

AND

WASHER

3 REQUIRED

N2I558-A

FIG. 20

Qua rter W indo w Housing Extension—LTD

II and

Cougar

GLASS ASSEMBLY

MOULDING ASSEMBLY

- 65291A32

SEAL

-

TO FRONT OF BODY 65297A80 BUTYL TAPE

ESB-M3G95-A SPACER

-

6629 7 60

BUTYL TAPE

SEAL

RACKET

SCREW

TAB ON

MOULDING

BUTYL TAPE

MOULDING

SEAL' / /

-

V I E W - B

N2646C

FIG. 21

Op era Win dow Installation—Continental Mark V— Thunderbird,

LTD II,

Cougar

and

Lincoln Continental Similar



43-01-15


43-0

NOTE: WHEN BODY ORNAMENTATION WELD STUDS ARE

DAMAGED OR MISSING, A BLIND RIVET, ITEM

1,

IS TO BE INSTA LLED TO THE DIMENSIONS

SHOWN IN APPROPRIATE VIEW.

PROVIDE (.129-.125) INCH DIAMETE R HOLE

TO RECEIVE BLIND RIVET, ITEM 1.

NORMAL

OVAL HEAD

BLIND RIVET

383229-B

.1

PEAK SURFACE

.095

.085

J_

BACK WINDOW OR WINDS

V I E W - C

N2

F IG . 22 Typical Body We ld Stud Instal lat ion



43-11-1

Stationary Glass-Butyl Type Seal

43-11-1

Stationary Glass -- Butyl Type Seals

P A R T

43-11

SUBJECT

PAGE SUBJECT

PAGE

REM O VAL

AND

INST AL L AT IO N

Glass

11-1

Back Window Mouldings

11-1

REM O VAL

AND

INSTA LLATION (Con t'd .)

Quarter Window Mouldings

11-1

Windshield Mouldings

11-1

REMOVAL

AND

INSTALLATION

Before removing the exterior


the type of retainer used whether a



removed to provide access.

If a weld stud is distorted or broken

off, it should be replaced with a screw

(37956O-S1O1). Also, refer to Fig. 23 in

Part 43-01.

WINDSHIELD MOULDINGS

The windshield mouldings for the

various models are shown in Figs. 1

through 6. If the mouldings are retained

with retainers set in the glass opening, the

moulding should be released from the

retainers with the tool shown in Fig. 1,

Part 43-01.

BACK W INDO W MOULDINGS

(EXCEPT FRENCHED)

The back window mouldings are

shown in Figs. 7 through 17. If the

mouldings are retained with retainers set

in the glass opening, the moulding should

be released with the tool shown in Fig.

1, Part 43-01.

FRENCHED BACK W IND OW

MOULDINGS

The Special Order frenched back

window option with the half padded vinyl

roof cover, extends over and tucks under

the back window mouldings. A

frenched back window appears to be

recessed down into the roof cover, with

no back window mouldings visible.

Removal

1. Using a sharp knife or razor blade,

remove the bead of silastic rubber

adhesive from between the roof cover

and the back window glass.

NOTE: When cutting the seal, hold

the knife blade cutting edge against

the glass to avoid the possibility of

cutting the roof cover (Fig. 8).

2.

Using a hooked tool fabricated from

a discarded Bowden control wire or

equivalent, (Fig. 8), carefully pull the

roof cover out from between the glass

and the covered back window

moulding.

NOTE: For added clearance, pry

up the covered moulding with a wood

wedge or a putty knife blade. Do not

use heat to soften the vinyl.

3 .

Carefully peel the roof cover back at

least one inch from the moulding.

This is a critical phase of the repair

as the vinyl cover and the padding can

be seriously damaged unless the cover

and the padding is carefully cut away

from the moulding and the roof panel.

Usually the padding will stick to the

cover as it is pulled up and back from

the moulding. A blunted putty knife

can be used to push the pad away or

a sharp knife can be used to cut the

pad away from the moulding and roof

panel.

4. Secure the peeled back cover and

padding with tape as shown in Fig. 8,

to about one inch beyond the

mouldings around the entire back

window.

NOTE: The cover and pad are

shown peeled back more than

necessary for illustration purposes.

5. Remove the back window mouldings

using tool shown in Part

43-01,

Fig.

1.

Installation

1. Install the back window mouldings.

2. Using Vinyl Top Adhesive (D4AZ-

19C525-A) (or equivalent) with the

CR2033A

instructions shown in part 46-20,

install the peeled back portion of the

roof cover. The vinyl roof cover

wrinkles can be carefully pulled out

and the material pushed back into

position under the mouldings using

the reworked putty knife and the

wedge (Fig. 8).

NOTE: Do not use heat in an

attempt to eliminate wrinkles.

3 . Reseal the glass-to-roof cover gap

with a thin bead of Dow Corning

Clear Silastic Adhesive or equivalent.

This adhesive can be tooled before it

starts to skin over so that it will not

show under normal inspection.

QUARTER W INDOW MOULDINGS

Cougar, LTD II, Ford and

Mercury Station Wagon Only—

For

all

other models, refer

to

Part 43-01.

The quarter window mouldings (Figs.

13 and 14), are retained with retainers set

in the glass opening and should be

released with the tool shown in Fig. 1,

Part 43-01.

G L A S S B U T Y L T Y P E S E A L

There are two procedures applicable

to the installation of glass with butyl type

seal.

Procedure No. 1 should be used with

butyl kit (03863) packaged with 5/16

diameter butyl (round type). DO NOT

use this kit if adhesion of existing butyl-

to-pinch weld flange is unreliable, as

indicated by a surface which is not

smooth and free of excessive skips,

bumps and contamination.

Procedure No. 2 should be used with

butyl kit (03863) packaged with I

beam type butyl, where complete



43-11-2


43-

T O P M O U L D I N G

03144

WINDSHIELD

GLASS

FIG. 1 Windshield and Exterior Moulding Installation Ford and Mercury—Typical

repla cem ent of exis t ing butyl is

necessary.

Removal (Procedure

No.

1

Engine must be off on vehicles

equipped with high voltage output type

heated glass.

1. Remove the windshield wiper arms

and blades if the windshield is being

replaced (Figs. 1 through 6).

2.

Remove the window mouldings (Figs.

7 through 14).

3.

On the heated back window, it will be

necessary to disconnect the window

wires at the connectors on both sides

of the window before proceeding with

the glass removal.

4.

With an electric knife Tool No. T70B-

42006-A or equivalent (Figs. 15, 16

and 18), insert the blade under the

edge of the glass. Cut the butyl seal

as close to the inside surface of the

glass as possible. To cut the butyl at

the lower corners of the glass, move

the handle of the tool as close to the

corner as possible. Then, rotate the

blade downward to cut the corner

butyl seal and remove the glass from

the vehicle using the glass holding

tool (Figs. 15, 16 and 18).

Installation

1. Temporarily position the replacement

glass in the windshield opening using

spacers to prevent glass-to-metal

contact. Adjust glass side to side to

the best glass-to-"A" pillar weld

flange overlap position and adjust

lower spacers, if necessary, for proper

positioning at the top. A minimum of

3/16" butyl tape-to-glass contact is

required around the periphery to

assure proper retention and adequate

seal. Mark this location with a crayon

on the outside surface of the glass and

a corresponding point of the glass

opening. Remove the glass and clean

the in s ide s u r f ace and edge

thoroughly.

2. Starting at the side of the glass

opposite the original butyl splice,

place the 5/16" diameter butyl

furnished in the kit on top of and in

a position that assures the 3/16"

minimum contact with the glass on

the existing butyl remaining on the

pinch flange. NOTE: Do not allow

the new butyl to overhang the edge of

the existing butyl and do not stretch

the butyl or bridge the corners of the

window opening.

3. Carefully splice the two loose ends of

the new butyl.

4. Apply the primer (furnished in the

kit) around the perimeter of the

cleaned inside surface and the edge of

the glass in the area that will contact

the butyl seal (Fig. 17). Allow the

primer to dry one minute before

installing the glass.

5.

Place the glass in the opening,

aligning the crayon marks.

N

6. Firmly press the glass again

butyl with hand pressure or w

Recheck to assure that the

contact between glass and bu

achieved. A dull spot indica

area where the butyl is not cont

the glass surface. A dditional pr

will seal such areas.

7.

From outside the vehicle,

C9AZ-19554-B Auto Glass L

Sealer (or equivalent) aroun

entire edge of the glass.

8. Remove any excess primer fro

inside surface of the glass with

blade and wipe the glass with

cloth dampened in naphtha.

9. When the liquid sealer has "sk

over" (approximately ten min

water tes t the ins ta l la t io

necessary, repair any leaks

additional liquid sealer.

10.

Install the mouldings and wipe

and blades.

11. On the heated back window, it

necessary to apply a piece of t

the pinch weld flange under the

Then, connect the wires and

the garnish and exterior mould

12. When cleaning the heated

window, use only liquid w

cleaning solvent. Do not use

wool or abrasive powders, as d

to the grid wires will result.

13. Clean the glass and surroundin

(Text continued on 43-1



43-11-3


4 3 - 1 1 - 3

.18 WIDTH VISIBLE

CONTACT (TYPICAL)

FIG. 2 Windshield and Exterior Moulding Installation—LTD II and Cougar



43-11-4


4 3 - 1 1

RETAINER

BUTYL SEAL

PRIMER

VIEW A

BUTYL SEAL

LOCATE SEAL ON

TANGENT OF RADIUS

SPACER

V I E W B

RETAINER

V I E W C

RETAINER

WELD STUD

RETAINER

WELD STUD

BUTYL SEAL

V I E W D

V I E W E

V I E W F

N138

FIG. 3 Windshield and Exterior Moulding Installation—Mustang



43-11-5


43-11-5

WINDSHIELD

SEALER

PRIMER

VIEW-B

MOULDING

03136-7

PRIMER

SEAL ASSEMBLY

0

30A28

PRIMER

45° CUT " "" ^S -UW \ SEA L

ASSEMBLY

VIEW-C 030A28

PRIMER

WINDSHIELD

VIEW-E

FIG. 4 Windshield and Exterior Mou lding Installation—T hunde rbird and Continental Mark V

RETAINER

42413

TOP

MOULDING

03144

MOULDING

16C13I

N1191-E

FIG. 5 Windshield and Exterior Mou lding Installation—Linco ln Co ntinental



43-11-6


43-11

PREFERRED CUT 45 °

VIEW I

RETAINER

V I E W H

TOP

MOULDING

PRIMER

LOCATE WINDSHIELD

FLUSH .06 TO FLANGE

EDGE

VIEW G

RETAINER

PRIMER

VIEW F

TOP

MOULDING

GLASS

VIEW A

V I E W B

RETAINER

SCREW

V I E W C

MOULDING

V I E W D

PRIMER

SPACER

V I E W E

F I G .

6 Windshield and Exterior Moulding Installation — Granada and Monarch



43-11-7


43-11-7

PREFERRED CUT 45°

45 °

FIG. 7 Back Window and Exterior Mou lding Installation—Ford and Mercury Except Stat ion W ago n—Typ ical



43-11-8


43-11

PADDING VIN YL TOP

VINYL ROOF ROLLED

BACK AND TAPED FOR

GLASS REMOVAL AND

INSTALLATION

GLASS HOLDING TOOLS

MOULDING

SEE VIEW A

VINYL TOP TUCKED

UNDER MOULDING

VIEW A

DISCARDED BOWDEN

CONTROL WIRE CAN

BE USED TO PULL VINY L

ROOF FROM BETWEEN

GLASS AND COVERED

BACK WINDOW M OULDING

WEDGE FOR

ADDED CLEARANCE

BACKG

GRIND PUTTY KNIFE OFF

FOR VINYL INSTALLATION

N

F IG . 8 Frenched Back Window Moulding Installation—Mark V and Lincoln



43-11-9


43-111-9

OUTSIDE UPPER

MOULDING 423A00-1

LOWER MOULDING

424A00

VIEW A

V I E W B

SPACER

420A22

V I E W C

PRIMER ON GLASS

•GLASS

V I E W D

V I E W F

N1661-E

FIG. 9 Back Window Exterior Mouldings—Mustang 2-Door

VIEW A

BUTYL SEAL

BUTYL SEAL

SPACER-420A22

VIEWB

VIEWC

(7) RETAINER

VIEWD N1660-G

FIG. 10 Back Window Exterior Mouldings—Mustang 3-Door



43-11-10


43-11-

VIEW A

PRIMER

A TRETAINER

42413

RETAINER

SEAL TO BE FLUSH

TO EDGE OF FLANGt

VIEWB

SPACER

AN D

RETAINER

ASSEMBLY

420A64

BUTYL S

SEALER

VIEWC

PRIMER

GLASS

BUTYL SEAL

SEALER

BUTYL SEAL

VIEWD VIEW E

VIEW F

N1

FIG.

11 Back Window Exterior Mouldings—Thunderbird and Continental Mark V



43-11-11 Stationary Glass-Butyl Type Seal

43-11 11

SPACER AND \\\

RETAINER ASSY

'420A64

± .06 FROM EDGE

OF FLANGE OR

FROM TANGENT

OF RADIUS

VIEW - G

VIEW - H

V I E W - J

V I E W K

N1129-E

FIG.

12 Back W indow Exterior Mouldings—Lincoln Continental 2-Door Show n—Ty pical 4-Door

F IG .

13 Quarter W indo w Moulding Instal lation—Ford and Mercury Station W ag on

Remova l (Procedure No. 2)

Engine must be off on vehicles

equipped with high voltage output type

heated glass.

1. Remove the windshield wiper arms

and blades if the windshield is being

replaced.

2.

Remove the window mouldings.

3.

On the heated back window it will be

necessary to disconnect the window

wires at the connectors on both sides

of the window before proceeding with

the glass removal.



4 3 - 1 1 - 1 2


43-11-

SPACER AND RETAINER

ASSY - 420A64

SEALER

FLUSH TO EDGE

±0.06 INCH.

VIEW A

SPACER AND RETAINER

ASSY -420A64

SPACER -420A24

(NOT ALWAYS USED)

VIEWB

BUTYL SEA

VIEWC

VIEWD

RIVET

VIEW

E

N24

FIG.

14 Quarter Window and Moulding Installation—LTD II Station Wagon



43-11-13

Stationary Glass-Butyl Type Seal 43-11-13

4.

With

a

electric knife (special Tool

T70B-42006-A

or

equivalent), insert

the blade under

the

edge

of

the glass.

C ut the butyl seal as close to the

inside surface of the glass as possible.

To cut the butyl at the lower corners

of the windshield, move the handle of

the tool as close to the co rn er as

p o ss ib le . Th en , ro ta te the b lad e

downward to cut the corner butyl seal

and remove glass from the vehicle

using the glass holding tool (Figs. 15,

16 and 18).

Installation

1. Clean all remaining butyl from the

pinch weld flange and wipe the sheet

metal with naphtha

or

equivalent

solvent

to

provide

a

clean surface

for

the replacement butyl.

2. Inspect flange carefully for sheet

metal deficiencies, and the sealing

surface of the pinch weld flange for

chipped

or

missing paint

and

repair

as necessary.

3. Tempo rarily position the replacement

glass in the windshield opening using

sp acer s to prevent g lass- to-m etal

contact. Adjust glass side to side to

th e b es t g las s - to - "A" p i l la r we ld

flange overlap position and adjust

lower spacers,

if

necessary,

for

proper

positioning

at the

top.

A

minimum

of

3/16" butyl tape-to-glass contact is

required around the per iphery to

assure proper retention and adequate

seal. Mark this location with a crayon

on the outside surface of the glass and

a corresponding poin t

of the

glass

opening. Remove

the

glass

and

clean

t h e i n s i d e s u r f a c e and e d g e

thoroughly.

4. Starting at the midpoint on one A

pillar, place the butyl tape flush to 1/

16"

inboard

of

the pinch weld flange

edge around

the

p er ip h ery

of the

opening and along the raised area of

the cowl top panel provided for the

seal. NOTE: Do not allow the butyl

to b r id g e co rn er s of the w in d o w

opening and do not stretch the butyl.

5. Cut the butyl at the required length

on a 45 degree angle and carefully

splice the two loose ends.

6. Apply

the

primer (furnished

in the

k i t ) a ro u n d the p e r i m e t e r of the

cleaned inside surface

and the

edge

of

the glass

in the

area that will contact

the butyl seal (Fig. 17).

7.

Allow

the

primer

to dry one

minute

before installing the glass.

8 . Place the g l a s s in the o p e n i n g ,

aligning

the

crayon marks.

9. Firmly press

the

glass against

the

butyl with hand pressure

or

weights.

Recheck to assure that 3/16 inch

contact between glass and butyl is

achieved. A dull spot indicates an

area where the butyl is not contacting

the glass surface. Additional pressure

will seal such areas.

10.

F r o m o u t s i d e the v eh ic le , ap p ly

C9AZ-19554-B Auto Glass Liquid

Sealer

(or

eq u iv a len t ) a ro u n d

the

entire edge of the glass.

11.

Remove

any

excess primer from

the

inside surface of the glass with a razor

blade

and

wipe

the

glass with

a

clean

cloth dampened in naphtha.

Tool-T70P-42006-A

12. When the liquid butyl has "skinned

over" (approximately ten minutes),

w a t e r t e s t the i n s t a l l a t i o n . If

n ecessary , r ep a i r any leaks with

additional liquid sealer.

13. Install the mouldings and wiper arms

and blades.

14. On the heated back window, it will be

necessary to apply a piece of tape to

the pinch weld flange under the wires.

Then, connect the wires and install

the garnish and exterior moldings.

15. W h e n c l e a n i n g

the

h ea ted b ack

w i n d o w ,

use

only l iquid window

cleaning so lvent .

Do not use

steel

wool

or

abrasive powders,

as

damage

to the grid wires will result.

16. Clean the glass and surrounding area.

3/ 8

INCH

PRIMER

GLASS

PORTION BELOW

SEAL LINE

HIDDEN WIPERS

N 1 8 3 1 - B

FIG.

15 Removing Butyl Type Seal

FIG. 17 Primer Installation

Glass Holding Tool

FIG.

16 Cutting Corner Seal

Too l -T70P-42006-A N1830-B



43-11-14


43-11

MOULDIN

USING AN ELECTRIC KN IFE, CUT THE EXISTING

BUTYL AS CLOSE TO THE GLASS AS POSSIBLE

BUTYL TAPE USED

FOR INSTALLATION

NO .

1

EXISTING BUTYL

MOULDING RETAINER

APPLY THE 5/16 DIAMETER BUTYL

TAPE (PART OF KIT) ON THE TOP

OF AND CENTERED ON THE

EXISTING BUTYL REMAINING EXISTING BUTYL

ON THE PINCH FLANGE.

BUTYLTAPE

USED IN

PROCEDURE

NO . 2

N27

FIG. 18 Butyl Type Seal Installation



44-01-1

Doors, Hood, Luggage Compartment Door and Tailgate

44-01

DOORS,HOOD,LUGGAGE

C O M P A R T M E N T

DOOR AND TAILGATE

GROUP

(16000 £

70000)

PART TIT LE PART NO.

Doo r, Hinge, We athe rstrip, Latch and Lock 44-06

Door, H ood , Luggage Com partment Door and

Tailga te - General Service 44-01

Hood ,

Hinge and Latch 44-21

Luggage Compartment Door, Hinge, Latch,

Lock and Wea therstrip 44-41

PART TIT LE PART NO

Power Door Locks 44-

Tailgate, Hinge, Latch and Lock

- Dual Ac tio n Gate 44-

Tailgate, Hinge, Latch and Lock

- Single Ac tion Gate 44-

CR2005

General Service

GENERAL INFORMATION

DOOR AND ROOFRAIL

WEATHERSTRIP LUBRICANT

Sil icone Lubr icant COAZ-19553-

A (Je l ly ) and COAZ 19533-C

(Spray) (or Equivalent)

This lubricant is to be used on the

door and window weatherstrips. It is

recommended that silicon lubricant be

applied to the weatherstrips at every

regular lubrication period and/or,

whenever necessary. Its use makes the

doors easier to close, avoids weatherstrip

squeaks, retards excess weatherstrip wear

from chafing between the door glass

upper frame and the weatherstrip. Also,

it helps to retain door window alignment

by reducing friction between the glass

frame and the rubber weatherstrip.

DOOR, HOOD, LUGGAGE

COMPARTMENT AND TAILGATE

HINGES-LUBRICANT

Polyethylene Grease C4AZ-

19 58 4 B (or Eq uivalent)

The lubricant is used to lubricate door

hood, luggage compartment and tailgate

CR2034-A

hinges. Apply an even coat to all m ov

hinge surfaces when a binding condi

occurs.

CYLINDER LOCK LUBRICANT

Lock Lubr icant B4A19587-A (o

Equivalent)

This lubricant is used to elimin

sticking or binding of all key l

cylinders.



44-06-1

Door, H inge, W eatherstrip, Latch and Lock

44-06-1

Door, Hinge, W eatherstrip,

Latch and Lock

P A R T

44-06

SUBJECT PAGE

ADJUSTMENTS

Door Alignme nt 06-1

Door Latch Striker 06-1


Doo r Hinge 06-3

Door Latch Remote Con trol -

Fro nt or Rear 06-7

Door Lock Cylinder 06-15

SUBJECT PAIS£

REMOVAL AND INSTALL ATION (Cont'd .)

Door Outside Handle 06-15

Doors 06-3

Front and Rear Door Weatherstrip 06-1

Fron t Door Latch 06 3

Rear Door Latch 0 67

Rear Door Latch Bellcrank

06

11

Roof Side Rail and Door Weatherstrip 06-1

ADJUSTMENTS

DOOR ALIGNMENT

The door hinges provide sufficient

adjus tm ent to corre ct mos t door

misalignment conditions. The holes of

the hinge and/or the hinge attaching

points are enlarged or elongated to

provide for hinge and door alignment

(Figs. 1 and 2).

The lubrication points on the door

hinges are shown in (Figs. 1 and 2).

Do

not cover up a poor door alignment with

a latch striker adjustment.

Side Doors

1. See Figs.

1

and 2, to determine which

hinge bolts must be loosened to m ove

the door in the desired direction.

2.

Loosen the hinge bolts just enough to

permit movement of the door with a

padded pry bar.

3. Move the door the distance estimated

to be necessary. Tighten the hinge

bolts and check the door fit, to be sure

there is no bind or interference with

the adjacent panel.

4.

Repeat the operation until the desired

fit is obtained, and check the striker

plate alignment for proper door

closing.

5. On all hardtop models, the door and

quarter glass must be checked to

assure proper alignment to the roof

rail and vertical weatherstrips. See

Group 42.

CR2035-A

DOOR LATCH STRIKER

The striker pin can be adjusted

laterally and vertically as well as fore and

aft. The latch striker should not be

adjusted to correct door sag.

The latch striker should be shimmed

to get the clearance shown in Fig. 3

between the striker and the latch. To

check this clearance, clean the latch jaws

and the striker area. Apply a thin layer

of dark grease to the striker. As the door

is closed and opened, a measureable

pattern will result on the latch striker.

Move the striker assembly in or out

to provide a flush itat the door and pillar

or quarter panel. Use Tool T7OP-21OO-A

to loosen and tighten the latch striker.


ROOF SIDE RAIL AND DOOR

WEATHERSTRIPS

The roo f s ide r a i l and door

weatherstrip installations are shown in

Figs. 6 through 15. Apply adhesive (Part

Number 19552) or equivalent, where

required to retain the weatherstrip to the

door or retainer.

FRONT AND REAR DOOR

WEATHERSTRIP

All Models Except Pinto, Bobcat,

Mav er ick, Comet and L inco ln

Cont inenta l

Removal

1. Remove the door weatherstrip front

and rear molded details attaching

screws (Fig. 4).

2.

Pry the door trim panel up and pull

the molded belt detail flap out from

under the door trim panel, tearing it

away from the retaining pin. Do this

at both the front and rear sections and

remove the weatherstrip from the

door.

Installation

1. P r i o r t o i n s t a l l a t i o n o f t h e

replacement weatherstrip, remove the

retaining pins from the molded detail

f laps of the new w eat he rs t r ip

assembly (Fig. 5).

2.

Slide the "flap" of both front and rear

molded belt details of the new

weatherstrip assembly under the door

trim panel. Proceed to complete

w ea the r s t ip in s ta l l a t ion , u s ing

adhesive where required (Part No.

19552) (or equivalent). Fully in-

sert all weatherstrip retaining pins.

Pinto,

Bobcat , Maver ick and

Comet

Removal

1. Pull weatherstrip away from door

panel by breaking loose f rom

adhesive.

2.

Clean off all the old adhesive

Installation

1. Apply adhesive to door panel.

2.

Position new weatherstrip and press

against door until secure. Fully insert

all weatherstrip retaining pins.

Lincoln Continental

Removal

1. Remove the retaining screws i< front-

door, 7 rear-door) and remove the

weatherstrip.



44-06-2

Door, Hinge, W eatherstrip, Latch and Lock

44-06-

1 ) LUBRICATIO N POINT -

* —

'

POLYETHYLENE GREASE - (19584)

GRANADA, MONARCH,

MAVERICK, COMET, FORD,

MERCURY , LINCOLN

CONTINENTAL

FRONT DOOR

GRANADA, MONARCH ,

FORD.

MAVERICK,

COMET, MER CURY, LINCOLN

CONTINENTAL REAR DOO R

N1087-K

FIG.

1 Side Door Hinge Adjustm ents—A ll Mod els Except LTD II, Cougar, Thunderbird and Co ntinental M ark V

FRONT DOOR

APPLY LUBRICANT (19584)

N 2206-E

FIG .

2 Side Door Hinge Adjustments—LTD II, Couga r, Thunderbird and

Continental Mark V

LATCH STRIKER

3/32 MINIMUM

5/32 MAXIMUM

LATCH

ASSEMBLY

N1126-C

FIG. 3 Door Latch Striker

Adjustment—Maverick and

Comet Shown



44-06-3

Door, Hinge, Weatherstrip, Latch and Lock 44-06-3

Installation

1. Position

the

weatherstrip

to the

door

flange.

2.

Install

the

retaining screws.

DOORS

Removal

1. Remove the tr i m p a n e l , the

watershield,

and all

usable outside

mouldings

and

clips

(if

the door

is to

be replaced).

2. Remove the wiring harness, actuator

and radio speaker from the door (if so

equipped).

3. Remove all usable window and door

latch components from

the

door

(if

the door is to be replaced).

4.

Support

the

door.

5.

Remove the hinge attaching bolts

from

the

door

and

remove

the

door.

6. Remove the weatherstrip from the

door.

Installation

1. Drill holes as necessary for attaching

the outside moulding. Install the door

weatherstrips in proper position.

2.

Position

the

door

to the

hinges

and

partially tighten th e bolts. Then, align

the door and t ighten the bol ts

securely.

3. Install the wiring harness, actuator

and radio speaker

in the

door,

if so

equipped.

4.

Install

the

latch mechanism,

the

window mechanism, glass, and the

glass weatherstripping. Adjust

the

window mechanism as outlined in

Group

42 and

striker adjustment

in

this Section.

5. Install

the

exterior trim , garnish

mouldings, watershield, and interior

trim.

DOOR HINGE

All Models

1. Support the door.

2.

Mark the location of the hinge on the

door

and

body.

3. Remove the hinge-to-body attaching

bolts.

4.

Remove the hinge-to-door attaching

bolts

and

remove

the

hinge.

5. Position the hinge to the door and

body, and install the attaching bolts.

6. Adjust

the

door

and

hinges

and

remove the support.

FRONT DOOR LATCH

Removal

1 . Remove

the

t r im p a n e l

and


2.

Ford, Mercury (4-door sedan

and

wagon) and Maverick, Comet, Pinto

and Bobcat; mark the location of the

rear

run

lower retaining bolt. Then,

remove the bolt.

N2525-A

FIG. 4 Removing Door Weatherstr ip—Trim Panel in Place (Typical)

ATTACHING

SCREWS

RETAINER

PIN -

REMOVE

FROM NEW WEATHERSTRIP

PRIOR

TO

INSTALLATION

THIS RETAINER PIN IS NOT

AFFECTED

FRONT OF BODY

VI2526A

F IG . 5

Instal l ing Door Weatherstr ip—Trim Panel

in

Place (Typical)

3.

Check all rod connections against

the

appropriate illustration (Figs. 16 thru

24).

Correct

any

misconnected

or

l o o s e c o n n e c t i o n s and c h e c k

operation before replacing parts.

4. Disconnect

the

rods from

the

latch.

All

can be

removed

on the

Maverick

and Comet, but on the other vehicles,

the remote link

and the

latch

to

lock

cylinder rod cannot be removed

b e c a u s e

of the

r o d ' s

end

configuration.

5.

Remove

the

lock cylinder

rod

from

the lock cylinder lever.

6. Remove

the

r emote con t ro l

as

outlined in the next section.

7. Remove the latch assembly attaching

screws; disconnect the door indicator

switch wire

(if so

equipped)

and

remove the latch from the door.

8. Remove

the

remote link,

the

latch

to

lock cylinder rods, and the door

indicator switch from the latch where

applicable.

Installation

1. Position the door indicator switch to

the latch and install the attaching

screw. Adjust

the

switch.

2.

Install

new rod

retaining clips

and

grommets

in the

new latch assembly,

using the removed latch as a guide.

3. Install the remote link and the latch

to lock cylinder rod. (All car lines

except Maverick

and

Comet,

Fig.

24.)

4.

Position the latch in the door and

connect the wire to the door indicator



44-06-4

Door, Hinge, Weatherstrip, Latch and Lock

44-0

RETAINER

4 REQ'D.

APPLY

1/8 DIA.

BEAD OF SEALER

2 "

BELOW BELT LINE

APPLY 1/8 DIA.

BEAD OF SEALER

2 " BELOW BELT LINE

FIG. 6 Retainer and Weatherstrip Installation—Granada and Monarch— 4-Door Shown— 2-Door Similar



44-06-5


44-06-5

NOTE: INSERT TABS IT E M ®

INTO LOCATING HOLES [

ROOF SIDE DRIP

MOULDING

517B16-7

SCREW - 384474

8 REQ'D. EACH SIDE

SECURE THi:

SCREW F IRS"

WEATHERSTRIP

51222-3

SCREW

384049

V | E W A

ADHES /E

N2374-D

FIG. 7 Roof Rail Weatherstrip Installation—Continental Mark V

ETAINER RETAINER

51204-5 24510

N 2 3 7 ' - |

F IG .

8 Retainer and Weathe rstrip Installation—L TD II , Cougar, Thunderbird 4 Door Show n— Station W ag on Similar



44-06-6

Door, H inge, W eathers trip, Latch and Lock

44-0

F I G . 9 Roof Rai l W eatherstrip Installation — LT D I I , Cougar and Thunderbird — Tw o Door

WEATHERSTRIP

20530-1

SCREWS

WEATHERSTRIP ASSY. IS '

SECURED FIRST BY INSERT-

ING PIN INTO EXISTING

BEFORE INSTALLING

SCREWS

SCREW

2-DOOR MODELS

SCREW

INSERT PIN

INTO EXISTING

HOLE BEFORE

INSTALLING

SCREWS

SCREW

FRONT DOOR -4 DOOR MODELS

SCREW

INSERT PIN INTO

EXISTING HOLE

BEFORE INSTALLING

SCREWS

SCR

REAR DOOR

N 2

FIG. 10 Front and Rear Door W eatherstr ips—LTD I I , Thunderbird and Cougar



44-06-7


44-06-7

SIDE MOULDING

- 517B16-7

V I E W B

SEALER

V I E W )

FIG. 11

Roof Side Rail Weatherstrip Installation—Ranchero

swi tch. Then, ins ta l l the la tch

attaching screws.

5. Reinstall the door latch remote

control as outlined in the next section.

6. Connect the latch to lock cylinder rod

to the lock cy linder lever (all vehicles

except Maverick/Comet).

7. Connect

the

rods

to the

latch that

were disconnected

for

removal

and

check

the

latch operation.

8. Install

the

rear

run

lower attaching

bolt

(if

removed). Locate

the

bolt

in

the original position

and

tighten

the

bolt.


on the door.

DOOR LATCH REMOTE

CONTROL—FRONT OR REAR

All models except Maverick,

Comet , Mustang, P into or

Bobcat

Removal


watershield.

2.

Remove the attaching screw or

poprivets (see appropriate Figs. 16

thru 24)

and

disengage

the

attaching

tab.

3. Rotate the remote control clockwise

on the r i g h t - h a n d d o o r and

counterclockwise

on the

left-hand

door, while moving

it

forward

to

disconnect

the

remote control from

the remote control

rod and the

door.

Installation

1. Install a new rod end bushing to the

remote control if the remote control

is to be replaced.

2. Position the remote control to the

door inner panel with the remote

control rod started into the remote

control bushing. Rotate

the

remote

control a quarter turn onto the remote

rod (counterclockwise

on the

right-

hand

and

clockwise

on the

left-hand

door).

3. Engage the tab

on

the remote control

into

the

slot

on the

inner panel

and

i ns t a l l the a t t a c h ing sc re w or

poprivets.

4. Check the remote control and latch

operation.

5. Install the w atershield and door trim

panel.

Mave rick, C omet, Pinto, Bobcat

and Mustang

Removal


watershield.

2.

Disconnect the retainer from the link

at

the

remote control (Maverick

or

Comet—see Fig. 18

and 19).

3. Remove the three (3) screws or nuts

attaching the remote control to the

door inner panel and remove the

remote control.

The

Mustang, Pinto

and Bobcat remote control must

be

rotated

off

the remote

rod to

remove,

similar

to

Step

3

above.

IM2220-A

Installation

1. Install a new bushing or retainer into

the new remote control, if the remote

control is to be replaced.

Rotate the remote arm onto the link

to engage the two parts for Mustang,

Pinto and Bobcat only.

Position

the

remote control

to the

door inner panel

and

install the three

attaching screws or nuts

(Figs.

18 and

19).

Connec t

the

link

to the

remote

control

and

secure with

the

retainer

(Maverick

and

Comet).

Check

the

remote control

and

latch

operation.

Install

the

w atershield

and

door trim

panel.

2.

3.

4.

5.

6.

REAR DOOR LATCH

Removal

1 . Re m ove the t r i m p a n e l and


2. Disconnect

the

door latch actuating

rod from

the

latch assembly—all

car

lines.

Also disconnect

the

remote

control

and

bellcrank link assemblies

from

the

Maverick

and

Comet doors

(Fig.

22).

3. Remove the rear door latch bellcrank

as outlined below

for all car

lines

except Maverick

and

Comet.

4. Remove

the

door la tch remote

control

as

outlined previously

for all

car lines except Maverick and Comet.



44-06-8

Door, H inge, W eathers trip, Latch and Lock

44-0

CORNER SCREWS MUST BE INSTALLED FIRST.

WEATHERSTRIP

513A68-9

RETAINER SIDE

RAIL WEATHERSTRIP

_ ^ { ?)--/< = -.

x

51238-9 WEATHERSTRIP

;V *)—

51222-3

SCREW

RETAINER 381101

24510-1

V I E W D

APPROX

ADHESIVE

V I E W F

NOTE:

FOAM TAPE, PART OF RETAINER

ASSY., MUST BE UNDER W/STRIP

AND NOT VISIBLE WHEN

INSTALLED ON PILLARS

APPLY LUBRICANT TO

ENTIRE W/STRIP ASSY.

WIPE OFF EXCESS LUBRICANT.

INSERT LOCATOR TABS-

ITEMS "P", INTO HOLES

PROVIDED.

VIEW A

V I E W B

APPROX. 2.00

V I E W

MODEL S3 71

INSERT LOCATOR TABS ITEMS

"P", INTO HOLES PROVIDED.

RETAINER-SIDE

RAIL WEATHERSTRIP

51238-9

WEATHERSTRIP

51222-3

ADHESIVE

VIEW A

ADHESIVE

OVERLAP SEAL

V I E W

OPTIONAL LOCATION.

ADHESIVE

.50

APPROX

VIEW D

V IE W E V IE W

MODELS 53 AND 57 N 15

F IG . 12 Roof Rail Weatherstrip Installation—Ford and Mercury Similar



44-06-9

Door,

Hing e, W eathe rstrip, Latch and Lock

44-06-9

APPLY GLYCOL LUBRICANT

TO UNDERSIDE OF WEATHERSTRIP

AT GLASS CONTACT SURFACE

WEATHERS TRIP

VIEW

APPLY GLYCOL

LUBRICANT

TO OUTER

SURFACE OF

WEATHERSTRIP

WEATHERSTRIP

BUMPER

WEATHERSTRIP

P IN

APPLY GLYCOL

LUBRICANT

PI N

WEATHERSTRIP

APPLY GLYCOL

LUBRICANT

WEATHERSTRIP

VIEW

WEATHERSTRIP

APPLY GLYCOL LUBRICANT

TO UNDERSIDE WEATHERSTRIP

AT GLASS CONTACT SURFACE

SCREW

7 REQ'D.

WEATHERSTRIP

VIEW

REAR

DOOR

WEATHERSTRIP

APPLY GLYCOL

LUBRICANT

G

BUMPER

FIG . 13 Door W eatherstrip Installation—Lincoln C ontinental-4-Door Sh own,

2-Door

Similar



44-06-10

Door, H inge, W eatherstrip, Latch and Lock

4 4 - 0 6

VIEW-A

REAR DOOR SHOWN

FRONT DOOR TYPICAL VIEW - B

WEATHERSTRIP

V I E W - C

N

F IG .

14 Door Weatherstr ips—Maverick, Comet Shown—Pinto and Bobcat Typical

5. Remove the three latch assembly

attaching screws, disconnect the wire

from the door indicator switch (if so

equipped), and remove the latch

assembly from the door.

6. Remove the door indicator switch

from the latch assembly (if so

equipped), and remove the two link

assemblies from the latch on all car

lines except Maverick and Comet.

Installation

1. Install new clips and grommets in the

new latch assembly, using the

removed latch as a guide.

2.

Install the door indicator switch on

the latch assembly and adjust as

outlined under adjustments.

3. Install the two link assemblies into

the lower lever gromm ets as shown in

Fig. 22 (all car lines except M averick

and Comet).

4.

Place the latch assembly to the door

and connect the wire to the door

indicator switch.

5.

Position the latch assembly to the

door and ins ta l l the three (3)

attaching screws (Fig. 22).

6. Connect the door latch actuating rod

to the latch assembly (all car lines)

and connect the two link assemblies

on Maverick and Comet.

PIN —INSERT PINS

AT EACH END FIRST DURING

WEATHERSTRIP INSULATION

N

F IG . 15 Door Weatherstr ips—Mustang



44-06-11

Door, H inge, W eathe rstrip, Latch and Lock

44-06-11

7. Reinstall the door latch bellcrank and

remote control as outlined under each

respective heading.

8. Check the operation of the latch

assembly.


on the door.

REAR DOOR LATCH BELLCRANK

Removal

1. Remove the lock control knob from

the push button rod.

2. Re m ove the t r im pa ne l a nd


3.

Remove the screw attaching the

bellcrank to the door inner panel.

Disconnect the bellcrank from the

lock control link by unclipping the

r e t a ine r ( M a ve r i c k /Com e t ) o r

rotating it of off the double 90 degree

bend on the other car lines (Fig. 22).

4. Remove the push button rod from the

bellcrank.

Installation

1. Install new rod retaining clips or

grommets in the new bellcrank if the

bellcrank is to be replaced.

2. Assemble the push button rod to the

bellcrank.

3. Assemble the bellcrank to the lock

control link by clipping the retainer

(Maverick/Comet) or rotating the

bellcrank onto the link on other car

lines.

4. Position the bellcrank to the door

inner panel with the push button rod

K N O B

2 1 8 5 0

GROMMET

(PINTO, MAVE RICK, COMET)

IN INNER PANEL - 21999

ROD-DOOR LATCH

ACTUATOR 221 52-3

STRIKER

2 1 9 8 2

N2102-E

FIG.

16 Door Latch and Striker Installation—Similar

NUT - 4533: -S2

2 REQ'D.

PUSH BUTTON

ROD

N27i:i-B

FIG. 17 Front Door Latch Mechanism — Granada and Monarch — 2-Door S how n, 4-Door Simi lar



44-06-12


44-06

LATCH PUSH

BUTTON ROD

21852-3

( ? ) S EE VIEW S " A " , " C " , & " D "

MODELS 62 SHOWN

MODELS 54 TYPICAL

PAD (SMALL 22448-9

ROD 22134

RETAINER 219A36

PAD (LARGE)

22428-9

REMOTE CONTROL

LINK 21914-5

3/32" MIN.

5 /32" MAX.

NOTE: OUTSIDE HANDLE BUTTON MUST RELEASE THE

LATCH ASSEMBLY WHEN FULLY DEPRESSED.

OUTSIDE HANDLE BUTTON MUST NOT

PRELOAD LATCH ASSEMBLY SO AS TO

PREVENT LOCK OR UNLOCK BY EITHER

THE LOCK CYLINDER OR LOCK BUTTON.

RETAINER

ASSEMBLY

219A36

REMOTE CONTRO

21818-9

STANDARD PRODUCTION

F IG .

18 Front Door Latch and Striker Installation—Maverick and Comet



44-06-13

Door, Hinge, Weatherstrip, Latch

and

Lock

44-06-13

V

R O D 2 1 8 A 6 - 7

»> \

L A T C H

.'

RO D 22134-5 2 1 8 1 2 - 3

FIG. 19

Door Latch

and

Striker Installation—Pinto

and

Bobcat



44-06-14


44-06

LINK

CLIP LOCK BUTTON LINKA GE - REAR DOOR

FIG.

20 Door Handle and Latch Installation—Lincoln Continental



44-06-15

Door, H inge, W eathe rstrip, Latch and Lock

44-06-15

DOOR LATCH

REMOTE CONTROL

21818-9

BUSHING

219A38

N1741-C

FIG.

21 Door Latch Remote Control—Typical

6.

inserted through the hole at the belt

l ine . T hen , in s ta l l the be l l c rank

attaching screw.

Check the operation of the bellcrank

and associated linkage.

Install the watershield and trim panel

on the door.

DOOR LOCK CYLINDER

The key code is stamped on the door

lock cylinder in the driver side door to

assist in replacing lost keys.

When a lock cyl inder is replaced,

both door lock cyl inders and igni t ion

lock cylinder should be replaced in a set.

This will avoid carrying an extra key

which will fit only one lock.

1. Remove trim panel and position the

watershie ld away from the access

holes.

2.

Disconnect the lock control-to-door

lock cylinder rod at the lock cylinder

arm (Figs. 16 through 24).

3.

R e m o v e t h e d o o r lo c k c y l i n d e r

retainer and remove the lock cylinder

from the door.

4.

Transfer the lock cylinder arm to the

new lock cylinder and replace the rod

re ta iner i f i t shows any wear or

warpage.

5.

Position the lock cylinder in the door

and install the lock cylinder retainer.

6. Conn ect the lock control-to-d oor lock

cylinder rod at the lock cylinder and

secure the retainer.

7. Carefully position the watershield to

the inner panel and install the trim

panel.

DOOR OUTSIDE HANDLE

Lincoln Cont inenta l , Maver ick,

Comet , Pinto and Bobcat

Removal


watershield from the door panel.

2.

Disconnect the la tch ac tuat ing rod

from the latch.

3.

R e m o v e t h e n u t s a n d w a s h e r s

retaining the handle to the door.

4.

Remo ve the handle, pads and latch

actuating rod from the door.

5 . Remove the ac tuat ing rod, :>ush

button and springs from the handle

(Figs. 18, 19 and 20).

Installation

1. Install the spring, push butto n, a new

clip and the rod on the new har die.

2.

Position the handle and pads to the

door and install the retaining screw

and/or nuts .

3.

Adjus t the la tch ac tuat ing rod and

c h e c k f o r p r o p e r o p e r a t i o n

(Maverick, Comet and Pinto only).

4.


on the door.

HANDLE ASSEMBLY

22400

iHANDLE ASSEMBLY ^

22400 — 26412-3

ASSEMBLY

BELLCRANK

LINK BUSHING

26408 S ^ 219A38

'RETAINER -21 SA36

FOR MAVERICK/

COMETONL V

REMOTE CONTROL

LINK -26114

REMOTE CONTROL

21818-9

LINK -26414-5

MAVERICK AND

V I E W B

>

« ' COMET N12I3O-H

FIG. 22 Rear Door Outside Handle and Latch Mechanism—Typical



44-06-16


44-0

All Except Lincoln Continental,

Maverick, Comet, Pinto and

Bobcat

Removal

1. Remove the door tr im panel and

watershield.

2. Disconnect the door latch actuator

rod from

the

latch (Figs.

22 and 23).

3. Remove two (2) nuts retaining the

h a n d l e to the d o o r . R emo v e the

handle and rod from the door.

Installation

1. Transfer

the

actuator

rod to the new

handle using a new bushing, if the

handle

is to be

replaced.

2.

Insert

the

handle

and rod

in

door

and

install

the two (2)

re

nuts.

3.

Connect

the

door latch a ctuat

to

the

door latch

(Fig. 22).

4. C h eck the o p era t io n of the

outside handle and the door l

5.

Install

the

watershield

and

do

panel.

RETAINER-KEY CYLINDER

22023

NUT AND WASHER

34655-S2

ROD-DOOR LATCH

ACTUATOR 22152-3

ROD-DOOR LATCH

TO LOCK CYLINDER

22134

N2099-B

FIG. 23 Door Handle and Lock Cylinder Installation—Mark V



4 4 - 0 6 - 1 7

Door, Hing e, W eathe rstrip, Latch and Lock 44-06-17

LOCK CYLINDER

KNOB

21850

LINK-DOOR LATCH

LATCH CONTROL ASSEMBLY

22164 IX

L A T C H

2 1 8 1 2 - 3

N1124-E

FIG.

24 Door Latch Installation—Typical



44-16-1

Power Door Locks

44-

Power Door Locks

P A R T

44-16

SUBJECT PAGE

DESCRIPTION

A ND

OPERATION

16-1

TESTING

Motor 16-1

Relay 16-2

Switch

16-1

SUBJECT PAG

REMOVAL

AN D

INSTALLATION

Electric Door Lock Actuator 16

Lock Control Switch

16

Tailgate Lock Actuator 16


The power door lock control system

uses electric switches controlled by the

front door lock push buttons (LTD II,

Cougar, Granada and Monarch), and

rocker type switches located in the arm

rests on Ford, Mercury, Lincoln

Continental, Continental Mark V,

Thunderbird and Cougar XR7 with

door lock push butto n switches. Relays

direct the current to the door lock

motors to lock or unlock the doors.

To lock the doors on the LTD II,

Cougar, Granada and Monarch,

push

down

firmly on either front door lock

push buttons and close the door(s). On

the Ford and Mercury push the rocker

type

switch

(forward)

to lock the door(s).

T h e L i n c o l n C o n t i n e n t a l a n d

Continental Mark V require pushing

the rocker type switch (inboard) to

lock the door(s). To unlock the doors

from inside the vehicle; lift the push

button(s) upward beyond the normal

travel (LTD II, Cougar, Granada and

Monarch. On the Ford, Mercury,

CR2036-

Thunderbird and Cougar XR7,

the control switch (rearward), a

the Lincoln Continental and Con

tal Mark V, push the control

(outboard).

The key will not lock or unl

doors from outside the vehicle. T

inserted into the door lock can o

used to lock or unlock each ind

door.

TESTING

MOTOR

Apply 12 volts to one terminal of the

motor's (actuator) connector and ground

the other terminal (Fig. 1). The motor

(actuator) gear should finish its travel in

less than one (1) second.

Using an am meter; the motor current

draw (stall test), should not exceed 6

amps. Reverse the power and ground

leads to the connector and re-test.

SWITCH

LT D I I ,

Granada,

Monarch an d

Cougar

Using a self-powered test light, there

should be no continuity between any

terminals with the switch in its normal

position.

Continuity should exist between

terminals A and B with the switch held

in one position and between terminals B

and C with the switch held in the other

position (Fig. 1).

Ford, Mercury, Lincoln

Continental, Thunderbird,

Cougar

X R7 and

Continental

Mark V.

Procedures for testing the power door

lock switch is the same as for the single

power window switch. Refer to Group

42.

RELAY

LT D I I , Cougar, Granada an d

Monarch

Remove both connectors to perform

the relay tests. The relay is located on the

brake pedal support.

Verify that terminal 1 on the relay is

grounded. If terminal

1

on the relay

is

not

grounded, check the relay case to ground

bolts for tightness. If the relay case to

ground bolts is tight, replace the relay.

If not, tighten and re-test.

Apply power to terminals 2 and 4 on

each relay, and connect a 12 volt te

between terminals 1 and 2, and g

(no longer than two minutes). T

light should light. If the operati

light does not light, replace the r

Refer to the Wiring and V

Diagrams manual, Form 365-22

electrical schematic wiring diagram

the locations of the wiring harnes

Ford,

Mercury, Lincoln

Continental, Thunderbird,

Cougar X R7 and Continent

MarkV

There is no relay test for the t

models. Power is supplied directl

door lock motor through the

located in the arm rest.

On four door vehicles and

wagon models, the relay is moun

right hand side on Ford and Merc

on the brake pedal support on L

and Cougar and the LTD I

Cougar relay test procedures



44-16-2

Power Door Locks

44-16-2


ELECTRIC DOOR LOCK

ACTUATOR MOTOR

To remove the door lock actuator

motor (Fig. 1), remove the door trim

panel and watershield. Then, disconnect

the actuator motor link from the door

latch. Remove the screws or pop rivets

attaching the actuator motor to the door

and disconnect the wir ing at the

connector. Remove the actuator motor.

To install the door lock actuator

motor , connec t the wir ing a t the

connectors and install the door lock

actuator motor in the door with screws

and/or pop rivets. Connect the actuator

motor link to the door latch . Then, install

the watershield and door trim panel.

DOOR LOCK CONTROL SWITCH

LTD I I , Cougar, Granada and

M o n ar ch

The power door switch is an integral

part of the door lock push button rod. To

replace the switch, remove the door trim

panel and watershield (Group 45). The

switch must be detached from the door

l a t c h a n d / o r b e l l c r a n k b e f o r e

disconnecting or connecting the wiring

connector. (See Fig. 1.)

Disengage the push button rod from

the latch. To disengage the wiring

connector from the switch, apply

pressure under the tab with a small

screwdriver (Fig. 1). Then, pry the

locking tab up from the flange of the

connector and pull them apart.

To reassemble the wiring connector

to the switch, press firmly together until

the tab locks behind the flange. Install the

swi tch to the door la tch and/or

bellcrank. Inspect the switch installation

to ensure that no binds to sheet metal or

tight wires exist.


to the door.

Ford , Mercury, L incoln Co nt inenta l ,

Thund erbi rd, Cougar XR7 and

Continental Mark V

To remove the con trol switch, remove

the control panel from the arm rest.

Release the connector attaching nuts and

remove the switch from the control

panel. See Part

42-01.

TAILGATE LOCK ACTUATOR


Cougar—Station Wagons

Remove the tailgate trim panel and

watershield. Then, remove the two

screws or rivets retaining the lock

actuator to the tailgate inner panel (Fig.

2). Disconnect the lock actuator rod from

the la tch, disconnec t the wir ing

connector and remove the actuator.

To install the tailgate lock actuator,

connect the wiring connector to the

actuator and then lock actuator rod to

the latch. A ssemble it to the tailgate inner

panel and install watershield and trim

panel.

SWITCH

ASSEMBLY'

V I E W A

LATCH ASSY.

CLIP AND BUSHING

ACTUATOR ASSEMBLY

VIEW B

RELAY TERMINALS

TAB FOR HOLDING WIRING

CONNECTOR TO SWITCH

SCREWDRIVER

ELECTRIC DOOK LOCK

SWITCH AND ROD

N2225-F

FIG.

1 Power Door Lock Actua tor, Switch and Relay—LTD II, Gra nad a, Monarch and Cougar



44-16-3

Power Door Locks

44-1

ACTUATOR

MOTOR

431A38

(LTD I I -COUGAR)

VIEW A

( F O R D - M E R C U R Y )

VIEW A& B

TEST

HERE

VIEW

B

N26

F IG .

2

Tailgate Actuator Motor Assembly—Typical



44-21-1

Hood, Hinge and Latch

44-21-1


P A R T

44-21

SUBJECT PAGE

ADJUSTMENTS

Hood Alignm ent 21-1

Hood Catch - Au xiliary 21-2


Hood 21-9

SUBJECT PAGE


Hood Hinge 21-9

Hood Latch 21-10

Hood Support Rod 21-9

Hood Latch Con trol Cable 21-9

CR2037-A

ADJUSTMENTS

HOOD ALIGNMENT

Thunderbird, Mercury, LTD II

and Cougar

The hood can be adjusted fore and aft

and side to side by loosening the hood-to-

hinge attaching screws, and repositioning

the hood. To raise or lower the hood,

loosen the hinge-to-fender reinforcement

attaching screws, and raise or lower the

hinge as necessary (Figs. 1 and 2). To

ensure that the rear corners of the hood

are pulled down snugly against the rear

hood bumpers, it may be necessary to

r o t a t e t h e h i n g e a r o u n d t h e t h r e e

attaching bolts.

Maverick and Comet

The hood is provided with fore and

aft, vertical, and side-to-side adjustments

(Fig. 3). These directions refer to the

position of the hood when it is fully

lowered. The elongated bolt slots in the

hinge and hood provide the side-to-side

an d fo re an d a f t ad ju s tmen ts . Th e

e lo n g a ted s lo t s a t th e f en d er ap ro n

provide for up and down adjustments.

Hood bumpers, located on the top left

and the top right surface of the radiator

support, can be adjusted up and down to

provide a level surface alignment of the

hood panel with the front fenders. To

insure that the rear corners of the hood

are pulled down snugly against the rear

hood bumpers, it may be necessary to

r o t a t e t h e h i n g e a r o u n d t h e t h r e e

attaching bolts. Adjust the bumpers on

each s ide of the radiator suppor t to

eliminate any looseness of the hood when

latched.

Pinto, Bobcat, M ustang , Granada

and Monarch


and from side-to-side by loosening the

two hood-to-hinge attaching bolts at both

hinges (Fig. 4). Then, reposition the hood

as required and tighten the hood-to-hinge

attaching bolts.

To raise or lower the rear of the hood,

loosen the hinge to body attaching bolts.

Raise or lower the hinge as necessary to

obtain a flush condition of the top of the

hood with the surrounding panels. Then,

tighten the hinge-to-body attaching bolts.

Lincoln Continental and

Continental Mark V


and side-to-side by loosening the hood-

t o - h i n g e a t t a c h i n g b o l t s a n d

repositioning the hood. To raise or lower

the hood, loosen the h inge- to-fender

reinforcement attaching bolts and raise

or lower the hinge as necessary. Then,

tighten the attaching bolts (Figs. 5 and 6).

To ensure that the rear corners of the

hood are pulled down snugly against the

rear hood bumpers, it may be necessary

to ro tate the h inge around the three

attaching bolts.

HOOD LATCH ADJUSTMENT

Maverick and Comet

1. Loosen the hood latch reinforcement

attaching screws (Fig. 7) until they

are just loose enough to move the

latch and reinforcement.

2. Move the reinforcement from side-to-

side to align the latch with the hood

latch hook.

3. When the latch is aligned from side-

to-side for engagement with the hood

latch hook, tighten the reinforcement

attaching screws.

4. Loosen the lock nuts on the tw<:> hood

bumpers and lower the bumpe's.

5. Loosen the two hood latch attaching

screws u n t i l th ey a r e ju s t lo o se

enough to move the latch.

6. Move the hood latch up or down as

necessary to obtain a flush fit between

the hood and the top of the fenders

when an up ward pressure is a pplied

to the front of the hood. Then, tighten

the hood latch attaching screws.

7 . R a ise th e two h o o d b u mp er s to

eliminate any looseness at the front of

the hood when closed. Then, tighten

the hood bumper lock nuts.

8. Open and close the hood several times

to check the operation.

All,

Except Maverick and Comet

B efo re ad ju s t in g th e h o o d la tc h

mechanism, make certain that the- hood

is properly aligned. The hood latch can

be moved from side-to-side to align it

with the opening in the hood inner panel

and up-and-down to obtain a flush fit

with the front fenders.

1. Loosen the hood latch attaching bolts

until they are just loose enough to

m ov eth e latch (Figs. 8 through 13).

2. Move the latch from side-to-side to

align it with the opening in the hood

inner panel.



44-21-2


44-21

3. Loosen the lock nuts on the two hood

bumpers and lower the bumpers.

4.

Move the hood latch up or down as

required to obtain a flush fit between

the top of the hood and fenders when

an upward pressure is applied to the

front of the hood. Then, tighten the

hood latch attaching screws.

5. R a i s e t h e t w o h o o d b u m p e r s t o

eliminate any looseness at the front of

the hood when closed. Then, tighten

the hood bumper lock nuts.

6. Open and close the hood several times

to check the operation.

AUXILIARY HOOD CATCH

To ch eck th e en g ag emen t o f th e

auxiliary hood catch, release the hood

latch to the pop open position and pull

up on the hood assembly . The catch

should prevent the hood from opening.

FENDER

NUT

45264-S101

FENDER APRON

N1036-F

F IG .

1 Hood Hinge Installation—Ford and Mercury

HOOD

HINGE

16800

S C R E W

| \

SCREW

5 7

?

4 8

57041

NU T

45261 SCREW

57041

N1071-E

FIG. 2 Hood Hinge Installation—LTD II, Thunderbird and Cougar



44-21-3

Hood,

Hinge and Latch

44-21-3

HINGE

16800 R.H

16801 L.H

N2222-A

FIG. 3 Hood Hinge Instal lation—Maverick and Comet

HOOD HINGE

16800

U-NUT

45263-S7

N2176-C

FIG. 4 Hood Hinge Instal lation and Adjustment—Pinto, Bobcat, Mustang,

Granada and Monarch



44-21-4


44-2

\

N2223-B

FIG. 5 Hood Hinge Installation—Lincoln Continental



44-21-5

Hood, Hinge

and

Latch

44-21-5

NU T

45264

SCREW

57040

N2224-B

FIG.

6

Hood Hinge Installation—Continental Mark

V



44-21-6

Hood,

Hinge and Latch

44-2

HOOD

LATCH

16700

REINFORCEMENT

16A603

N2387-A

FIG.

7 Hood Latch—Maverick and Comet

HOOD LATCH

ASSIST SPRING

16C644

HOOD LATCH

•

16700

HOOD LATCH CABLE

RETAINER PLATE 16B968

N2226-C

F IG .

8 Hood Latch Installation—Pinto, Bobcat and Mustang



44-21-7

Hood,

Hinge and Latch

4 4 - 2 1 - 7

HOOD LATCH SUPPORT

16717

HOOD LATCH CABLE

RETAINER PLATE

16B968

AUXILIARY CATCH

16C708

N2529-B

FIG. 9 Hood Latch, Auxiliary Catch and Cable Installation —G ranad a and

Monarch.

AUXILLIARY CATCH

16C708

NUT

CABLE ROUTING

VIEW B

VIEW B

CL P

NJ768-A

F IG .

10 Hood Latch, Auxiliary Catch and Cable Installation—LTD II, Thunderbird and Cougar



44-21-8


44-21

SPRING NUT 45257

BRACKET 16C730

d ^

J

NON-LOCKING

INSTRUMENT

PANEL

SCREW

HANDL E AND CABL E

16B975

INSTRUMENT

PANEL

LOCK SET

SPRING NUT 45263

HOOD ASSY.

LATCH 16C708

SPRING NUT 45268.

SCREW AN D WASHER

-

384932

TORQUE 12-20 FT.LB.

CABLE ROUTING N2642

FIG. 11 Hood Latch Auxiliary Catch and Cable Installation—Ford and Mercury

FIG.

12 Hood Latch Auxiliary Catch and Cable Installation—Continental Mark V



44-21-9


4 4 - 2 1 - 9

* VIEW A V IE W B

FRONT HOOD LATCH

CABLE ASSY-16C656

VIEWC

CATCH ASSY

VIEWD

VIEWE

HOOD LATCH CABLE

RETAINER PLATE-16B968

CLIP

FRONT HOOD LATCH

CABLE ASSY - 16C656

VIEWF

LATCH COVER

16N782

N2493-B

FIG. 13 Hood Latch, Auxiliary Catch and Cable Installation—Lincoln

Continental


HOOD LATCH CONTROL CABLE

All Except Maver ick and Comet

Removal

1. From inside the vehicle, open the

hood.

2.

Remove the hood latch cable retainer

plate (one screw), and the cable clip

(Figs.

10 through 14).

3. Disengage the cable and ferrule away

from the hood latch assembly (Figs.

10 through 14).

4.

Remove the cable retaining clips.

5.

From inside the vehicle, remove the

cable mounting bracket attaching

screws and carefully pull the hood

latch cable assembly through the

retaining wall.

Installation

1.

Position the cable assembly through

the retaining wall, seat the grommet

securely, and install the cable

mounting bracket attaching screws.

2.

Route the cable as shown in Figs. 10

through 14, and retain in position

with new clips.

3. Install the cable and ferrule to the

hood latch assembly.

4. Install the cable clip and the hood

latch cable retainer plate (one screw).

5.

Check the hood latch cable release

operation before closing the hood.

HOOD

Removal

1. Open the hood and support the hood

in the open position. Mark the hood

hinge locations on the hood.

2.

Protect the body with covers to

prevent damage to the paint.

3. Remove the two bolts attaching each

hinge to the hood, taking care not to

let the hood slip when the bolts are

removed.

4.

Remove the hood from the vehicle.

Installation

1. Position the hood to the hood hinges

and install the attaching bolts .

Remove the body covers.

2.

Adjust the hood for an even fit

between the fenders and for a flush fit

with the front of the fenders.

3. Adjust the hood for a flush fit with

the top of the cowl and fenders.

4. Adjust the hood latch, if necessary.

HOOD HINGE

Removal

1. Open the hood and cover the fenders

and cowl top panel.

2.

Prop the hood in the open position

and remove two hood hinge-tohood


hood.

3. R e m o v e th e h i n g e - t o - f e n d e r

reinforcement attaching screws and

remove the hinge.

Installation

1. Position the hinge to the fender

reinforcement and install the three

attaching screws snug.

2.

Position the hinge to the hood and


3. Adjust the hood.

HOOD SUPPORT ROD

Must ang , Maver ick , Com et ,

Pinto, Bobcat, Granada and

Monarch

Removal

1. Open the hood and temporarily

support the hood in the open position

with something other than the

support rod.

2.

Remove the support from its snowed

position on top of the radiator

support.

3. Unsnap the hood support rod retainer

from the support rod and pull the rod

out of the hole in the retainer (Fig.

15).



44-21-10

Hood,

Hinge and Latch

44-21

Installation

1. Insert the end of the support rod into

the hood support rod retainer and

snap the retainer over the support rod

(Fig. 15).

2. Place the support rod in its stowed

position, remove the temporary hood

support and close the hood.

HOOD LATCH

Removal

1. Open the hood and remove the hood

latch cable retainer plate (vehicles so

equipped) and cable clip (Figs. 10

through 14).

2.

Disengage the cable and ferrule away

from the hood latch assembly

(vehicles so equipped).

3. Remove the latch attaching screws

and remove the latch assembly.

Installation

1. Position the latch assembly to the

vehicle and install the two attaching

screws.

2. Position the hood latch control cable

and ferrule to the latch assembly and

install the cable clip.

3. Install the hood latch retainer plate.

4.

Adjust the latch assembly.

NON-LOCK ING V

N

F IG .

14 Hood Latch Cable Installation—Mustang, Granada, Monarch, Pinto

and Bobcat

V I E W B

N2527-C

F IG .

15 Hood Support Rod-Mustang—Others Similar



44-41-1

Luggage Compartment Door, Hinge, Latch, Lock and Weatherstrip

44-41-1

Luggage Compartment Door, Hinge,

Latch, Lock and Weatherstrip

P A R T

44-41

SUBJECT PAGE

DESCRIPTION 41-1


ADJUSTMENTS

Door Hinge Torsion Bar 41-2

Luggage Compartment Door 41-2

Luggage Compartment Door Latch 41-3

SUBJECT

PAGE:

REMOVAL

AND INS TALLATION

Glove Compartment Lock and Knob 41-9

Luggage Co mp artment Door Wea therstrip . . . . 41-8

Luggage Compartment Latch and Lock

41-8

Luggage Compartment Lift Assembly 41-8

CR2038-A

DESCRIPTION

ELECTRIC LUGGAGE

COMPARTMENT RELEASE

Ford,

Mercury, Lincoln Continental,

Thunderbird and Continental Mark V

A switch mounted in the glove box

actuates

a

solenoid which

is an

integral

part

of the

luggage com partm ent latch

assembly

(Fig. 1).

INSTRUMENT

PANEL

CONNECTOR

SCREW

SWITCH ASSEMBLY

LAMP

ASSEMBLY

INSTALLATION WITH R.P.O. ELECT. LUGG. COMPT. DOOR LOCK

THUNDERBIRD AND MARK V

MARK V INSTALLATION

N1728-F

FIG. 1 Lugga ge Com partm ent Electric Lock



44-41-2


44-41

GENERAL INFORMATION

LUBRICANT

Apply lubricant (Part 19584 or

equivalent) to all areas shown in Fig. 2

when required.

VIEW E

VIEW F

VIEW F

INBOARD SIDE SHOWN

VIEW E

VIEW F

VIEW E

VIEW F

OUTBOARD SIDE SHOWN

VIEW A

VIEW E

VIEW E

VIEW F

VIEW B

VIEW E

VIEW E

VIEW F

VIEW F

VIEW F

VIEW E

OUT BO ARD SIDE SHOWN VI EW C

VIEW F

VIEW F

VIEW F

INBOARD SIDE

SHOWN

VIEW F VIEW D

LUBRICATE

A P P L I C A T I O N O F L U B R I C A N T

19584 TO TYPICAL AREAS

VIEW

LUBRICATE

LUBRICATE

LUBRICATE

LUBRICATE

A P P L I C A T I O N O F L U B R I C A N T

19584 TO TYPIC AL AREAS

VIEW F

N2238-

FIG. 2 Hinge Lubrication Areas—Typical

ADJUSTMENTS

LUGGAGE COMPA RTMENT DOOR

The luggage compartment door,

(third door and/or deck lid), can be

shifted fore and aft on all models and

from side to side on Pinto and Bobcat by

loosening the hinge to door attaching

screws. The up and down adjustment is

made by loosening the hinge-to-door

attaching screws and raising or lowering

the door and/or adding or removing

shims (Fig. 3 through 6).

The luggage compar tment door

should be adjusted for an even and

parallel fit with the door opening. The

door should also be adjusted up and

down for a flus h fit with the surrounding

panels. Care should be taken not to

distort or mar the luggage compartment

door or surrounding body panels.

Pinto and Bobcat Station Wagon

Only

If the liftgate door ajar warning

switch is replaced, all adjustments to the

liftgate and latch must be made before

installing the switch.

DOOR HINGE TORSION BAR

All Except Pinto and Bobcat

Model 64 and 73 and Mustang

Model 69

1. Open the luggage compartment door

and note the pop-up distance of the

door. The door should have adequate

finger clearance.

2. If the door does not have adequate

finger clearance, the torsion bars

tension should be increased. See

appropriate Figs. 3 through 13.

3. If the door pops open with more force

than is desired, the torsion bar tension

can be decreased. Use care when

adjusting the torsion bar as it is under

tension and could spring out of

control if not handled properly.

4. Support the door in the full open

position before adjusting the torsion

bar.

5. To adjust the torsion bar, grip the

with a pipe wrench (typical) (Fig.

Then, move the torsion bar end

another position (notch) to increa

or decrease the tension.

6. Adjust one torsion bar and check t

adjustment before adjusting the oth

torsion bar.

7. After torsion bar adjustment, t

difference of the position of t

torsion bar ends, between the rig

and left side, must not be more th

one slot.

3rd Door Pinto, Bobcat and

Mustang

To adjust the hinge, pull down t

weatherstrip across the entire top edge

the door opening. Carefully loosen a

pull down the headlining to expose t

access holes to the hinge nuts (Figs.

and 12). Adjust the hinges as necessa

Apply trim cement to the sheet me

flange, install headlining and smooth o



44-41-3


44-41-3

any wrinkles. Apply rubber cement to the

upper surface of the flange and reinstall

the weatherstrip.


Open the luggage compartment and

support the door in the open position.

Remove the liftgate hinge cover panel

(ten screws). Using vise grips, remove the

torsion bar (Fig. 13).

LUGGAGE COMPARTMENT DOOR

LATCH

Door Mounted Latch Adjustment

The striker plate can be adjusted up

and down and the latch can be adjusted

from side-to-side. Before adjusting the

deck lid latch make sure that the deck lid

is properly aligned. To adjust the latch,

loosen the attaching screws, move the

latch as required to enter the striker

without deflecting the deck lid sideways,

and tighten the attaching screws. Move

the striker plate up or down as necessary

to provide proper deck lid seal between

the deck lid and the lower back panel.


Liftgate

A two-po sition (seconda ry and

p r i m a r y ) d o o r l a t c h s y s t e m i s

incorporated into the liftgate of Pinto and

Bobcat Station Wagon models. This latch

cycle consists of a first or secondary

position which latches the liftgate but is

not intended to seal the door to the

liftgate weatherstrip. The second or

primary latch position

is

designed to hold

the door firmly into the weatherstrip

section to preclude water leaks and/or

wind noise. To assure that the

primary

latch has been activated when the liftgate

is fully closed, adjust the liftgate latch

striker plate as required to establish a

firm door-to-weatherstrip seal in that

position.

Back Panel Mounted Latch

Adjustment

The luggage compartment door latch

can be moved up and down in elongated

holes to obtain a snug fit between the

door and the weatherstrip. The latch

striker can be shifted from side to side to

obtain alignment with the striker.

The la tch can be adjus te d by

loosening the attaching screws just

enough to move the la tch . Then,

reposition the latch up or down, as

required, to obtain a water tight fit

between the luggage compartment door

and the weatherstrip, and tighten the

attaching screws. After the latch is

adjusted, reposition the latch striker for

proper engagement and alignment with

the latch.

FIG.

3 Luggage Compartment Door Minge and Torsion Bar—Ford and Mercury

SCREW AND

WASHER ASSY

57502 S2

HINGE ASSEMBLY

42700-1

N1598-C

FIG.

4 Luggage Co mpa rtme nt Door Hinge—LTD II, Cougar and Th underbird



44-41-4


44-41

NUT AND RETAINER

45268-S2 (2 REQ'D.)

SCREW AN D WASHER

ASSEMBLY-57041-S2

N2381-B

FIG. 5 Luggage Compartment Door Hinge-Lincoln Continental

N1543

FIG .

6 Luggage Compartment Door Hinge and Torsion Bar—Lincoln Continental



44-41-5

Luggage Compartment Door, Hinge, Latch, Lock and Weatherstrip 44-41-5

LEFT TORSION BAR 44891

ADJUSTMENT NOTCHES \ \

FOR RIGHT BAR

X

F IG . 7 Torsion Bar Adjustment-Typical-Maverick and Comet

YELLOW COLOR CODE

(RIGHT BAR OhLY)

ADJUSTMENT NOTCHES

1600-C

R. H. TORSION BAR

44890

HINGE ASSEMBLY

42700

R. H. TORSION BAR

44890

NOTE:

RIGHT HAND TORSION BAR IS

IDENTIFIED BY YELLOW PAINT

ON THE " U " SHAPED END.

R. H. TORSION BAR

44890

N1721-

FIG. 8 Torsion Bar Adjustment—LTD II, Thunderbird and Cougar Shown—

Continental Mark V and Lincoln Similar



4 4- 41 -6 Luggage Compartment Door, Hinge, Latch, Lock and W eatherstrip 4 4 -4

ADJUSTMENT

SLOTS

RIGHT

TORSION

BAR

(YELLOW)

L EF T ' S -

TORSION

BAR '/ > %

ADJUSTMENT

=5

=*=

&

-_ SLOTS

FIG.

9 Torsion Bar Adjustment—Granada and Monarch

N2709-A

Y E L L O W C O L O R CO D E I D E N T I F I E S

R I G H T H A N D T O R S I O N B A R .

H I N G E A S S E M B L Y

42700 -1

VIEW A

VIEW B

N2183

FIG.

10 Torsion Bar Adjustment—Pinto and Bobcat 2-Door



44-41-7

Luggage Compartmen t Doo r, Hinge, Latch, Lock and W eather strip

44-41-7

L U G G A G E C O M P A R T M E N T

( T H I R D D O O R )

.10110

H I N G E

42700 -1

V I E W A

SCREW

57367

D O OR L I F T B R A C K E T \

A S S E M B L Y - 4 2 7 A 4 8 v

N U T

376838

V I E W B

N2I07-C

FIG. 11 Luggage Compartment Door, Hinge and Lift Assembly-Pinto and Bobcat 3-Door

S C R E W

V I E W C

N2710-A

F IG . 12 Luggage Compartment Door, Hinge and Lift Assembly—Mustang 3-Door



44-41-8


44-4

CENTER4.INE OF BODY

R A I L A S S E M B L Y

•11302

H I N G E A S S E M B L Y

12900-1

TO FRONT OF BODY

N O T E :

R I G H T H A N D T O R S I O N B A R I S I D E N T I F I E D

B Y Y E L L O W P A I N T A T P O I N T " A "

N26

FIG.

13 Hinge and Torsion Bar Installation-Pinto and Bobca t—Station W ag on


LUGGAGE COMPARTMENT DOOR

WEATHERSTRIP

Removal

1. Remove the weatherstrip from the

door opening.

2. Remove all old cement and rubber

from the weatherstrip mounting

surface (Fig. 14).

Installation 2.

1. Apply a 1/4 inch bead of rubber

cement 19552 (or equivalent) in the

bottom of the weatherstrip trough

except in the drainage depressions.

(See Fig. 14 Note .) 3.

Position the new weatherstrip in

trough as shown in Fig. 14. Cu

new weatherstrip approximately

2 inches longer than required and

together without adhesive.

Apply a 3/32 inch bead of ru

WEATHERSTRIP TO BE CUT

1"TO 2"I_ONGER THAN REQUIRED

AND BUTT TOGETHER WITHOUT ADHESIVE

NOTE: OMIT ADHESIVE AROUND

DRAINAGE DEPRESSIONS

2" THUNDERBIRD, CONTINENTAL MARK V,

FORD AND MERCURY

3" MUSTANG AND LINCOLN CONTINENTAL

0" MAVERICK, COMET, BOBCAT AND PINTO

DRAINAGE

N1537

FIG. 14 Luggage Compartment W eatherstrip Installation-Typical All Models



44-41-9

Luggage Compartment Door, Hinge, Latch, Lock and W eatherstrip

44-41-9

cement 19552 under the outboard

lip

of the weatherstrip between points

shown

in

Fig.

14.

LUGGAGE COMPARTMENT LIFT

ASSEMBLY—PINTO, BOBCAT

AND MUS TANG—3- DOOR

RUNABOUT

Refer to Figs. 11

and

12

for

Removal

and Installation procedures (Luggage

Compartment Lift Assembly).

LUGGAGE COMPARTMENT

LATCH AND LOCK

1.

Open the luggage compartment door.

2.

Remove

the

lock cylinder retainer

screw and/or r ivet. Remove

the

retainer, and remove the lock cylinder

(Figs. 15 through

24).

3. Remove

the

latch attaching screws.

Disconnect

the

electric latch wire

(if

so equipped),

and

remove

the

latch.

4. Connect

the

electric latch wire

(if

so

equipped). Position

the

latch

to the

luggage compartment door,

and

install

the


5.

Adjust

the

latch

as

outlined under

Adjustments.

GLOVE COMPARTMENT LOCK

AND K NOB

All Models Except Pinto and

Bqbcat

Removal and Installation

1. Fabricate

a

tool from

a

discarded

Bowden cable

or

equivalent wire

stock,

by

forming

a 1/4

inch hook

(Fig.

25) if

Tool T71P-19703-C

(or

equivalent)

is not

readily available.

LATCH

-

EXTENSION

6543200

-

6543283

B R A C K E T -

6543268

SUPPORT

-

66432A48

SLEEVE &CCv/ER

- 6543320

SCREW & WASHER

- 57472

(7-11 FT-LB TORQUE)

R I V E T -

375203

SCREW & WASHER

-

57472

(7-11 FT-LB

TORQUE)

\

^

\

R.P.O. ELECT.

^T_65432C'O

f

^PLATE

-

6543202

N1723-H

FIG. 15 Luggage Compartment Latch and Lock Continental Mark V

2. Unlock the glove compartment door.

3. Insert the fabricated tool and /or Tool

T71P -19703-C

(or

equ iva len t )

through

the key

slot with

the

hook

turned towards

the

center

of

the

car

(Fig.

25).

4. Feel

and

engage

the

spring clip

retainer with

the

tool

and

then pull

the glove compartment knob from the

lock assembly.

5.

Remove the lock assembly screws and

remove

the

lock assembly.

6. Install

the new

lock assembly

and

retaining screws (snug).

7. Push

the

knob

on the

lock assembly.

8. Adjust the lock assembly

as

required

and tighten

the

retaining screws.



44-41-10


44-41-

EXTENSION -

6043283

PLATE(RPO)

- 6543202

ELECTRIC LATCH

ASSY. (RPO)

- 6543200

SCREW & WASHER

- 5 7 4 7 2

TORQUE TO

7-11 FT-LB

\

TO FRONT OF BODY

\

R I V E T -

375203

N104

FIG. 16 Luggage Compartment Latch and Lock-Thunderbird

EXTENSION

STRIKER

PLATE

N2237-D

FIG. 17 Luggage Compartment Latch and Lock—M ercury



44-41-11

Luggage Compartment

Door,

Hinge, Latch, Lock and W eatherstrip 44-411-11

RELEASE LEVER

LATCH

COVER

RETAINER

LOCK MOUNTING

BRACKET

LATCH

STRIKER

LOCK CYLINDER PAD

REINFORCEMENT

LOCK CYLINDER

RETAINER

N2530 A

FIG.

18 Luggage Compartment Latch and Lock—Ford

LATCH

ASSEMBLY

RETAINER

N 2 5 3 1 B

FIG.

19 Luggage Compartment Latch and Lock—Granada and Monarch



4 4- 41 -1 2 Luggage Compartment Door, Hinge, Latch, Lock and W eatherstrip 44 -4 1

LOCKSET

LATCH

43200

N1596-D

FIG. 20 Luggage Compartment Latch and Lock—LTD II and Cougar

RETAINER

S C R E W - 3 R E Q ' D .

TORQUE 7-11 FT-LB N2239 E

FIG. 21 Luggage Compartment Latch and Lock—Mustang



44-41-13


44-41-13

LOCK CYLINDER

RETAINER

MODEL 64

V I E W C

SPACER

MODEL 7 3 IM21

35-E

FIG.

22 Luggage Compartment Latch and Lock—Pinto and Bobcat



4 4- 41 -1 4 Luggage Compartment Door, Hinge, Latch, Lock and W eatherstrip 44 -4 1

STRIKER 43252

SCREW

LATCH 43200

FIG. 23 Luggage Compartment Latch and Lock Maverick and Comet

LOCK CYLINDER

SLEEVE & COVER

ASSEMBLY

LOCK CYLINDER RE TAINE R-436 29

SEAL-433A28

N2

N1212 G

FIG. 24 Luggage Compartment Latch and Lock Lincoln Continental

FIG.

25 Glove Compartment Lock

Knob Removal



44-61-1

Tailgate Hinge and Latch—Single Action Gate

44-61-1

Tailgate Hinge, Latch and L o ck -

Single Action Gate

P A R T

44-61

SUBJECT PAGE

SUBJECT

PAGE

ADJUSTMENTS 61-1


Hinge- Le f t S ide


Hinge - Right Side 61 1

Latch 61 1

61-1

ADJUSTMENTS

TAILGATE HINGE

(Ranchero Only)

The tailgate can be adjusted fore and

aft and up or down at the hinge-to-body

mounting bolts.

CR2039-A

To

adjust the tailgate from

side

to side

in the tailgate opening, remove the trim

panel, loosen the hinge-to-tailgate bolts

and shift the tailgate, as required.


TAILGATE HINGE—RIGHT SIDE

Removal

1. Open the tailgate and mark the hinge

location on the tailgate and body.

2.

Remove the tai lgate tr im panel,

watershield and access cover.

3.

Support the tailgate with a suitable

prop.

4.

R e m o v e t h r e e h i n g e - t o - b o d y

attaching bolts (Fig. 1).

5. Remove three hinge- to- ta i lga te

retaining nuts and remove the hinge.

Installation

1. Position the hinge to the tailgate and

body and install the three hinge-to-

tailgate retaining n uts.

2. Ins ta l l the three hinge- to-body

attaching bolts.

3.

Align the tailgate and tighten the

hinge retaining nuts and attaching

bolts.

4. Install the access cover, watershield

and trim panel on the tailgate.

TAILGATE HINGE—LEFT SIDE

Removal

1. Open the tailgate and mark the hinge

location on the tailgate and body.

2. Remove the tai lgate tr im panel,

watershield and access cover.

3. Retain the torsion bar in the tension

position with a deep socket and an

extension.

4. Remove the torsion bar retainer

bracket at taching screws. Then,

release the torsion bar tension and

remove the bracket and retainer (Fig.

1).

5. Support the tailgate with a suitable

prop.

6. R e m o v e t h r e e h i n g e - t o - b o d y

attaching bolts and disconnect one

end of the cable assembly (Fig. 1).

7. Remove three hinge-to-tailgate

retaining nuts and remove the hinge.

Installation


install the three hinge-to-tailgate

retaining nu ts.

2.

Ins ta l l the three hinge- to-body

attaching bolts and three retaining

nuts.

3.

Align the tailgate and tighten the

hinge retaining nuts and attaching

bolts.

4. Apply tension to the torsion bar and

install the torsion bar bracket and

retainer.

5. Install the access cover, watershield,

and trim panel on the tailgate.

TAILGATE LATCH

Removal

1. Open the tailgate and remove the

tailgate trim panel.

2.

Disconnect the latch release link from

the latch (Fig. 1).

3.

Remove three latch attaching screws

and remove the latch.

Installation

1. Position the latch in the tailgate and

install the three attaching screws.

2. Connect the latch release link to the

latch and snap the link retainer onto

the link.

3.

Install the tailgate trim panel.



44-61-2

Tailgate Hinge and Latch—Single Action Gate

44-61-

LATCH ASSEMBLY

43151

HANDLE ASSEMBLY

431C62

LATCH ASSEM

43151

CABLE ASSEMBLY

43052

HINGE ASSEMBLY

43000-1

APPLY LUBRICANT

AT

POINTS

T-U-V-W AND X

LINK 43869

STOP 444A16

WASHER

VIEW B

LATCH ASSEMBLY

BUSHING 219A38

LATCH ASSEMBLY

43151

VIEW C

J LINK ASSEM

43869

VIE

TORSION

BA R

N160

FIG.

1 Tailgate Latch Mechanism —Single-Action Ga te



44-76-1

Tailgate Hinge , Latch, Lock and W eathe rstrip— Dua l Action G at e

44-76-1

Tailgate, Hinge, Latch, Lock and

W eatherstrip - Dual Action Gate

P A R T

44-76

SUBJECT PAGE

ADJUSTMENTS

Tailgate Striker 76-1

Upper Hinge and Latch Release

Link Adju stme nt 76-1

Upper Latch-To-Lower Latch

Link Adjustm ent 76-1


Lower Hinge 76-3

Tailgate Latch Release Co ntrol 76-6

SUBJECT PAGE


Tailgate Lowe r Catch 76-4

Tailgate Manual Windo w 76-6

Tailgate Outside Handle 76-5

Tailgate Upper Latch 76-4

Tailgate Windo w Lim it Switch 76-4

Tailgate Windo w Switch 76-4

Torsio n Bar 76-4

Upper Hinge 76-4

CR2020-A

ADJUSTMENTS

UPPER LATCH-TO-LOWER LATCH

LINK ADJUSTMENT


Cougar

Place tailgate latches in the closed

(latched) position (Figs. 1 and 2).

Disconnect the upper latch-to-lower

latch link from the lower latch tailgate

latch operating lever against the stop.

Then, adjust the upper latch-to-lower

latch link to engage with the lower latch

with no load on the link.

To check the adjustment, the upper

latch must not close when the lower latch

is in the. OPEN position. The upper and

lower latches must open at the same time

when the outside handle is operated.

UPPER HINGE AND LATCH

RELEASE LINK ADJUSTMENT

Loosen the latch release control

attaching screws (Figs. 1 and 2), and

close the upper latch. Position the latch

release handle against the rubber stops.

Then, move the latch release control

down and rotate the control clockwise

(bottom toward the latch) until slack is

removed from the links. Then, tighten the

latch release control attaching screws.

Adjustment Check

1. The electric window regulator must

not operate when the latch release

control is in the released position.

2.

The manual window crank must free

wheel and not operate the window

regulator when the upper larch is

locked by the key or the inside latch

push button.

The inside release handle muit not

operate when the window is down and

the upper latch is locked by either the

key or the inside push button.

TAILGATE STRIKER

Fore and aft and up and down

a d j u s t m e n t o f t h e s t r i k e r s i s

accomplished by means of square holes

in the pillar, backed by floating tapping

p l a t e s . L a t e r a l a d j u s t m e n t is

accomplished by adding or removing

shims (Fig. 3).



44-76-2

Tailgate Hinge, Latch, Lock and W eatherstrip—Du al Action G ate

44-7

TAILGATE UPPER LATCH 43150

LATCH RELEASE

HANDLE-431C62

LATCH PUSH

BUTTON-31A32

TAILGATE LATCH

OPERATING LEVER

WINDOW REGULATOR

ACCESS COVER 07090

GROMMET-051 1 UPPER HINGE RELEAS

'L INK-431E60

UPPER HINGE-43090

UPPER HINGE

RELEASE-431E60

LATCH RELEASE

• ASSEMBLY-431C62

COUNTER BALANCE

TORSION BAR 43012

UPPER L ATCH-TO -

LOWER LATCH LINK

431A24

CLIP-21952

ADJUSTER-21816

VIEW-A

VIEW-C

•TAILGATE LOWER

LATCH 431D88

UPPER HINGE

RELEASE-431E60

TAILGATE LATCH TAILGATE LATCH

CONTROL-43884 RELEASE LINK 431D54

N175

F IG .

1

Tailgate Latch Mechanism—Ford

and

Mercury

431F6 4 LATCH UPPER

43150

LINK

431D54 ^

BRUSHING AND /

CLIP /

X

N

F IG . 2

Tailgate Latch Mechanism—LTD

II and

Cougar



44-76-3

Tailgate Hinge, Latch, Lock

and

We atherstrip—Dua l Action G ate

44-76-3


LOWER HINGE

Ford,

Mercury,

LTD

II

and Cougar

Removal

1. Open the tailgate as a drop gate and

place a support under the tailgate.


watershield.

3. Remove the wire clip from the hinge.

4. Mo v e the tai lga te g lass to the up

position.

5. Mark the location of the hinge and

remove four nuts retaining the hinge

to the tailgate.

6. Remove four hinge-to-body attaching

bolts (Fig. 4).

7 . R emo v e the t o r s i o n bar r e t a i n e r

bracket

and

remove

the

hinge. Use

cau t ion wh en work in g wi t h the

torsion bar as the bar is under tension

when installed.

Installation

1. Position

the

hinge

to the

body

and

tailgate, and install the retaining nuts

and attaching bolts.

2. Position

the

torsion

bar and

retainer

to

the

body with

a

pipe wrench

and

install the retainer bracke t a ttaching

screws.

3. Install the wire clip on the hinge.

4.

Adjust the tai lgate and tighten the

FIG. 3 lailgate Striker Adjustment—Typical

attaching bolts and retaining screws.

NOTE: APPLY LUBRICANT AT POINTS

"AC," "AD," "AE," AND "AG."

UPPER HINGE

43086

BOLT

TIGHTEN 25-38 FT. I.B.

SCREW

TORQUE 25-38 FT. LB.

TORQUE- 25-38 FT. LB

FIG. 4 Tailgate Hinges — Ford and Mercury Shown —

LTD

II

and

Cougar S imilar



44-76-4

Tailgate Hinge, Latch, Lock and Weatherstrip—Dual Action Gate

44-

5. Install the watershield and tailgate

inside cover.

UPPER HINGE

Ford,

Mercury, LTD II

and Cougar

Removal


watershield from

th e

tailgate.

2.

Disconnect the upper hinge link from

the hinge (Fig. 4).

3. Remove three screws attaching the

upper hinge to the tailgate and

remove the hinge.

4.

Remove the link clip and bushing

from the hinge.

Installation

1. Install the link clip and bushing on

the hinge.



3. Connect the upper hinge link to the

hinge.

4. Install the watershield and inside

cover on the tailgate.

TORSION BAR

Ford and Mercury

Removal

1. Open the tailgate as a door and

remove two brackets retaining the

torsion bar to the bottom of the

tailgate (Fig. 1).

2. Remove the two torsion bar bracket

retaining screws from the left end of

the tailgate (Fig. 1).

3. Remove the torsion bar from the

tailgate, and remove the bracket from

the torsion bar.

Installation

1. Position the bracket on the torsion

bar.

2. Position the torsion bar to the

tailgate.

3.

Install the two bracket retaining

screws.

4. Install the two brackets retaining the

torsion bar to the bottom of the

tailgate.

LTD II and Cougar

Removal

1. Open the tailgate as a door and

remove the trim panel, watershield

and access hole cover.

2. Remove the torsion bar retainer

bracket on the body pillar, and the

screws and washers from the two

retaining brackets (Fig. 1) in the

tailgate.

3. Remove the torsion bar from the

tailgate.

Installation

1.

Position the torsion bar into the

tailgate.

2.

Install the two brackets and retaining

screws in the tailgate.

3. Install the torsion bar retainer bracket

on the body pillar.

4.

Install the access hole cover and

watershield.

5. Install the trim panel.

TAILGATE UPPER LATCH

Ford, Mercury, LTD II

and Cougar

Removal


watershield.

2. Disconnect the four links from the

latch (Figs. 1 and 2).

3. Disconnect the two links with double

90 degree ends from the clips on the

other end of the link.

4. Remove the tailgate outside handle.

5. Remove three latch attaching screws

and remove the latch.

6. Transfer the rod clips to the new

latch.

Installation

1. Position the latch in the tailgate and


2. Install the tailgate outside handle.

3.

Connect the rods to the latch.



TAILGATE LOWER LATCH

Removal

1. Remove the interior trim panel and

access cover from the tailgate.

2.

Disconnect the latch actuator link

from the lower latch (Figs. 1 and 2).

3. Remove three lower latch attaching

screws and remove the lower latch

from the tailgate.

Installation

1. Install a new retainer clip in the lower

latch.

2. Position the lower latch to the tailgate

and install the three attaching screws.

3. Adjust and connect the latch actuator

link to the lower latch.

BUSHING

219A38

4. Adjust the lower latch strik

necessary.

5. Install the access cover and trim

on the tailgate.

TAILGATE W IND OW LIMIT

SWITCH

Ford,

Mercury, LTD II and

Cougar

Removal

1. Remove the tailgate inside cov

watershield.

2. Remove the wiring connector

the limit switch.

3. Remove the rubber boot from

switch plunger and unscrew the

switch from the mounting brac

Installation

1. Assemble the limit switch t

bracket (mounting) finger tight

2. Install the rubber boot over the

plunger and threaded portio

switch shell.

3. Connect wiring connector to s

4.

Install the watershield and


TAILGATE W IND OW SWITCH

Ford and Mercury

Removal

1. Remove the tailgate inside cov

watershield.

2. Disconnect the tailgate latch ro

the switch (Fig. 5).

3. Remove the lock set retainer (F

4. Disconnect the switch wire

remove the wire clips. Then, re

the switch and wire assembly

the tailgate.

Installation

1. Position the switch and wire ass

in the tailgate. Connect the wire

install the wire clips.

2. Position the switch to the

cylinder and install a new retain

clip (Fig. 5).

OUTSIDE H

430A70

CLIP

21952

N

FIG.

5 Tailgate Window Switch—Ford and Mercury



44-76-5


44-76-5

BUSHING -

RETAINER

219A38

HANDLE AND

HOUSING-

430A70

N1641-D

BRACKET 430A66

ROD 43876

FIG.

6 Tailgate Window Switch—LTD II and Cougar

3.

Connect the tailgate latch rod to the

switch.



LTD II and Cougar

Removal

1. Remove the tailgate inside trim panel.

2.

Remove the access hole cover.

3.

Disconnect the rod at the bellcrank

(Fig. 6).

4.

Remove the clip and remove the

switch assembly from the lock

cylinder assembly (Fig. 6).

5.

Disconnect the multiple connectors

and remove the switch and wire

assembly.

Installation

1. Route the wires and connect them to

the connectors. Then, position the

switch to the lock cylinder assembly

(Fig. 6).

2. Install the clip to the switch and lock

cylinder assembly.

3.

Connect the rod to the bellcrank.

4. Check the window operation.

5. Install the access hole cover.

6. Install the inside trim panel.

TAILGATE OUTSIDE HANDLE

Ford and Mercury

1. Remove the inside tailgate trim panel.

2.

Remove the access hole cover.

3.

Disconnect the rod, handle retaining

nuts and remove the handle (Fig. 7).

LTD II and Cougar


2. Remove the access hole cover.

3.

Disconnect the outside handle rod

retainer from the handle assembly

(Fig. 6).

PAD 430A74

LOCK CYLINDER LEVER 431F60

RETAINER 22023

N17f :? -A

FIG.

7 Tailgate Outside Handle and Lock Cylinder—Ford and Mercury

4.

Remove the retaining nuts and

washers and remove the handle

assembly.

Tailgate Lock Cylinder

Removal


2. Remove the access hole cover.

3.

Disconnect th e rods from the lock

cylinder lever (Figs. 5, 6, 7 and 8).

4. Remove the lock cylinder clip and

remove the lock cylinder from the

tailgate.

Installation

1.

Insert the lock cylinder into the

tailgate and lever, and install the lock

cylinder retaining clip (Figs. 5, 6, 7

and 8).



44-76-6


44-7

2.

Connect the rods to the lock cylinder

lever.

3. Install the tailgate inside access hole

cover and trim panel.

TAILGATE MAN UAL W INDO W

HANDLE

LTD II and Cougar

1. Remove the tailgate inside trim panel

and access hole cover.

2. Roll the window up to the closed

position.

3.

Disconnect the regulator handle

release rod and clip assembly.

4.

Remove the r egu la to r hand le

retaining nuts (Fig. 9) and remove the

handle.

TAILGATE LATCH RELEASE

CONTROL

Removal

1. Remove the interior trim panel from

the tailgate.

2.

Raise the glass part way out of the

tailgate.

3. Disconnect the rods from the latch

release control (Figs. 1 and 2).

4. Remove three latch release control


control from the tailgate.

Installation

1. Position the latch release control to

the tailgate and install the three


2.

Connect the rods to the latch release

control.

3. Lower the glass and adjust the latch

release control and tighten the

attaching screws.

4. Install the trim panel on the tailgate.

WEATHERSTRIPS

All weatherstrips should be trimmed

to obtain a good butt joint.

The tailgate weatherstrip is shown in

Figs.

10 and 11 . Apply adhesive

(19552 or equivalent) where required

for weatherstrip retention. On Ford

and Mercury models, before removing

the weatherstrip, remove any trim

panels necessary to assure proper seat-

ing of new weatherstrip. Start the

weatherstrip installation on the left

side of the tailgate opening as shown

in Fig. 10.

On LTD II and Cougar models,

before removing the weatherstrip,

remove the four retaining screws and any

trim panels necessary to assure proper

seating of the new weatherstrip (Fig. 11).

RELEASE

ROD

N1

FIG. 8 Tailgate Lock Cylinder—LTD II and Cougar

HANDLE ASSEMBLY

ADHFSIVF REGULATOR

ADHESIVE

H A N D L E p A D

44011

N113

FIG. 9 Tailgate Manual Window Regulator Handle Installation—LTD II and

Cougar



44-76-7

Tailgate H inge, Latch, Lock and W eathe rstrip— Dua l Action G ate

44-76-7

APPLY LUBRICANT TO

WEATHERSTRIP AT

GLASS SEALING

SURFACE

WEATHERSTRIP

41608

STARTING POSITION

MUST BE WITHIN 1 INCH

OF DEPRESSION

A

N23H8-B

FIG. 10 Tailgate Weatherstrip and Inside Cover Assembly—Ford and Mercury

COVER

ASSEMBLY

40726

WEATHERSTRIP APPLY LUBRIC ANT TO

ASSEMBLY WEATHE RSTRIP AT

41608 GLASS SEALING SURFACE

N23H9-C

F IG .

11 Tailgate W eatherstrip an d Inside Cover Assembly—LTD II and Cougar



45-03-1

Interior Trim

45-03

INTERIOR TRIM

GROUP

(70000)


Carpets and Floo r Mats 45-26

Door and Quarter Trim Panels 45-03

Floo r Console 45-31

Headlining 45-41

PART TITLE PART NO

Instrum en t Panel Pad 45-61

Interior Mouldings 45-16

Rear Package Tray 45-2 1

CR2006-A

Interior Trim

P A R T

45-03

SUBJECT

PAGE SUBJECT

PAGE


Center Pillar and Quarter Trim Panels

03-11

Door Trim Panels . .

Quarter Trim Panels

03-1

03-7


CR2042-A

DOOR TRIM PANELS

The following door and quarter trim

p a n e l r e m o v a l a n d i n s t a l l a t i o n

procedures generally apply to all car

lines. If some of the steps do not apply

to the particular vehicle being serviced,

proceed to the next step. See Figs. 1

through 9.

1.

Remove the door lock pushbutton

control knob and garnish moulding.

2. Remove the window regulator handle

retaining screw access cover (if so

equipped) and remove the screw and

regulator handle.

3.

Remove the door la tch handle

retaining screw access cover (if so

equipped) and remove the screw(s)

from the door latch handle.

4. Remove the screws from th e armrest

door pull cup area (if so equipped).

5.

Remove the retaining screws from th e

armrest assembly, disconnect switch

wiring (if so equipped) and remove

the armrest.

6. Remove the mirror remote control

bezel nut.

7. Remove the door trim panel retaining

screws.

®

<D

<D

INSIDE HANDLE

LTD I I , COUGAR,

AND MARK IV

DOOR

LATCH

REMOTE

CONTROL

V I E W C

PLATE

REGULATOR

MAVERICK

AND COMET

SHOWN

TYPICAL

ALL MODELS

VIEW A

LINCOLN CONTINENTAL

SHOWNTYPICAL -FORD, |

MERCURY

THUNDERBIf

ANDCOl

XR7

DOOR LATCH

REMOTE

CONTROL

MAVERICK AND COM ET

C

V I E

MUSTANG SHOWN

TYPICAL - PINTO

BOBCAT. GRANAD

AND MONARCH

SCREW

V I E W E

R138

FIG . 1 Typical Door and Win dow Regulator Handle Installation



45-03-2

Door and Quarter Trim Panels

45-03-2

DOOR INSIDE

HANDLE

CLIP

(14REQ'D)

FRONT

-

2-DOOR

ARM REST

24140 1

V I E W D

R I 3 9 4 H

FIG. 2 Ford and Mercury — Trim Panel Installations



45-03-3

Door and Quarter Trim Panels 45-03

CLIP (14REQ'D)

PAD 24100-1

TRIM PANEL 23942-3

FRONTDOOR

R18

FIG . 3 Door Trim Panel Installation—Thunderbird, LTD II and Cougar

8. With a putty knife or similar tool, pry

the trim panel retaining clips from the

door inner panel and disengage the

panel.

9. Disconnect all wiring (if so equipped)

and remove the trim panel.

10.

If the trim panel an d/o r the arm rest

is to be replaced, transfer the pull

handle pop rivets and/or retaining

screws, retaining clips, finish panel,

trim mouldings, etc., to the new

assembly. If the watershield has been

removed, be sure to position it

correctly in place before installing the

trim panel. Be sure that the armrest

retaining clips are properly positioned

on the door inner panel. If they have

been dis lodged, they must be

reinstalled before installing the

watershield.

11. Position the trim panel to the door

inner panel and connect the wiring (if

so equipped) and route the mirror

control cable through the hole.

12.

Push the trim panel and retaining

clips into the inner door panel holes

and install the retaining screws.

13.

Install the remote control mirror

bezel nut.

14. Position the armrest to the trim panel,

connect the wiring (if so equipped)

and install the retaining screws.

DOOR TRIM PANEL

- 23942

ARM REST 24140

R18

FIG .

4 Door Trim Panel Installation (Luxury Trim)—Mustang



45-03-4


45-03-4

^

U-NUT

/ ? 45263

ARM REST

B A S E - 3 1 6 0 4

ARM REST

P A D - 2 4 1 0 0

REAR DOOR

R1II11-D

FIG. 5 Door Trim Panel Installation—Maverick and Comet

WATERSHIELD

VIEW

B

,RM REST

PAD

24100-1

ARM REST BASE ASSEMBLY

24156-7

R142;»-l

FIG. 6 Door Trim Panel Installation—Thunderbird and Continental Mark V



45-03-5


45-03

CLIP-

383033

(15 REQ'D.)

PULL HANDLE

SUPPORTS -

22684

CLIP

-

383033

PULL HANDLE

-22656

ARM REST

-

24140-1

382288

FRONT

- 4

DOOR SHOWN

2 DOOR TYPICAL

TRIM

PANEL ASSY.

-

23976-7

\

SCREW -

SCREW

-3 8 5 6 8 4

TRIM PANEL

ASSY. - 23976-7

NUT -381803

R.H. SIDE ONLY

V I E W

A

ARM REST \

r u P

» «

Y

SCREW- \ PANELS-REAR, 22896 7

24006-7

ARM REST PANEL

- FRONT 24092-3

R1915-B

F IG . 7 Door Trim Panel Installation—Lincoln Continental

CLIP

24146

VIEW

A

N2187

FIG. 8 Door Trim Panel Installation—Pinto and Bobcat



45-03-6


45-03-6

REINFORCEMENT

ASH

RECEPTACLE

CLIP

BOTTOM

A R M R E S T 4 R E Q D

REAR DOOR

TUCK FOAM

TAPE

IN

WEATHERSTRIP

FIG.

9 Door Trim Panel Installation—Granada and Monarch



45-03-7


45-03

TRIM PANEL ASSY.

31012-3

ARM REST ASSY.

31600-1

SCREW & WASHER ASSY.

382288-S

FIG.

10 Quarter Trim Panel Instal lation

—

Fo rd and Mercury

15. Install the armrest finish panel (if so

equipped).

16.

Position the door latch and window

regulator handles and install the

retaining screw(s).

17. Clean old cement from the han dle

access covers with naphtha. Use a 1

3/4 x 3/8 inch tape such as 3M No.

Y9122 and cement the cover(s) back

in place.

18. Install the garnish moulding and door

lock pushbutton control knob.

QUARTER TRIM PANEL—TWO-

DOOR MODELS

Ford, Mercury, LTD I I

and Cougar

Removal

Basically, all quarter trim panels,

except Ford and Mercury, are retained in

the same manner. In view of this, one

removal and installation procedure will

cover all models. The top of the Ford and

Mercury quarter trim panel is retained by

four (4) "J" clips which are retained by

BRACKET 311A22

TRIM PANEL

31012-3

ARM REST

PAD 24100

REINFORCEMENT

31296-7

R15

FIG. 11 Quarter Trim Panel Installation—Thunderbird and Cougar



45-03-8


45-03-8

four (4) screws which retain the roof side 1. Remove the rear seat cushion and 2. Rem ove the wind ow re gu la to r

trim panel. back assemblies. See Group 41. handle, if so equipped.

QUARTER TRIM

PANEL - 31136-7

REAR SEAT

BELT OPENING

VIEW A

3-DOOR

R 1 7 0 0 D

F IG . 12 Quarter Trim Panel Installat ion—Pinto and Bo bcat—Ex cept Station W ag on

SCRE N -

3806 i 1

REAR SEAT BELT

OPENING BEZEL

- 611B90

3-DOOR

2DOOR

R1: 89-H

F IG .

13 Quarter Trim Panel Instal lat ion—Mustang



45-03-9


45-0

3. Remove any screws retaining the trim 4. Then, unclip the trim panel retaining

pan el to the inner pane l, arm rest clips and pull the trim panel from the

retaining screws, garnish moulding

retaining screws and the door sill step

plate rear screw.

qua rter panel (Fig s. 10 and 11).

Disconnect the power window switch

wires (if so equipped) from the switch.

Installation

1. Position the trim panel to the qu

panel and connect the power wi

wires, if so equipped. Then, sna

retaining clips in the holes.

R170

FIG. 14 Quarter Trim Panel Installation—Maverick and Comet

QUARTER TRIM

PANEL -31012-13

4 DOOR

2 DOOR

R191

FIG. 15 Quarter Trim Panel Installation—Granada and Monarch



45-03-10


4 5 - 0 3 - 1 0

2.

Instal l the tr im panel at taching

screw(s).

3. Instal l the armrest and window

regulator handle, if so equipped.

4. Install the rear seat cushion and back

assemblies.

Granada, Monarch, Maverick,

Comet Mustang, Bobcat and

Pinto—Except Station Wagon

Removal

1.

Open the luggage compartment door

and lower the rear seat on 3-Door

Models. On 2-Door Models, remove

the rear seat cushion and seat back

(Group 41).

2.

Rem ove the door sill scuff plate.

3. Rem ove the seat belt retractors from

the door sill (Group 41).

4. Remove the trim panel attaching

screws (Figs. 12, 13, 14 and 15).

5. Push the trim panel forward and

away from the installed position.

Remove the bezel from the rear seat

belt opening in the trim panel, and

remove the belt from the opening. On

Mustang, unsnap shoulder belt lower

bezel and slide belt out through upper

bezel opening. Then, remove the trim

panel.

Installation

1.

Position the trim panel in the vehicle.

Insert the rear seat belt through th e

opening and install the bezel. Slide the

shoulder belt into the opening and

install the bezels on Mustang Models.

2. Position the trim panel to the quarter

and install the attaching

screws.

3.

Install the seat belt retractors

in the

door sill,

a nd

install the

door sill scuff

plate.

4. Install the rear seat back

and seat

cushion on 2-Door Models.

Thunderbird and Continental

Mark V

Removal

1.



2.

Pry up on the armrest assembly (Fig.

1 6 ) an d d is en g a g e i t f ro m th e

retaining clips (five).

3. Remove the lower quarte r trim panel

retain ing screws and the retain ing

screw at the rear of the step plate.

4. Remove the lower quarte r trim panel.

Installation

1.

Position the qua rter trim panel to the

quarter panel and connect the power

window wires . Then, snap in the

retainers and clips together with the

attaching screws.

2. Position the roof side trim panel and

retain with clips and screws.

3.

Push

armrest assembly firmly in place

until retained by five retaining clips.

4. Install rear seat cushion and back

assembly.

Lincoln Continental

Removal

1. Carefully pry off the armrest finish

panel

(Fig. 17).

2. Remove the three screws attaching

the armrest and remove the armrest.

3. Remo ve the seat cushion and back

a s s e m b l i e s ( n o t s h o w n o n

illustrations).

4.

R e m o v e t h e n e c e s s a r y i n t e r i o r

b a c k l i t e g a r n i s h m o u l d i n g s ( n o t

shown on illustration).

5.

Remove one screw securing the coat

hook and remove coat hook.

6. R e m o v e o n e s c r e w b e h i n d t h e

shoulder belt at the roof rail.

7. Pry loose the quarter trim finish panel

starting at the rear.

CAUTION: When the finish panel

attaching clips have been extracted

from the quarter trim panel, be sure

to pull the panel directly rearward

first and then inboard in order not to

break the clips at the front of the

panel. The finish panel is not designed

to pivot around the front clips.

8. Remove three screws securing the

lower quarter trim panel and remove

the panel.

9. Rem ove three screws along the belt

line securing the quarter tr im panel

and pry loose the one clip located at

t h e f r o n t o f t h e t r i m p a n e l .

Disconnect the courtesy lamp wiring

and then, remove the trim pane.

N O T E : T a k e a l l n e c e s s a r y

precautions to protect the quarter

trim panel from damage or dirt.

Installation

1.

Position the quarter trim panel t;> the

q u a r t e r p a n e l a n d c o n n e c t t h e

courtesy lamp wiring. Retain with

clips and screws.

2.

Instal l coat hook and retain with

screw.

3. I n s t a l l i n t e r i o r b a c k l i t e g a r n i s h

moulding.

4. Install seat cushion and seat back.

5. Install armrest and retain with ihree

screws.

6. Install armrest finish panel.

ROOF SIDE TRIM PANELS

Removal

1. Remove rear seat cushion and seat

back.

2.

R e m o v e q u a r t e r t r i m p a n e l a n d

related par ts (moulding , arm rest ,

trim and retaining screws).

ARM REST

PAD 31718-9

UPPER TRIM

PANEL 31012-3

SCREW 55961

VIEW C

FIG.

16 Quarter Trim Panel and Armrest Installation—Continental Mark V

CLIP - 38 3134 - MARK V

CLIP - 383033 • THUND ERBIR D

VIEW B

R 443-D



45-03-11


45-03-1

3. Ford 2-Door only

—Remove four (4)

"J" clips and screws, plus screw at

seat belt opening and coat hook screw

(Fig. 18).

Thunderbird and Continental Mark

V only

—Remove screw re ta ining

seat belt opening cover (Fig. 18).

Granada and Monarch 2-Door only

—Remove screw at seat belt opening

(Fig. 18).

4. Pull roof side trim pan el away from

body until released by retaining clips.

5. Granada and Monarch 2-Door only

— D i s c o n n e c t s e a t b e l t a n d s l i p

through opening in roof s ide t r im

panel. Move trim panel upwards and

remove.

Ford 2- Door , Th u n d erb ird an d

Continental Mark V only

—

Slip seat

belt through opening in roof side trim

p a n e l , t h e n r e m o v e p a n e l , a f t e r

disconnecting courtesy lamp wiring.

Installation

1. Ford 2- Door , Th u n d erb ird an d

Continental Mark V only —

Slip seat

belt through opening in roof side trim

panel. Connect courtesy lamp wiring

harness.


—Slip seat belt through opening, then

connect seat belt assembly to anchor.

2.

Position roof side trim panel and push

inward until retained by clips.

3. Ford 2-Door only

—Install four "J"

clips and retaining screws, plus screw

at seat belt opening and coat hook.

Thunderbird and Continental Mark

V only

— Ins ta l l seat be l t op ening

cover and retaining screw.


—Install screw at seat belt opening.

4.

Install quar ter trim panel and related

parts .

5. Ins ta l l rear sea t cushion and seat

back.

CENTER PILLAR AND QUARTER

TRIM PANELS—FOUR DOOR

MODELS

Before removing the center pillar post

trim panel, it may be necessary to remove

the shoulder belt upper pivot and the

upper garnish moulding (if so equipped).

Then, remove the retaining screws, slide

the shoulder belt out through the slot,

and remove the center pillar trim panel.

Before removing the rear quarter trim

panel assembly, remove the rear sea t

cushion and back assembly (Group 41).

Remove the retaining screw(s), unthread

the seat belt and bezel from the trim

panel, and remove the trim panel (Fig.

19).

QUARTER TRIM PANEL—STATION

W A G O N

Removal

1. Rem ove the rear door sill scuff plate.

2.

On Pinto and Bobcat, remove the seat

belt retractors from the door sill.

3.

Fold the rear seat to the cargo (down)

position.

4.

Remove the quarter window lower

moulding, if so equipped.

5.

Remove the t r im pane l a t t a ch i

screws (Figs. 20 and 21).

6 . Remove the t r im panel from t

ins ta l l ed pos i t ion . On P in to a

Bobcat, remo ve the bezel and seat b

from the trim panel.

7 . Remove the t r im panel from t

vehicle.

Installation

1. Position the trim panel in the vehi

and insert the seat belt through

t r im pane l on P in to and Bobc

models. Install the seat belt bezel.

2. I n s t a l l t h e t r i m p a n e l a t t a c h i


3.

I n s t a l l t h e q u a r t e r w i n d o

mouldings, if so equipped.

4.

On Pint o and Bobcat, install the s

belt retractors in the door sill.

5.

Install the rear door sill scuff plat

r- ®. —-^r—-~~

QUARTER TRIM PANEL

LOWER

ARMREST

FIG.

17 Quarter Trim Panel Installation—Lincoln Continental 2-Door

ARMREST FINISH

PANEL R1777



45-03-12


45-03-12

PANEL

THUNDERBIRD AND MARK V

FIG.

18 Roof Side Trim Panels—Typical



45-03-13


45-03-

CENTER

PILLAR

PACKAGE

TRAY

MOULDING

SEAT

BELT

PLUG

FIG .

19 Typical Center Pillar and Quarter Trim Panel

VIEW c

R

177

FIG . 20 Ty pical Station Wa gon Quarter Trim Panel—LTD II and Cougar



45-03-14


45-03-14

VIEW A

PINTO MODEL 73

BOBCAT

QUARTER TRIM

PANEL-31 01 2-3

R1812-C

FIG.

21 Q uarter Trim Panel Installation—Pinto and Bobcat Station W ag on



45-16-1

Interior Mouldings

45-1

Mouldings

CR2043

GENERAL INFORMATION

The installation of interior mouldings mo ulding . If this cond ition is found, it overlapping moulding before remova

are shown in Figs. 1 throu gh 4. In most will be necessary to loosen or remove the the desired moulding,

instances, one moulding overlaps another

UPPER GARNISH MOULDING

03590

SIDE GARNISH MOULDING

03598-9

COWL SIDE TRIM PANEL R1445-B

FIG. 1 Typical W indshield Garnish Moulding Installation—C ontinental Mark V

R144

FIG. 2 Typical Roof Side Interior Moulding Installation—Mustang



45-16-2

Interior Mouldings

45 16 2

SUDE GARNISH—"*N.

MOULDING J

42416-7

A

rr

/

CREW

1 REQUIRED

EACH SIDE

I \

I ^4-

= ^ =

SCREW

5 REQUIRED ^«- .

SCREW

/ 1 REQUIRED

f ALONG TOP

. V (9

UPPER GARNISH

MOULDING

42324-5

* 7

^^^£

(B) /

- 7 LOWER GARNISH

MOULDING

42304

VIEW A

R1447-C

FIG.

3 Typical Back Window Garnish Moulding Installation

—

Continental Mark V

FRONT GARNISH

MOULDING

29014-5

QUARTER

TRIM PANEL

FIG.

4 Typical Quarter Window

Mouldings

- Model 71 - LTD II Shown



45-21-1

Rear Package Tray

45-21

Rear Package Tray


PACKAGE TRAY-TRIM PANEL

Removal of the rear seat cushion and 2.

rear seat back assembly is necessary on

all models for replacement of the package 3.

tray trim panel. See Group 41 for rear

seat cushion and seat back removal and

installation procedures. On some models 4.

it will be necessary to remove the quarter

trim panel extension assemblies. See Figs.

1 through 6.

Remove the back window mouldings

and defogger and speaker grille (if so

equipped).

Remove the trim panel retaining

screws.

Pull the trim panel forward and

slightly upward and remove it from

the package tray.

If a new trim panel is being replaced,

transfer the defogger and radio

speaker grille to the new panel if

required.

5.

Position the trim panel to the pac

tray and install the retaining scr

at the back panel.

6. Install the back window garn

mouldings (if so equipped).

7. Ins ta l l the quar ter t r im pa

extension assemblies (if so equipp

8. Install the defogger and radio spe

grille retaining nuts (if so equipp

9. Install the rear seat back and cus

assembly.

PACKAGE TRAY

SCREW R 1332-D

FIG.

1 Package Tray Trim Panel—Continental Mark V

UPPER 1/4 TRIM PANEL EXTENSION

PACKAGE TRAY

46665-6

1/4 TRIM PANEL

R1331-O

F IG .

2 Package Tray Trim Panel—Pinto and Bobcat



45-21-2

Rear Package Tray

45-21-2

RETAINER

SOUND ABSORBER

VIEW A

PACKAGE TRAY

TRIM PANEL

SCREW

RETAINER

R1928 A

FIG.

3 Package Tray Trim Panel—Maverick and Comet

ROOF SIDE PANEL

VIEW A

VIEW B

53 & 60 ONLY

VIEW C

PACKAGE T

:

A Y

TRIM PANE L

46668

DEADNER

R1448-D

FIG.

4 Package Tray Trim Panel—Ford and Mercury



45-21-3

Rear Package Tray

45-2

PACKAGE TRAY

TRIM PANEL

REAR WINDOW

MOULDING

MODEL 53 SHOWN

MODEL60 TYPICAL

SCREW

VIEW A

F IG .

5 Package Tray Trim Panel—Lincoln Continental

PANEL ASSEMBLY

- 6046668

ROOF SIDE

TRIM PANEL

V I E W - D

V I E W - B

N2866-

F IG .

6 Package Tray—LTD I I , Cougar and Thunderbird



45-26-1

Carpets and Floor Mats

45-26-1



FRONT

On vehicles equipped with a floor-

shift transmission, remove the console

(see Part 45-31) or shift quadrant.

Remove the front seat(s) and seat

tracks, plus the seat belts and outboard

retractors. (Refer to Part 41-01 through

41-20 for Seat Track Removal and Part

41-50 for Seat Belt Removal.)

On some models, it is necessary to

remove the " B " pillar and cowl trim

panels, plus retaining screws. Remove the

right and left doo r sill scuff p lates and all

carpet retaining screws (Fig. 1). Remove

the carpet from the vehicle.

REAR

On Lincoln Continental models,

remove the front seat and seat tracks. On

all other models, remove only the seat

track-to-floor pan retaining nuts and tilt

the front seat forward.

Remove the right and left door sill

scuff plates, "B" pillar, and quarter trim

panels, and seat belts. On Cougar models

also remove the rear carpet retainers

from each side of the vehicle.

On Lincoln Continental models,

remove the four (4) screws at the back

edge of the carpet and remove the rear

carpet. On all other models, remove the

rear seat cushion, position the front seat

forward, and remove the rear carpet.

FRONT AND REAR (ONE-PIECIi)

On vehicles equipped with a floor-

shift transmission, remove the console

(see Part 45-31), shift quadra nt o r shifter

bezel. On Pinto, Bobcat and Mustang

models, it is also necessary to remove the

parking brake bezels and shakebrace.

Remove the front seat(s) and seat

tracks, rear seat cushion, seat belts and

outboard retractors, cowl trim panels,

" B " pillar trim panels, quarter trim

panels and d oor sill scuff plates. Remove

all carpet retaining screws and remove

the carpet from the vehicle.



45-26-2


45-2

INSULATO

CARPET

R192

FIG. 1 One-Piece Carpet Installation—Granada and Monarch— 2-Door Shown—Other Models Similar



45-31-1

Floor Console

45-31-1

Floor Console


Removal

Open the console glove box door and

remove the retaining screws from the

bottom of the glove box and the top finish

panels (except the gear shift opening

panel of Mustang models Fig. 3). From

the console assembly, disconnect all wire

connections and remove the console

assembly from Cougar XR7, LTD II,

Thunderbird, Granada, Monarch and

Mustang models (Figs. 1, 3 and 4). On

Pinto and Bobcat models (Fig. 2) remove

the attaching screws and remove the

console. On the Granada and Monarch

also remove the screws from the forward

stowage area (Fig. 4).

Installation

Connect al l wires, posit ion the

console and install all the retaining

screws at the bottom of the glove box

(forward stowage area on Granada and

Monarch) and the top finish panel.

CR2046-A

PLATE

SCREWS

BRACKl iT

R IVET

R177O-B

FIG. 1 Floor Console Installation—Cougar XR7, LTD II and Thunderbird



45-31-2

Floor Console

45-3

COVER-INSTRUMENT PANEL

TO-FLOOR BRACE

44G02

: \

F IG .

2 Floor Console (Mini) Installation—Pinto and Bobcat

N2

CONSOLE

ASSEMBLY

045A06

REAR BRACKET

045B34

AUTOMATIC

TRANSMISSION

(4 SPEED STANDARD)

VIEWBB

F IG . 3 Floor Console Installation—Mustang



4 5 - 3 1 - 3 Floor Console

45-31-3

AUTOMATIC

TRANSMISSION

CONSOLE PANEL SHIFT

LEVER OPENING PLATE(S)

WIRING HARNESS

TO WARNING

INDICATOR LIGHTS

CONSOLE DO:)R

ASSY. - 060A '0

REAR MOUNTING

BRACKET

N2774-A

FIG . 4 Floor Console Installation—Granada and Monarch



45-41-1

Headlining

45-4

SUBJECT

ADJUSTMENTS

Sun Visor

Headlining

PAGE SUBJECT


41-1

P A R T

45-41

PAGE

41-1

CR2047-A

ADJUSTMENTS

SUN VISOR—WITHOUT LIGHT

Occasionally a sun visor will not stay

in engagement with the retaining clip at

the center of the windshield. This could

be caused by the rod at the end of the

visor being too far in or out. Outboard

edge of rubber tip should be flush with

center clip (outer walls). Work the visor

in or out for proper engagement. If the

rod length is OK, the rubber tip on the

end may be worn.

SUN VISOR—WITH LIGHT

If the visor will not stay engaged in

the retaining clip at the center of the

windshield, loosen the visor retaining

screw (near the elbow) and shift the

sideways into proper position.

Tighten the v isor retain ing s

snug enough to hold the visor in the

position, but loose enough to allow

visor to be rotated up and down o

pivot shaft.


HEADLINING

Sedans and Hardtops— Except


M a r k V

The fo llowing headlin ing removal

and instal lat ion procedures generally

apply to all models. If some of the steps

do not apply to the par t icu lar model

being serviced, proceed to the next step.

Th e Mav er ick , C o met , P in to an d

Bobcat require windshield and back

window glass removal for headlin ing

installation. See Group 43. Refer to the

appro priate F igs. 1 throug h 29.

Removal

1.

Remove the sun v isor and bracket

assemblies.

2. Remove the windshield upper garnish

moulding. Remove the upper screw

from the two windshield side garnish

m o u l d i n g s a n d p o s i t i o n t h e

mouldings away from the windshield

A pillar.

3. Remove the shoulder belt assemblies,

sh o u ld er b e l t r e ta in er s an d co a t

hooks.

4.

Remove the roof s ide and center

garnish mouldings. On al l 4-door

sedans, f irst remove the center cap

from the junction of the front and

rear s ide mouldings at the center

pillar. On some 4-doors, there is also

a joint cover at the rear quarter. On

2-door hardtops, there is one joint

cover at the rear quarter.



6. Remove the right and left quarter

trim panels (Group 45).

7. Remove the roof side rear trim covers

(right and left).

8 . Remove the back window garnish

mouldings and remove the package

tray (Group 45).

9. Unho ok the headlining from the tabs.

10. Remove the dome l ight and upper

rear quarter lights. Pry off lens and

remove the attaching screws.

11. Rem ove the staples th at fasten th e

headlining to the roof side retainer

assemblies.

12.

Pull th e head linin g loose from a ll

cemented areas.

13.

Un hook the right and left retain ers

from the headlining rear support rod,

disengage all support rods from the

holes in the left and right roof rails,

and remove the headlining from the

vehicle.

Installation

1. Unpackage the new headlining and

lay it out on a flat surface.

2. Trim the listings (or "pockets") on

t h e n e w h e a d l i n i n g t o t h e

approximate length of those on the

old one. Remove the suppor t rods

from the old headlining and install

them in the same relative rod listings

of the new headlining.

Roof headlining support rods are

co lo r co d ed a t each en d . Wh en

ordering new rods, be sure to not

color at each end of the rod.

3. Position the headlining in the ve

T o m a i n t a i n t h e m o s t d r

h e a d r o o m a n d w r i n k l e -

headlining, insert the support

into the

upper holes in the hi

possible hole in the right hand

without having support rod sn

across unit.

4.

Hook the rear retainers to the

support rod.

5. Staple the headlining to the ret

assemblies.

6. Cem ent the headlining in place

trim the excess material.

7. Install the roof side rear trim co

the package tray, the rear win

garnish mouldings and quarter

panels and lights.

8. Cut a hole in the headlining ma

for the dome light and install the

and bezel.

9 . Instal l a l l the garn ish mould

shoulder belt assemblies, retai

coat hooks and sun visors.

Maver ick , Comet , P into and

Bobcat

Removal

1. Rem ove the right and left winds

wiper arm assemblies.

2. R e m o v e th e w i n d s h i e l d

mouldings by using the proce

outlined in Group 43.

3. Remove the weathers tr ip f rom

glass opening.



45-41-2

Headlining

45-41-2

ADHESIVE

WITH VISOR VANITY MIRROR

SUN VISOR

WITH LIGHTED VANITY MIRROR

IG .

1 Sun Visors—Lincoln Continental Shown—Typical



45-41-3

Headlining

45-4

R1922-

F IG .

2 Lighted Visor Vanity Components—R.H. Shown (L.H. Similar)

ADHESIVE

VIEW A

ADHESIVE

VIEW B

VIEW AC

52104- BLUE-GREEN

52103 - BLUE-BLUE

52101 -YELLOW -BLUE

BLUE-BLACK - 52105

BLUE-PINK - 52106

BLUE-PLAIN - 52107

BLUE-BRONZE - 52109

VIEW B

RETAINER

52180

HEADLIN ING SUPPORTS

SHOWN IN POSITION

VIEW D

RETAINER f HEADLINING

52148-9 51916

VIEW E ASSEMBLED

FIG.

3 Station W ag on H eadlining Installation—Fo rd and Mercury

4. Remove the rear window glass from

the opening by using the procedures

outlined in Group 43.

5. Remove the r ight and the lef t

shoulder belt fasteners, 1 bolt on each

side.

6. Remove the right and left shoulder

belt retainer hooks which are fastened

7.

8.

with 1 screw on each side. Then,

remove the right and left coat hooks

which are retained with 1 screw on

each side.



Remove the quarter tr im panels

(Group 45).

R108

9. Open the trunk lid and remove

nuts retaining the right and left u

quarter trim panels.

10. From the interior of the veh

remove the one remaining screw

each side and remove the quarter

mouldings.

11. Remove the right and left sun vi



45-41-4

Headlining

45-41-4

(PURPLE - BROWN)

- 6552102

(BROWN - BROWN)-

- 6 5 5 2 1 0 1

(GREEN - BROWN)

- 6552103

(BLACK - BROWN)

- 6552104

(PINK - BROWN)

- 6552105

RETAINER

6552180

FIG. 4 Headlining Supports—Ford and Mercury 2-Door Models

12.

Remove the head cap mouldings a t

the top of the A pillar posts, right and

left side (pry off carefully).

13.

Remove the visor bracket and dome

light assembly.

14.

Remo ve the right an d left B pillar cap

mouldings (pry off carefully).

15.

Cut h eadl iner para l le l to the do or

opening and pull the right and left

strip from the retainer.

16.

L o o s e n t h e h e a d l i n e r f r o m t h e

re ta ining tabs a t the bl ind quarter

areas and pull the glued areas loose.

17.

Disconnect the bows and remove the

headliner from the car.

Installation


lay it out on a flat surface. Mark and

trim the new headlining using the old

one as a pattern.

2.

Trim the listings (or "poc kets" ) on

t h e n e w h e a d l i n i n g to t h e

approximate length of those on the

old one . Remove the support rods

from the old headlining and install

them in the same relative rod listings

of the new headlining.


co lo r coded a t e ach end . When

ordering new rods, be sure to note the

color at each end of the rod.

3.

Position the headliner in the vehicle

and connect the bows.

4. Start ing a t the rear window area ,

apply trim cement and align the rear

bow to the vertical position.

5. Work ing f rom the cen te r to the

outboard s ide , s t re tch and cement

h e a d l i n i n g t o t h e b a c k w i n d o w

opening flange.

6 . App ly cement to the winds h ie ld

opening flange. Align the bows and

pu l l the head l in ing fo rward and

cement into position at the windshield

opening.

7. Working from front to rear, stretch

and cement headlining to the quarter

and retainer areas. Insert headlining

into roof rail retainer with a putty

knife.

8. Fasten the headlining to the retaining

tabs at the blind quarters and cement

the corner areas. Trim excess material

where necessary.

9 . Trim a l l excess materia l , leaving

approximately 1/2 inch to wrap into

the glass opening pinchweld areas (1

1/2-inch

Pinto and Bobcat Model

73).

10. Apply cem ent and w rap pinch weld

areas.

11.

Snap on the 2 cap mouldings at the

A pillar post area.

12.

Snap on the 2 cap mould ings at th e

B pillar post area.

13.

Connect the wire to the dom e light

and install the visor bracket and dome

light assembly.

14.

Install th e visor assem blies.

15.

Install the package tray mouldings by

attaching two nuts from the rear for

N2885-A

each mou lding and 1 screw on each

side from the in terio r of the veh icle.

16. Position the quarter trim panels, push

r e a r w a r d t o s e c u r e a t t h e d o o r

open ing and ins ta l l the re t a i l ing

screws.

17.

Place the rear seat back assembly into

position. Install the 2 retaining bolts

and tighten securely.

18.

P lace the rea r s ea t cus h ion in to

position. Install the 2 retaining bolts

(if so equipped) and tighten securely.

19.

Install the rig ht and left coat h ooks.

20. Insta ll the rig ht an d left seat and

shoulder belt retaining hooks.

21 . Ins ta l l the r ight and lef t should er

belts.

22 .

Ins ta l l the back window us ing the

d r a w c o r d m e t h o d d e s c r i b e d i n

Group 43.

23 . Apply sealer to the outside perimeter

of the back window.

24. Install the windshield using the draw

cord method described in Group 43.

25.

Apply sealer to the outside perimeter

of the windshield.

26.

Install the windshield mou ldings.

27.

Install the windshield wiper arm s :tnd

blades.

28.

Clean a l l excess sea ler from ihe

windshield and back window areas.

Station W agons

Removal

1. Remove the right and left sun visor

and bracket assemblies.



45-41-5

Headlining

45-4

6052103

(BLACK-RED)

(BLACK-PINK)

6052104

(BLACK-GREEN)

6052105

(BLACK-BROWN)

6052102

(BLACK-WHITE)

VIEW

V I E W - A A

N2

FIG. 5 Headlining Supports—Ford and Mercury with Opera Windows

5352102

(BLACK-YELLOW)

5352104

(GRAY-YELLOW)

5352105

(BRONZE-YELLOW)

5352101

(BLUE-YELLOW)

RETAINER

9752180

VIEW

-

AA

VIEW

N2887

F IG .

6 Headlining Supports—Ford and Mercury 4-Door Models



45-41-6

Headlining

45-41-6

HEADLINING

51916

ADHESIVE IS APPLIED

ALONG ENTIRE WINDSHIELD

FLANGE, REAR WINDOW

OPENING AND ALONG ROOF

HEADLINING SIDE RETAINERS

RETAINER

52136-7

MODEL-71

RETAINER -

52148-9

SUPPORT ROD COLOR CODE

NUMBER 1 (WHITE-WHITE)

NUMBER 2 (BROWN-BROWN)

NUMBER 3 (BROWN-PURPLE)

NUMBER 4 (BROWN-GREEN)

NUMBER 5 (BROWN-BLACK)

NUMBER 6 (BROWN-PINK)

NUMBER 7 (BROWN-GRAY)

NUMBER 8 (BROWN-BRONZE)

ADHESIVE

HEADLINING

- 5 1 9 1 6

SCREW -

9 REQ'D.

RETAINER - EACH SIDE

52148-9 OF BODY

VIEW

-

A

HEADLIN \ IG

ADHESIVE

VIEW - B

ADHESIVE:

SCREW- 6 REQ'D

EACH SIDE OF

BODY

S C R E W - 9 R E Q ' D .

EACH SIDE OF BODY

HEADLINING

VIEW - D

R1776-A

FIG. 7 Station Wagon Headlining Installation—LTD II

2.

Remov e the windshield upper garnish

moulding.

3.

Remove the s c rews re ta in ing the

upper ends of the A post mouldings

and pos i t ion the mouldings away

from the upper end of the A post.

4. Rem ove the right and left roof side

rear moulding caps (one screw each).

5.

Remove the r ight and lef t quarter

window front garnish mouldings.

6. Pull off the front and rear (extrud ed

plastic) roof side mouldings at both

the left and right sides of the

roof.

7. Rem ove the right and left sho ulder

belt assemblies (one bolt each).

8. Remove the right and left tacking

strips.

9. Remov e the front dom e light bezel

and lens.

10.

Rem ove the r ig ht and lef t upp er

garnish mouldings.

11.

R e m o v e t h e b a c k w i n d o w u p p e r

garnish mouldings.

12.

Rem ove the right and left upper rear

corner finish mouldings.

13.

Remove the rear dome light lens (two

screws).

14. Remove the w eatherstrip an d/o r lift

gate hinge cover from the flange at the

top of the tailgate opening for access

to the area to which the headliner is

cemented.

15.

Rem ove the staples tha t fasten the

headlining to the retainer assemblies.

16. Unhook the headlining from the tabs.

17.

Cut the headlining under the quarter

window weatherstrips.

18.

Pull the he adlinin g loose from the

cemented area over the windshield.

19.

Pu l l the he ad l i n in g loos e a t th e

tailgate flange.

2 0 . U n h o o k t h e s u p p o r t r o d r e a r

re ta iners from the rear headl ining

support rod, disengage a l l support

rods from the holes in the right and

le f t roo f ra i l s , and remove the

headlining from the vehicle.

Installation



2. T r i m t h e l i s t i n g s on t h e n e w

headlining to the approximate length

of those on the old one. Remove the

support rods from the old headlining

and install them in the same relative

rod listings of the new headlining.


co lo r coded a t e ach end . When

ordering new rods, be sure to note the

color at each end of the rod. Th e color

codes are indicated in the Car Parts

Master Catalogue.

3.

Hook the rear retainers to the rear

support rod.

4. Secure the headlining to the retainer

assemblies above each door opening.

5.

8.

Apply cement to the quarter window

areas , tuck the materia l under the

weatherstrip, and trim the excess.

Hook the headlining to the tabs.

Cement the headlining to the <irea

a long the f l ange a t the t a i lga te

opening and install the weatherstrip

to the rear flange.

Cut a hole in the headlining material

and install the rear dome light lens

(two screws).

9. Install the right and left upper rear

corner finish mouldings.

l O . I n s t a l l t h e b a c k w i n d o w u p p e r

garnish moulding.

11.

Install the right and left quarter upper

garnish mouldings.

12.

Cut a hole in the material and install

the front dome light bezel and

le

us.

13.

Install the right and left shoulder belt

assemblies (one bolt each).

14. Install the four ex truded plastic roof

side mouldings (front and rear on

right and left sides).

15.

Ins ta l l the r ight and lef t q ua rte r

window front garnish mouldings.

16.

Install the right and left roof side n;ar

moulding caps.

17.

Reposition the u pper ends of the A

p o s t m o u l d i n g s a n d i n s t a l l t h e

retaining screws.

18.

Install the wind shield up per g arnish

moulding.



45-41-7

Headlining

45-4

5352102 5352103 5352104

(PINK-PLAIN) (PINK-GREY) (PINK-BRONZE)

5352105

(PINK-YELLOW)

RETAINER

6565210

HEAD LINING SUPPORTS

HEADLINING ASSEMBLY

VIEW AA

FIG. 8 Headlining Supports - LT D II and Cougar 4-Door M odels

19. Install t he right and left visor and

bracket assemblies.


Mark V

Removal

1. Remove the sun visor and bracket

assemblies.

2.

Remo ve the windshield upper garnish

mouldings. Remove the upper screw

from the two windshield side garnish

m o u l d i n g s a n d p o s i t i o n t h e

mouldings away from the windshield

A pillars.

3. Remo ve the shoulder belt assemblies,

r e t a i n e r s , c o a t h o o k s a n d s i d e

mouldings.


b ack as semb l ies (Gro u p 4 1 ) an d

remove the package tray and back

window garnish mouldings.

5.

Remo ve the rear roof side trim cover

retaining screws (unsnap retainers)

and disconnect the courtesy lights.

6. Remove the upper halves of both rear

quarter tr im panels (Group 45).

7. Pull the headlining from the tacking

strips (Fig. 5). Pull the headlining

away from all cemented areas.

8. Unho ok the headlining supports from

their retaining clips in the roof side

inner rails, and remove the he adlining

assembly from the vehicle (Fig. 5).

Mark the holes from which the

supports are removed so that the same

holes are used during installation.

Installation



2. Remove the supports from the old

headlin ing and instal l them in the

same relative support listings of the

n ew h ead l in in g . Roof headl ining

supports are color coded at each end.

When ordering new supports, be sure

to note the color at each end o

support.

3. Position the headlining to the

panel.

4. Apply adhesive to the areas show

Fig. 5 and staple the headlining t

retainers.

5.

Install the upper halves of both

quarter trim panels.

6. Place the roof side trirn covers

posit ion and connect the cour

lights. Install the retaining clips.

7. Install the package tray and rear

cushion and back assemblies.

8. I n s ta l l th e b ack win d o w g ar

mouldings.

9. Install the side mou ldings, shou

belt, retainers and coat hooks.

10. I n s t a l l t h e w i n d s h i e l d g a r n

mouldings (upper) and install the

visors.

11. Install the A p illar post mouldin



45-41-8

Headlining

45-41-8

HEADLINING SUPPORTS

6552102

(BLACK-PINK)

6552103

(BLACK-PLAIN)

6552105

(BLACK-BRONZE)

5 4 5 2 1 8 0 - R E T A I N E R

(2 REQUIRED)

V I E W - A A

V I E W - C C

FIG.

9 Headlining Supports—LTD II and Cougar 2 Door Models

9752101 9752102

(GRAY-GRAY) S (BRONZE-BRONZE)

N2H90-A

FIG.

10 Headlining Supports - LTD II and Ranchero



45-41-9

Headlining

45 -4

ROOF RETAIN

HEADLINING

SUPPORT REA

2 REQUIRED

L

t.L

(

STAP

VIEW

AR T A

R192

FIG. 11 Headlining Installation—Thunderbird and Continental Mark V



45-41-10

Headlining

45-41 10

(BLACK-YELLOW) (BLACK-WHITE)

- 6 0 5 2 1 0 3 - 6 0 5 2 1 0 4

(BLACK-PINK)

- 5352102

(BLACK-GREEN)

- 6 0 5 2 1 0 5

(BLACK-BLACK)

- 5 3 5 2 1 0 1

R E T A I N E R - 6 0 5 2 1 8 0

(2 REQUIRED)

HEADLINING ASSEMBLY

V I E W - A A

VIEW BB

V I E W - C C

N2891-A

FIG.

12 Headlining Supports—Thunderbird

6552101 6552102 6552104

(GREEN-BLUE) (GREEN-BROWN) (GREEN-BRONZE)

RETAINER

- 6 2 5 2 1 8 0

65521042

(GREEN-BROWN)

HEADLINING SUPPORTS

HEADLINING ASSEMBLY

V IE W -A A V IE W -B B

N2892-A

FIG. 13 Headlining Supports—Mark V



45-41-11

Headlining

45-41-

6052102

VIEW A A

N2893

FIG . 14 Headlining Supports—Mark V with Sun Roof



45-41-12

Headlining

45-41-12

H E A D L I N I N G

5 1 9 1 6 - A W A

VIEW -

AA

VIEW-EE

RETAINER

52182

V * ^

SCREW

52183 \ T 55927-S2

VIEW-FF

B

"

ADHESIVE

VIEW-CC

STRAP

52194

52195 SCREW

55927-S2

ADHESIVE

HEADLINER

V I E W - D D

WITHOUT HEADLINING WITHOUT HEADLINING

FIG. 15 Headlining Retainers—Pinto and Bobcat 2-Door Sedan Shown—3-Door Typical

N2190-B



45-41-13

Headlining

45-41

SUPPORT

52102

BLUE-BROWN

SUPPORT

52101

BLUE-BLUE

N 2 1

FIG.

16 Headlining Retainers—Pinto and Bobcat

2-Door

Shown—3-Door Similar

WHITE-BLUE

WHITE-RED

WHITE-YELLOW

WHITE-GRAY

WHITE-PINK

WHITE-GREEN

VIEW B

FIG.

17 Headlining Supports—Pinto and Bobcat Station W ago n

R17



45-41-14

Headlining

45-41 14

HEADLINING

PINTO

HEADLINING SUPPORTS

R.P.O. SUN ROOF

CLIP

51026

SUPPORT

52101

R178 ' A

FIG.

18 Headlining Supports—Pinto and Bobcat W ith

R.P.O.

Sun Roof

HEADLINING

RETAINER 51916

VIEW

HEADLII^ING

STAPLES

375346

RETAINER R 1 K1 3 - A

FIG .

19 Headlining Installation—Pinto and Bobcat Station Wa gon



45-41-15

Headlining

45-41-

SCREW 379183

SCREW 55962

FIG. 20 Liftgate Hinge Cover—Pinto and Bobcat—Station Wagon

R

17



45-41-16

Headlining

45-41-16

HEADLINING 51916

ADHESIVE

ADHESIVE

HEADLINING

RETA NJER

521SI4-5

ADHESIVE

V IE W B V IE W D

FI1595-A

FIG.

21 Headlining Installation—Mustang



45-41-17

Headlining

45-41-

RED - GREEN

- 6 0 5 2 1 0 3

R E D - B L A C K

- 6 0 5 2 1 0 4

R E D - B L U E

- 6 0 5 2 1 0 2

V IE WAA

FIG .

22 Headlining Supports—Mustang

RETAINER -

6952180

VIEW BB

N2894

HEADLINING SUPPORT

- 6052101

HEADL IN ING -

6052102

V I E W A A

N

2895-A

FIG . 23 Headlining Supports—Mustang with Sun Roof



45-41-18

Headlining

45-41-18

RED-BROWN

6952103

RED-RED

6952101

VIEW BB

VIEW-AA

N2895-A

FIG. 2 4 Headlining Supports—Mustang 3-Door

RETAINER -

6053983

RETAINED

6050982

SCRHW

3775:57

RETAINER -

6052194

S C R E W -

377537

N28H7-A

FIG .

25 Headlining Retainers—Mustang



45-41-19

Headlining

45-41-1

HEADLINING ASSY.

-6051916

A A

M2G149-ADHESIVE

M2G149-ADHESIVE

VIEW-AA

VIEW

BB

N2898-A

FIG. 26

Roof H eadlining— Mustan g

ADHESIVE

-

M2G149

COVER ASSY.

60518

RETAINER

HEADLINING

RETAINER ASSY

- 6052124

ADHESIVE-

M2G149

m

VIEW

-

BB

VIEW - DD

HEADLINING

At

* -*

-RETAINER

ADHESIVE ^

M2G149

U/

VIEW - CC

M2G150 - ADHESIVE

r AT EDGE OF HEADLINING

fl J-&* •JrZZ' BRU SH- M2G150

/ rSr\

t

ti >'

\ ALONG EDGE OF

K ^ T ^ g g ^

9

HEADLINING BEFORE

' 3 § ^ ^ INSTALLING

^ VIEW EF WEATHERSTRIP

N2P84-A

FIG. 27

Roof H eadlining— Mustan g with Sun Roof



45-41-20

Headlining

45-41-20

SCREW

ADHESIVE 3REQ'DT

ADHESIVE

V I E W C

VIEW D TYPICAL

RETAINER

B1924-A

FIG. 28 Headlining Installation—Granada and Monarch



45-41-21

Headlining

45-41-2

R.H. SIDE SHOWN

L.H. SIDE TYP ICAL

TRIM

HEADLINING

EVEN WITH

TOP OF HOLE

(BRONZE-YELLOW)

(GRAY-YELLOW)

(PINK-YELLOW)

(BLACK-YELLOW)

(BLUE-BRONZE)

(BLUE-GRAY)

(BLUE-PLAIN)

(BLUE-PINK)

(BLUE-PURPLE)

MODEL 54

* NOTE

:

ADHESIVE

-

.38 TO .50 WIDE

APPLIED TO ENTIRE EDGE OF HEADLINING

MATERIAL AND PINCHWELD FLANGE AT

WINDSHIELD OPENING, BACK WINDOW

OPENING. FRONT DOOR OPENINGS AND

QUARTER WINDOW OPENINGS.

MODEL 62 SHOWN

MODEL 54 TYPICAL

WITHOUT HEADLINING

SCREW

3 R E Q ' D . - M O D E L 6 2

4 REQ'D.

-

MODEL 54

WITH HEADLINING

HEADLINING

\

>Vrr .T. VV;

TACKING

TABS

SUPPORT

V I E W H

R192

FIG. 29 Headlining Installation—Maverick and Comet



45-61-1

Instrument Panel Pad

45-61-1



Ford

1. Remove one screw on each side of the

defroster nozzle opening (Fig. 1).

2. Remove three screws on the ledge

above the glove box doo r.

3. Remove four screws around the

instrument cluster opening and

remove the instrument panel pad and

upper finish panel assembly.

4. If the pad is to be replaced, remove

the six retaining nuts and separate the

pad from the upper finish panel (Fig.

1).

5. Position the instrument panel pad and

finish panel. Then, install the nine

attaching screws.

Mercury

1. Remove one screw on each side of the

defroster nozzle opening (Fig. 2).

2. Remove four screws going up into the

pad (entire length of pad).

3. Remove one screw at each end of

pad

( inboard s ide) and remove the

instrument panel pad and upper finish

panel assembly.

4. If the pad is to be replaced, remove

the retaining nuts and separate the

pad from the upper finish panel.

5. Position the instrum ent panel pad and

finish panel. Then, install the eight

attaching screws.

Maverick and Comet

Removal

1. If vehicle is equipped with air

conditioning, remove A/C grilk that

is retained by two (2) screws.

2. Disconnect speedometer cable at

cluster.

3.

Remove two (2) cluster retaining

screws. Position cluster outward.

Disconnect multiple connector and

bulb. Remove cluster assembly

4. Pu l l of f t he he a t e r a nd a i r

conditioning control knobs. Then,

carefully pry off the control bezel.

Remove three (3) control retaining

INSTRUMENT PANEL PAD

- 0 4 2 8 2

SCREW

56930

S C R E W - 5 6 9 3 0

7 REQ'D.

VIEW A

VIEW B

R 1382 E

FIG. 1 Instrument Panel Pad—Ford



45-61-2


45-61

UPPER FINISH PANEL

- 044B28

PAD AND RETAINER

A S S E M B L Y - 0 4 2 8 2

R IVET

PANEL ASSY.

-04304

INST. PANEL-TO-PAD

RETAINING SCREWS

- 55962

FIG.

2 Instrument Panel Pad—Mercury

screws and position the assembly

rearward.

5. Remove headlight switch stem and

bezel (Group 32) and position switch

rearward.

6. Remove seven (7) screws that retain

glove box and lower vent control (Fig.

3).

7. Remove two (2) screws and position

inner lock module away.

8. Remove nine (9) nuts that retain the

i n s t r u m e n t p a n e l p a d t o t h e

instrument panel and remove the pad.

Installation

1.

Position new instrument panel pad in

place and install nine (9) nuts and two

(2) screws.

2. Position inner lock module and install

two (2) retaining screws.

3.

Install glove box and lower vent

control with seven (7) screws.

4. Position headlight switch and install

bezel and stem.

5. Position heater and air conditioning

control and install three (3) screws,

bezel and knobs.

6. Position cluster assembly, connect

multiple connector and bulb, then

install two (2) retaining screws.

7. Connect speedometer cable.

8. If equipped with air conditioning,

install A/C gril le with two (2)

retaining screws.

Thunderbi rd, LTD I I , Ranchero

and Cougar

Removal

%

1. Remove two screws from a round the

instrument cluster opening, one screw

above steering column, and two

screws from above the glove box door.

2.

Remove one screw from the top right

surface of the instrument panel upper

finish panel.

3. Remove the instrument panel pad by

pulling rearward and then up to

disengage clips from the cowl top

flange.

4.

If the pad is to be replaced, remove

five retaining nuts and separate the

pad from the upper finish panel (Fig.

4).

Installation

1. When installing an instrument panel

pad and f inish panel assembly,

replace any spring clips that were

distorted or damaged during pad

removal.

2. Position the pad and finish panel in

the vehicle and engage the S-clips on

the finish panel with the cowl top

flange.

3. Push the instrument panel pad and

finish panel forward and install the

five pad retaining screws and one

finish panel attaching screw (Fig. 4).

Continental Mark V

Removal

1. Disconnect the ground cable from the

R138

battery.

2. Remove one screw from the left e

and three screws from the right e

of the instrument panel (Fig. 5).

3. Remove four screws from under

lower right side of the instrum

p a n e l p a d a b o v e t h e g l o

compartment opening.

4. Remove three re ta ining scre

(Continental Mark V) or two

taining screws above the instrum

cluster. These screws also ret

the access cover over the clus

5. Remove the instrument panel clu

finish panel as outlined in P art 33-

6. Remove the instrumen t panel pad a

retainer assembly and the upper fi

panel from the instrument panel

tilting upward and pulling rearwa

7. If the pad is to be replaced, remo

six retaining nuts and separate

pad from the upper finish pan

Remove three screws attaching

right finish panel to the upper fla

Then, tilt down and pull rearwar

Installation

1. When installing an instrument pa

pad and retainer assembly and

upper finish panel, replace the spr

clips at the three outside positions

the windshield edge of the upp

finish panel.

2.

Position the instrume nt panel pad a

retainer and upper finish panel in

vehicle. Engage the spring clips on



45-61-3


45-61-3

FT

927

B

F IG . 3 Instrument Panel Pad—Maverick and Comet



45-61-4 Instrument Panel Pad

45-61

UPPER FINISH PANEL

044A90

PAD AND RETAINER ASSEMBLY

04282

RETAINING SCREW

RETAINING

SCREWS

R139

FIG. 4 Instrument Panel Pad — Thun de rbi rd, LTD I I , Ranchero and Cougar

UPPER FINISH PANEL

044A90

AT [ACHING

CRtWS

VIEW A

VIEW

FIG .

5 Instrument Panel Pad—Continental Mark V

upper finish panel with the co wl panel

upper tabs.

3. Install the instrument panel pad

retaining screws.

4. Install the instrument panel cluster

opening finish panel as outlined in

Part 33-50. Then, connect the ground

cable to the battery and check the

operation of the instruments and

controls.

Lincoln Continental—Upper Pad

Removal

1. At the left and right ends, an end

finish panel is retained by screws to

the upper pad assembly and the

instrument panel. Remove the scre

at each end and remove the end fin

panels (Fig. 6).

2. The map light body assembly (sw

plate) contains not only the map lig

and switch, but also the cont

switches for a number of option

accessories such as speed control, r



45-61-5


45-61-5

STEERING COLUMN

OPENING COVER

044F08

RIGHT

FINISH

PANEL

044B28

VIEW A

LOWER PAD

AND RETAINER

RIGHT FINISH PANEL I VIEW A

LOWER PAD AND

RETAINER ASSY. VIEW C

UPPER PAD

UPPER FINISH

PANEL

INST. PANEL

VIEW A

ACCESS HOLE i

COVER

V I E W B

UPPER FINISH

PANEL

VIEW C

INST. PANEL

VIEW D

NUTS (4 EACH SIDE)

45259 -S2

INST. PANEL UPPER PAD

AND RETAINER ASSY.

04282

SCREWS (4 REQ'D.)

4 2 3 7 3 - S 2

SCREWS

( 4 E A C H S I D E )

3 8 4 1 5 4 - \2

(INCLUDES 1 EACH SI DE

ATTACHING MAP LIGHT

BODY ASSEMBLY.)

END FINISH PANEL

l- l

R1252-G

FIG. 6 Instrument Panel Pad—Lincoln Continental



45-61-6 Instrument Panel Pad

45-6

radio speaker or fader con trol, heated

backlite or defogger etc. Remove the

switch plate from the instrument

panel access hole covers ( three

retaining screws) and disconnect all

e l e c t r i c a l a n d v a c u u m h o s e

connections.

3. Remove the instrument panel left and

right access hole covers from the

upper pad assembly (three screws

each, Fig. 6).

4. The instrument panel upper pad

assembly and the upper finish panel

(Fig. 6) can now be removed as one

assembly. Remove the (four) screws

that retain the pad and finish panel to

the instrument panel across the front.

Pull the entire assembly out forcing

the three clips free and remove the


Installation

1. If the pad and retainer assembly is

being replaced, lift up the insulation

where necessary for access, remove

the (five) pad-to-upper finish panel

screws (Fig. 6), and transfer the upper

finish panel from the old, to the new

pad. Install the (five) nuts and glue

the insulation to the upper finish

panel. Transfer the (nine) Tinnerman

nuts to the new pad assembly.

2.

Install (three) new clips on the upper

finish panel. Position the upper finish

panel and pad assembly to the

instrument panel making sure that

the (three) clips engage the cowl top

inner panel (Fig. 6). Secure the

assembly to the instrum ent panel with

the (four) retaining screws.

3.

Install the left and righ t access hole

covers (three screws each).

4.

Connect all the electrical and vacuum

hose connections to the map light

body (switch plate), position the plate

to the access hole covers and install

the (three) retaining screws.

5.

Install the (two) end finish panels to

the upper pad assembly and the

instrument panel (three screws each

side,

Fig. 6).

Lincoln Continental Lower Pad

Removal

Remove the steering column opening

cover from the instrument panel (two

screws). From behind the panel, remove

the (two) nuts that retain the right end

of the lower pad to the instrument panel

(Fig. 6). Remove the five pad-to-

instrument cluster screws along the

bottom edge. Remove left hand end finish

panel (three screws). Swing the pad

assembly out so as to disengage the two

tabs at the top from the grooves at the top

of the cluster and remove the pad

assembly.

Installation

If the lower pad assembly is being

replaced, transfer the two spring nuts to

the new pad.

Position the pad so that the tabs on

the upper edge engage the grooves at the

top of the cluster and install the retaining

screws and nuts. Install the finish panel

(three screws).

Position the steering column opening

cover to the instrument panel and install

the retaining screws.

Monarch and Granada

emoval

and Installation

T h e G r a n a d a a n d M o n a r c h

instrument panel is shown in Fig. 7.

Remove one screw from each defroster

opening and six screws from along the

lower edge of the pad. Then, pull the pad

and upper finish panel rearward and

away from the instrument panel.

To install, position the pad and upper

finish panel on the instrument panel and

attach with eight screws.

Mustang

The Mustang instrument panel pad is

shown in Fig. 8. Remove one screw from

each defroster opening and five screws

from along the lower edge of the pad

(Fig. 8). Then, pull the pad and finish

panel rearward and away from the

instrument panel.

To install, position the pad and finish

panel to the instrument panel, and install

the seven attaching screws (Fig. 8).

Pinto and Bobcat

Removal

1. Disconnect the battery negative

ground cable.

2.

Disconnect the speedometer cab

pressing on the flat surface o

plastic connector (quick connect

pulling the cable away from

speedometer head.

3. Remove the (2) retaining screw

the top of the cluster and remov

cluster from the instrument p

(Group 33).

4. Remove the (2) screws securin

glove compartment door and rem

the door.

5.

Remove the righ t and left air re

assemblies (Snap-out).

6. Remove the righ t and left air reg

ducts from the plenum (secured

1 clip on each side).

7. Remove (6) nuts retaining the

edge of the instrument panel

These are reached from unde

dash panel area (Fig. 9).

8. Remove 4 screws retaining the

lower edge of the instrument p

pad.

9. Remove the instrument panel

from the vehicle.

Installation

1. Position the instrument panel p

the instrument panel.

2.

Install the (6) nuts and (4) sc

loosely to facilitate alignment o

holes without binding.

3.

Tighten all fasteners securely.

4.

Install the right and left air reg

ducts to the plenum by sliding

position.

5.

Install the right and left air reg

assemblies and secure with (1) cl

each side.

6. Install the glove compartment do

screws) and adjust if necessary.

7.

Position the cluster assembly, con

the multiple connector and se

with (2) screws.

8. Connect the speedometer cabl

pushing and locking the q

connect.

9. Connect the negative ground cab

the battery.



45-61-7


45-61-7

SCREW

CLIP

VEHICLE

IDENTIFICATION

PLATE

FINISH PANEL

RADIO COVER

INSTRUMENT

PANEL LOWER

STEERING COLUMN

COVER PLATE

INSTRUMENT PANEL

CLUSTER OPENING

FINISH PANEL

R 1 8 J 7 B

FIG. 7 Instrument Panel Pad—Monarch and Granada



45-61-8


45-6

FINISH PANEL

044 A90

F IG .

8 Mustang Instrument Panel Pad

N2192

FIG.

9 Instrument Panel Pad—Pinto and Bobcat



46-01-1

Tops and Exterior Finishes

46-0

TOPS AND EXTERIOR FINISHES


Top and Exte rior Finish General Service 46-01

Electric Moo n Roof 46-05

Manua l Sun Roof Panel 46-11

GROU

(70000

PART TITL E PART

Removable Sun Roof 46

Roof Outside Cover 46

Woo d Grain Transfer 4

CR2007

GENERAL INFORMATION

For detailed information on paint

repair, refer to the handbook entitled

Spot Repairing Original Enamel finishes

with Acrylic lacquer, Form FD-7953-Q.

CLEANING

Paint

The outside finish should be washed

frequently. Never wipe the painted

surface with a dry cloth. Dusting the

finish when it is dry tends to rub the dust

and dirt into the baked enamel, and

leaves a sandpaper effect on the surface.

To keep the finish bright and attractive

and eliminate the necessity of using

polish, wash the car whenever it has

accumulated a moderate amount of dirt

and road salt.

Wood Grain Transfers

Never wipe the panels or trim rails

with a dry cloth. This method of cleaning

tends to rub dust particles into the

finished surface and leave fine scratches.

Flush off all loose dirt and

elements, and wipe the body panel

rails with a sponge and plenty of

water. If desired, a mild soap ma

used. Rinse thoroughly with clear

and wipe dry.

Glass

The glass should be cleaned

Ford Glass Cleaner (C8AZ-19C50

or equivalent, using a clean, soft, lin

cloth. Follow the directions shown o

container.



46-05-1

Electric Moon Roof

46-05-1

Electric Moon Roof

P A R T

46-05

SUBJECT PAGE

DESCRIPTION

AND

OPERATION

Electric Operation

05-1

Manual Operation

05-1

REMOVAL

AND

INSTALLATION

Body Opening Weatherstrip

05-4

Cable

or

Drive Gear

05-3

Felt Seal (Front)

05-3

Glass and Metal Sliding Panel 05-2

Halo Moulding (Glass Panel)

05-1

Rear Seal

05-4

Shade

05-2

Track

05-3

ADJUSTMENTS

Binding Operation

05-5

Ratcheting Noise From Cable

and Drive Assembly

05-5

SUBJECT PA£E


Roof Parallel Alignment

05-4

Sliding Panel Flushness

or

Height Adjustment

05-5

WATER DRAINAGE SYSTEM AND

WATER LEAK CORRECTIONS

Drain Hoses .05-13

Overcrowned Rear Roof Panel

05-14

Roof Electrical Connections

05-15

Rubber Seal (W eatherstrip) 05-14

Shimming

The

Felt Seal

05-13

Sliding Panels

05-13

Undercrowned Front Roof Panel

05-14

Water Leak

at

Glass Mo ulding 05-1 )

Wet Headliner

-

Sides

05-14


ELECTRIC OPERATION

The sliding moon roof panel moves

on

guide rails and is actuated by a reversible

electric motor.

When the control switch is moved to

open,

the

sliding roof panel moves from

the closed position into a storage space

between

the

headl ining

and

s ta t ionary

roof panel. This exposes

an

opening over

the front passenger seating area.

When the control is moved to close

the panel,

the

sliding panel travels from

the storage position. Near

the end of the

forward travel, the rear portion of the

s l id ing pane l moves upward

on two

r a m p s and the rea r l ink ro ta te s to

position

the

panel into

the

roof opening.

MANUAL OPERATION

To close

the

sliding panel manually

(in case

of

electrical power failure),

remove

the

drive cover

by

pull ing

downward. Then remove

the

screw

CR2852-A

w h i c h

is

v i s ib le when

the

c o v e r

is

removed using the handcrank provided

in

the

glove compartment.

To close the sliding panel, insert :he

screwdriver

end of the

crank handle into

the auxiliary socket dirve. Turn the crank

handle clockwise

to

close

the roof.

After perf ormin g these operatic ns,

r e m o v e

the

c rank han d le , in s ta l l

the

screw and the drive cover.

REMOVAL

AND

INSTALLATION

HALO MOULDING

T o pe r fo rm mos t ad jus tmen ts

or

repairs on a moon roof, it is necessary to

remove

the

halo moulding.

NOTE:

If

the

vehicle has been sitting in the cold (less

than 70 °F), let the vehicle warm up prior

to performing repairs.

The

plastic halo

moulding is very brittle when cold and

may crack if the moulding is deflected.

To remove the halo moulding:

1. Cycle shade to most-rearward

position.

2.

Cycle

the

sliding panel about halfway

open.

3.

Remove

the

screws

on the

forward

s ur face of the h a l o m o u l d i n g (5

screws

for

Lincoln

and

Mark

V, 3

screws

for

other m odels).

(See

Fig.

1).

4.

For Lincoln and M a r k V vehicles,

l o w e r

the

front ed ge

of the

ha lo

moulding, cycle the sliding panel to

5.

fully closed position

and

remove

the

ha lo mould ing by loosening the 2

s c r e w s r e t a i n i n g

one

rea r s l id e ,

m o v i n g

the

s l i d e i n b o a r d

a id

unsnapping it from the track. Then

turn

the

halo moulding sideways

and

down as shown in Fig. 2.

F or

all

o the r

car

lines, cycle

the

moon roof to a nearly closed posi-

t ion

and

pul l

the

forward center

of

the halo moulding downward

so t he



46-05-2

Electric Moon Roof

46-0

horizontal tabs at the front of the halo

moulding are removed from the track

mechanism as shown in Fig. 3.

NOTE: Place a clean rolled-up

shop towel in the front horizontal

tabs, to prevent the sharp corners

from tearing the headliner when the

sliding panel

is

cycled. Cycle

the

moon roof

to the

fully closed and

raised position. Slide halo moulding

forward. Pull

the

rearward center

section so the horizontal track slide

surface is removed from the track

assembly. Slide the halo moulding

forward and remove from the vehicle.

Reverse the procedure for

installation.

SHADE REMOVAL

For Lincoln and Mark V models the

halo moulding must be removed first.

With the sliding panel in rearmost

position pull the shade full forward and

then bow the shade upward at the

center and lift the shade out of the

tracks (See Fig. 4). For all other models,

first remove the halo moulding and

sliding panel. Then from outside the

vehicle, push the sun shade in the center

as shown

in Fig. 5.

Slide

the

shade

forward

and

upward

out of

the vehicle.

R e v e r s e

the

p r o c e d u r e

for

installation.

GLASS AND METAL SLIDING

PANEL

Refer to the halo moulding or metal

tr im panel removal procedure and

remove the halo moulding. Then:

1. Detach the sliding panel from both

left and right front slide assemblies.

(2 screws each side). (See Fig. 6, View

A).

Lincoln and Mark V

2. Release the rear slide tension springs

by rotating them

to the

inboard

position.

3. Detach the sliding panel from the two

rear slide assemblies by removing the

two retaining screws and removing

the mount ing bracke t to pa ne l

retainers from the tabs in the panel.

(See Fig.

6,

View

B).

All Other Models

2. Grasp rear sliding panel retainer pins

and slide pins inboard to disengage

from the pivot bracket. Rotate p ins

away from the pivot brackets as

shown in Fig. 7.

3. From outside the vehicle, remove the

sliding panel.

4. Reverse procedure

for

installation.

NOTE:

If

the sliding panel

is to be

replaced transfer

the

front guide shoes

from the removed pane l . The rear

weatherstrip assembly on Lincoln and

FIG.

1 Halo Mo ulding Remov al

FIG.

2 Halo Moulding Removal



46-05-3

Electric Moon Roof

46-05-3

Mark V can also be transferred to the

new panel. All other models should have

a new felt seal (of the appropriate color)

installed on the rear sliding panel. Use

trim cement to attach the felt seal to the

rear of the panel. Install the seal so the

thick bulbous section is flush to the top

surface of the sliding panel.

CABLE ASSEMBLY

Lincoln and Mark V

To remove a cable assembly the halo

moulding and sliding panel must first be

removed. Remove the front cable cover

and the side track retainers. Remove the

cable retainer at the drive gear (2 screws)

and lift and slide the cable assembly

forward out of the track. (See Fig. 8).

Reverse the procedure for installation.

For initial alignment of new

cables,

insert

them in the tracks, install the side cable

retainers and pull the cables as far

forward as they will go. (Fig. 9). Then lay

the cables into the front track, insert in

the teeth of the drive gear and install the

cable retainer and the front cable cover.

All Other Car Lines

To remove a cable assembly first

remove the halo moulding and sliding

panel. Then remove cable drive housing

cover plate, remove track extension and

corner cover housing. Remove cable

retaining clip, and lift cable from drive

housing. Slide the cable forward to

remove from side track assembly. It may

also be necessary to remove the track

retaining screws and lift the track so the

cable will slide out the front of the track.

Drive Gear

If the motor runs but the sliding panel

does not operate, drive clutch slippage

should be suspected. To tighten the

clutch, remove the drive cover from the

headlining and tighten the cap screw with

the emergency crank handle.

To remove the drive gear, remove the

front cable cover and cable retainer and

remove the " C " clip that retains the gear

to the motor shaft. Slide the drive gear

upward and off the motor shaft.

Track

To remove the side track assemblies

the front track cover and cable retainer

must be removed first. Remove the side

track retaining screws, raise the front

edge of the track and slide the track

forward to disengage the track rail guide

pin from the housing (See Figs. 10 and

11).

FELT SEAL (FRONT)

Ail Models Except Lincoln and

Mark V

To replace the front felt seal, remove

the halo moulding and sliding panel (See

Removal and Installation).

1.

GRASP CENTER OF HALO

MOULDING AND DEFLECT

MOULDING DOWNWARD TO

DISENGAGE FRONT TABS

FROM TRACK.

NOTE: PLACE A CLEAN ROLL-

ED UP SHOP TOWEL AT EACH

FRONT TAB TO PREVENT THE

SHARP CORNERS FROM TEAR-

ING THE HEADLINER.

2. CYCLE MOON ROOF CLOSED

AND SLIDE HALO MOULDING

FORWARD.

3. DEFLECT CENTER PORTION AT

REAR OF HALO MOULDING

DOWNWARD SO HORIZONTAL

TRACK SLIDE IS REMOVED

FROM TRACK ASSEMBLY.

SLIDE HALO MOULDING

FORWARD AND REMOVE

HALO MOULDING FROM

VEHICLE.

5. HORIZONTAL TRACK SLIDE

SURFACE MUST BE

POSITIONED IN UPPER

SLOT IN TRACK WHEN

DISASSEMBLING.

FRONT TAB

FIG. 3 Halo Moulding Removal

NJ862-A

FIG. 4 Sun Shade Removal



46-05-4

Electric Moon Roof

46-0

Remove the old seal and clean the seal

mounting surface w ith suitable solvent or

Spot Remover (Part No. B7A-19521-A).

If the felt seal ends were not securely

glued at the rear roof opening radius,

inspect the area very closely to determine

if silicone sealer is evident on the felt seal

mounting surface and carefully remove.

Do not remove from the corner where the

module is mounted to the roof panel. If

removed, this can result in water leaks.

Apply masking tape on the roof

panel, around the opening as shown in

Fig. 12, View B. Apply weatherstrip

adhesive Part

No .

COAZ-19552-A or 3M

adhesive Part No. 1099, on the seal

mounting surface and the backside of the

felt seal.

Remove masking tape from the roof

panel. Star t ing in the rear corner ,

position the felt seal 3 /4 inch to 1 inch

behind opening. Carefully position the

felt seal into the opening so that it is flush

to the roof panel surface. Use extra

pressure in the front corner(s) so that the

seal will not "pull" or "short cut" at the

corners. Trim off excess seal material at

the other rear corner, so that 3 /4 inch to

1 inch of the seal is positioned rear of the

opening.

Install the sliding panel and halo

moulding. Then, cycle to assure that the

sliding panel functions normally. If the

sliding panel appears to bind against the

new seal assembly, apply si l icone

lubricant spray Part No. COAZ-19553-C

or equivalent on th e new seal to facilitate

"break-in".

BODY OPENING WEATHERSTRIP

Lincoln and Mark V

It is not necessary to remove the halo

moulding or sliding panel to service the

front weatherstrip on these vehicles. To

replace, dr i l l out the weatherstr ip

attaching rivets with a 1/8 inch dia. drill

and install new wea therstrip with 1/8

inch aluminum blind rivets by aligning

FRONT OF VEHICLE

DEFLECT CENTER OF SUN SHADE

UPWARD TO DISENGAGE SUN

SHADE FROM TRACK AND

SLIDE SUN SHADE FORWARD

AND OUT OF VEHICLE.

FIG. 5 Shade Removal

rear edge of weatherstrip with the notch

in the roof downstanding flange.

REAR SEAL

All Models Except Lincoln and

Mark V

To replace the rear felt seal, remove

the halo moulding and sliding panel. See

Removal and Installation.

Place the removed sliding panel on a

clean work bench. Remove the old seal

from the rear of the sliding panel (Fig. 12,

View A). Then, apply weatherstrip

adhesive Part

No.

COAZ-19552-A or 3M

adhesive Part No. 1099 on the seal

mounting surface. Also, apply adhesive

to the backside of the felt seal. Rem

the masking tape from the sliding p

and install the seal so that the th

bulbous section is flush to the surfac

the sliding panel.

Install the sliding panel and h

moulding. Then, cycle to assure that

sliding panel functions norm ally and d

not bind or interfere with the front

seal.

Lincoln and Ma rk V

The rear seal on these vehicles i

integral part of the rear weathers

assembly. It is attached to the slid

panel with 12 screws.

ADJUSTMENTS

ROOF PARALLEL ALIGNMENT

CAUTION: Do not activate the

control switch while the cover or cables

are removed from the track, as this can

cause cable damage.

It is not necessary to remove the halo

moulding to perform parallel alignment

adjustment on the sliding panel.

1. Open the sliding panel approximately

1/4 inch to 1/2 inch.

2. Sight down the opening to determine

the para l le l re la t ionship of the

forward edge of the sliding panel with

the forward edge of the opening in the

roof panel and note the variation, see

Fig. 8.

3. Open the sliding panel approximately

8 inches to gain access to the

cable/drive gear mechanism.

4. Remove the front track cover and

cable cover to gain access to the drive

gear. (See Fig. 13).

5. Pry metal retaining clip off the cable

drive gear mechanism if so equipped.

6. Remove one of the cables from the

track as shown in Fig. 10.

7.

Slide one side of the sliding pan el

assembly slightly fore or aft as

r e qu i r e d t o ob t a in a pa r a l l e l

alignment.

8. Insert the cable into the track. If

unit utilizes a cable clip as show

Fig. 14 be sure that it is prop

oriented, and install the -cover.

NOTE: The front and rear fla

on the clip are not the same wi

The narrow side of the clip mus

positioned toward the front of

vehicle, and firmly seated into

notches in the track assembly. If

clip is improperly positioned in

track, the flanges will not go into

grooves in the track and will resu

extensive damage to the cables.

Fig. 14, View A.



46-05-5

Electric Moon Roof

46-05-5

9. C y c l e t h e s l i d i n g p a n e l t o

approximately 1/4 inch from the

closed position and check the parallel

relationship.

10. Repeat above procedure, if required,

unt i l a para l le l re la t io nship i s

obtained.

SLIDING PANEL FLUSHNESS OR

HEIGHT ADJUSTMENT

To obtain a flush fit of the sliding

panel to the roof panel, remove halo

moulding to gain access to adjusters and

refer to Fig. 15 for correct flushness

specif ications and the procedures

outlined below:

1.

To raise or lower the rear edge of the

sliding panel on all vehicles except

Lincoln and Mark V, loosen the rear

retainer pin attaching nut (Fig. 15).

The pin assembly is located in the

slotted lifter bracket (See Fig. 16,

View A). Position the sliding panel up

or down as required to obtain a flush

fit to the adjacent roof panel. Re-

torque pin retainer nut to 20-23 in-lbs.

To raise or lower the rear edge of the

sliding panel on Lincoln and Mark V

vehicles, loosen the rear slide adjusting

nut (See Fig. 17), raise or lower the panel

to achieve correct alignment, and tighten

the adjusting nut (24-36 in-lbs).

2. To raise or lower the forward edge of

the sliding panel, loosen the forward

track shoe retaining screws. Refer to

F ig . 18 . Ro ta t e t he a d jus t e r

( c l o c k w i s e l o w e r s p a n e l ,

counterclockwise raises panel) as

required to obtain a flush fit to

adjacent roof panel. Re-torque the

track shoe attaching screws to 18-23

in-lbs.

BINDING DURING PANEL

MOVEMENT

All Car Lines Except Mark V and

Lincoln

Sliding panel binding can be caused

by unparallel alignment of sliding panel

causing the sliding panel to cock in the

opening (Fig. 19) or binding of the pivot

pins which does not allow the sliding

panel to raise at rear corners when cycled

to full closed position (Fig. 20).

To diagnose binding:

1. Cycle the roof open about 1/4 inch

and sight down the opening to assure

that the sliding panel is parallel to the

opening. Refer to parallel alignment

to correct.

2. The pivot pins, which are attached to

the lifter b rackets may be too tight in

the pivot brackets. This causes the

system to function normally through

all cycles except the lift cycle. At that

point in the cycle, the pivot pins must

freely rotate in the pivot bracket.

VIEWB

FIG. 6 Sliding Roof Panel Removal

Binding pivot pins can cause the pivot

pins to "walk" out of the pivot

bracket when the system is cycled

numerous times. (Refer to Fig. 19.) If

the condition is caused by binding

pivot pins, remove the pins from the

brackets and ream with a 13/64 inch

drill. Apply silicone lube on the pivot

pin and reinstall. Cycle system to

assure that the panel is fully raising.

Adjust the panel, if required, to

obtain a flush fit to the roof panel.

(Refer to Fig. 21.)

Lincoln and Mark V

Diagnose binding the same as

previously describe. If the panel fails to

raise fully at the rear when closed, make

the following adjustments:

Move the sliding panel as far forward

as it will go. Check rear lifting links to

determine whether or not they have

reached full vertical position. If one or

both links do not attain vertical position,

LOOSEN INBOARD SCREW AND

ROTATE GUIDE SHOE SO SLIDE

PORTION IS DISENGAGED FROM

TRACK

R1880B

disengage the cable from the drive gear,

manually lift the panel and rotate the

links to vertical. Then re-engage the cable

and re-assemble.

RATCHETING NOISE FROM CAELE

AND DRIVE ASSEMBLY

If the cable-drive m echanism emit s a

ratcheting noise when sliding panel is

fully opened or closed, the drive gear may

be overriding one of the cables due to

insufficient cable to gear engagement.

Remove the center track cable drive

assembly cover plate and cable retailer

clip.

Examine gear to cable engagement.

Pull cables and examine for wear. If the

cables do not exhibit excessive wear,

reinstall cables and position the retainer

clip. Install a .030" shim between the

track wall and retainer clip to provide

additional gear to cable engagement on

the side that exhibits clearance. Refer to

Fig. 22.



46-05-6

Electric Moon Roof

46-05

GRASP RETAINER PIN AND DISENGAGE

PIN FROM PIVOT BRACKET. ROTATE

•, LIFTER BRACKE T SO PIN IS POSITIONED

-" AWAY FROM PIVOT BRACKE T.

R1881-A

FIG. 7 Sliding Roof Panel Removal

N2863-A

F IG .

8 Cable Removal



46-05-7

Electric Moon Roof

46-05-7

FIG.

9 Initial Cable Alignment



46-05-8

Electric Moon Roof

46-

CABLE ASSEMBLY

COVER PLATE

(2 SCREWS)

CABLE RETAINER CL

MOTOR DRIVE

GEAR AND "C"

CLIP RETAINER

SIDE TRACK RAIL GUIDE PIN

R

F IG . 10 Cable, Drive Gear and Track Removal—All Except Lincoln and Mark V



46-05-9

Electric Moon Roof

46-05-9

R E A R S L I D E

AND

C A B L E A S S E M B L IE S

C A B L E L E F T G U ID E R A I L

R I G H T G U I D E

R A I L

R E A R R E T A I N E R

151882)

C A B L E F R O N T G U I D E R A I L ( 5 0 2 A 1 0 )

L O C A T I N G

TAB

R154 3-B

FIG. 11

Cable

and

Guide Rail System—Lincoln

and

Mark

V

WITH A FEELER GAUGE CHECK FOR:

CHECK CLEARANCE WITH A

0.020 FEELER GAUGE AT REAR

PANEL.

FIT

SHOULD

BE

SNUG

ACROSS PAN EL

AND

CORNERS.

USE 0.010 FEELER

GAUGE AND ATTEMPT

TO CHECK CLEARANCE

BETWEEN PANEL AND

SEAL. ZERO CLEARANCE

SHOULD EXIST.


0.010 FEELER GAUGE ON

BOTH SIDES, AN INTERFERENCE

SHOULD BE NOTED.

APPLYING MASKING TAPE

TO

ROOF PANEL

AS

SHOWN BEFORE

APPLYING ADHESIVE TO FELT

SEAL MOUNTING SURFACE.

R195J: A

FIG. 12 Pane l Check ing Procedures



46-05-10

Electric Moon Roof

46-05

CABLE DRIVE HOUSING COVER

CABLE CLIP

R1883-A

FIG. 13 Cable Cover Removal

POSITION CABLE

AWAY

FROM GEAR. SLIDE ONE

SIDE OF MOON ROOF

FORE OR AFT AS

REQUIRED

TO

OBTAIN

PARALLEL RELATIONSHIP

CAUTION:

DO

NOT

ACTIVATE

MOON ROOF CONTROL

SWITCH WHILE CABLE

COVER OR CABLES

ARE REMOVED. THIS

COULD CAUSE DAMAGE

TO THE CABLE

ASSEMBLIES.

THE DOWNSTANDING FLANGES

ON THE CLIP ARE DIFFERENT

WIDTHS (DIMENSIONS A AND B).

THE NARROW PORTION

OF THE

CLIP (DIMENSION

"B")

MUST

BE

POSITIONED TOW ARD

THE

FRONT

OF THE

VEHICLE

OR

THE CABLES WILL

BE

DAMAGED

WHEN MOON ROOF IS CYCLED.

R1884

A

FIG.

14 Cable Clip Position



46-05-11

Electric Moon Roof

46-05-11

PANEL MUST BE CLOSED

FRONT OF VEHICLE

SLIDING PANEL

MOON ROOF PANEL NOT

FLUSH TO ROOF

WEATHERSTRIP

VIEW A - IMPROPERLY ADJUSTED PANEL

FRONT OF VEHICLE

FRONT MUST BE FLUSH

TO 1/16" BELOW THE

ROOF LINE

REAR CAN BE APPROXIMATELY

1/16" HIGHER THAN ROOF LTJE

- BUT MUST BE CONSISTENT

ACROSS ENTIRE WIDTH.

WEATHERSTRIP

FELT SEAL

SLIDING PANEL

VIEW B - PROPERLY ADJUSTE D PANEL

FIG. 15 Correct Sliding Panel Flushness Setting

R18::5-B

1. LOOSEN PIN RETA INING NUT .

2. POSITION SLIDING PANEL UP OR

DOWN AS REQUIRED TO OBTAIN

PROPER FLUSHNESS SETTING.

3. TORQUE RETAINING NUT TO

20-23 INCH LBS.

FIG.

16 Rear Sliding Flushness Adjustment



46-05-12

Electric Moon Roof

46-05-

N2865-A

FIG.

17 Rear Roof Panel Adjustment

1. LOOSEN ATT ACH ING SCREWS.

2. ROTATE ADJUSTOR NUT TO

RAISE OR LOWER MOON ROOF

TO OBTAIN PROPER FLUSHNESS

SETTING.

3. TORQUE ATTACH

ING

SCREWS

TO 18-23 INCH LBS.

mlmmmMip

F IG .

18 Front Sliding Panel Flushness Adjustment



46-05-13

Electric Moon Roof

46-05-13

SIGHT DOWN GAP BETWEEN ROOF

PANEL AND MOON ROOF TO

DETERMINE IF PANEL IS

POSITIONED PARALLEL IN

THE OPENING.

INSPECT PIVOT PIN TO DETERMINE

IF PIVOT PIN IS BINDING OR

I "WA LKING OUT " OF PIVOT BRACKET,

R1949 A

FIG.

20 Inspection for Binding Pivot

Pin

FIG. 19 Sliding Roof Panel Parallel Adjustment

R1882-A

WATER DRAINAGE SYSTEM AND WATER LEAK CORRECTIONS

DRAIN HOSES

The roof panel module contains the

track assemblies , cable and drive

mechanisms, and a drain trough that

encircles the sliding panel. Attached to

the module are four (4) drain hoses. One

drain hose is attached at each corner of

the module. The two front drain hoses

are routed down the windshield pillars

and into the cowl sides existing at rocker

panel drain darts—ends of hose are

not

reusable. The two rear drain hoses are

routed down the rear pillars over the rear

wheel house and into the rear quarters.

Refer to Fig. 23.

NOTE: Prior to performing any

repairs, first verify that the drainage

system is not plugged or restricted. Use

a pint size container and pour water into

the drain trough. Look at the rear of the

vehicle to ensure that the water drains

from the rear quarter panels or rocker

panels.

If

the water flow is restricted, use

compressed air to "blow-out" any

material in the drain hose system. Test by

pouring water slowly into the system

again.

After assuring that the drainage

system is not restricted, verify that gaps

do not exist around the edge of the panel.

If a gap exists, the gap must be brought

to specification before any further action

is taken (Fig. 24).

With the clearances within speci-

fication, remove the halo moulding.

Close the panel and have an assistant

spray water on the sliding panel

while you're on the inside visually

inspecting the panel area to see if an

excessive amount of water is entering the

drain trough. A large volume of water

indicates that an excessive clearance

exists between the sliding panel and the

felt seals. See shimming the felt seal, this

section.

SLIDING PANELS

The sliding panel has a controlled

water leak at the roof panel felt seals.

Clearances between the felt seal at the

front of the panel are "zer o" . Using a

.010" feeler gauge, an interference

should be note d at the sides of the

panel. .020" maximum clearance

should be noted between the rear of

the sliding panel felt seal and the roof

panel opening. If these tolerances are

not maintained, water will overflow

the drain troughs and enter the mod-

ule, running down into the passenger

compartment when the vehicle is

stopped abruptly. Refer to Fig. 24,

View A.

SHIMMING THE FELT SEAL

If the vehicle is equipped with a full

vinyl roof, remove the felt seal in the

"gapped" area, peel up the vinyl roof

material and install shim material as

required on the sheet metal to fill the

void. Re-cement the vinyl over the shim

material, and re-attach the felt seal. If the

gap is at the rear of the opening, the shim

is installed at the front felt seal. Refer to

Fig. 25.

If the vehicle is equipped w ith the 1/2

vinyl roof and the roof panel surrounding

the sliding panel is a painted surface, the

best material to use for shimming is the

felt seal in the appropriate color. Use a

pair of tin snips and trim off the bulbous

section at the top of the seal and install

between the existing seal anc the

REMOVE PIVOT PINS AND REAM

OUT HOLES

USE 13/64" DRILL TO REAM OUT

HOLE IN PIVOT BRACKETS. PRIOR

TO REINSTAL LING PINS, APPLV

SILICONE OR GRAPHITE LUBE DN

PIVOT PINS.

R15I55-A

FIG. 21 Reaming Pivot Bracket for

Pivot Pin

POSITION .030" SHIM STOCK

BETWEEN RETAINER CLIP AND

TRACK WALL TO INCREASE

CABLE TO GEAR ENGAGEMENT.

R19EI6-A

FIG. 22 Increasing Cable-To-Geai

Engagement



46-05-14

Electric Moon Roof

46-05-1

downstanding flange, across the front of

the opening (Fig. 26). If the gapping

condition exists at the rear corners, it

may be necessary to add shim behind the

seal, in the corners and at the rear of

the sliding panel.

RUBBER SEAL (WEATHERSTRIP)

Water collecting in the module area

may be caused by the rubber seal at the

rear of the sliding panel. The rubber seal

must be positioned at the rear edge of the

panel so that a water channel is provided

to drain any water that bypasses the felt

seal to the side drain troughs.

On models with foam rubber spacer

mounted under the rubber seal, inspect

for proper mating and that no gap exists.

Water

flowing

hrough the gap will cause

water to accumulate in the rear of the

module (Fig. 27).

If the water leak is at the foam spacer,

apply a bead of clear silicone sealer or

liquid butyl sealer along the surface of the

panel where the filler strip is attached as

shown in Fig. 28.

WET HEADLINER—SIDES

Water may drip from the headliner

above the door or quarter window

because.

1. Module is not sealed to underside of

roof panel at the rear of the opening.

Apply caulking cord in joint between

roof panel and module as shown in

Fig. 29.

2.

Weld burn exists in the drain trough

area. Use paintable plastic sealer and

touch up with appropriate color.

Refer to Fig. 30.

3.

Drain tube(s) disconnected from

module. Apply trim cement on metal

W ITH A FEELER GAUGE CHECK FOR:

REAR DRAIN HOSE

REAR HOSE CLIPS

-« HOSE

FIG.

23 Wa ter Draina ge System

drain tube nipple, and insert drain

hose (Fig. 18).

OVERCROWNED REAR ROOF

PANEL

If the roof panel is overcrowned to the

contour of the sliding panel (at rear of

sliding panel), this can cause wind noise

or water leak conditions.

Remove sliding panel from vehicle

and apply hand pressure on center of roof

panel to flatten the contour (Fig. 31).

R 155

UNDERCROWNED FRONT ROOF

PANEL

A glass panel scratch can be caus

by the front of the roof panel bei

slightly undercrowned.

Open the sliding panel assemb

slightly and compare the contour of ro

panel and glass panel. If the roof pa

appears flattened in the center, and

glass scuffs are on the underside of

roof panel, remove the sliding panel fro


0.020

FEELER GAUGE AT REAR '

PANEL. FIT SHOULD BE SNUG

ACROSS PANEL AND CORNERS.

USE 0.010 FE ELER

GAUGE AND ATTEMPT

TO CHECK CLEARANCE

BETWEEN PANEL AND

SEAL. ZERO CLEARANCE

SHOULD EXIST.

CHECK CLEARANCE W ITH A

0.010 FEELER GAUGE ON

BOTH SIDES. AN INTERFERENCE

SHOULD BE NOTED.

APPLYING MASKING TAPE TO

ROOF PANEL AS SHOWN BEFORE

APPLYING ADHESIVE TO FELT

SEAL MOUNTING SURFACE.

VIEW A

V I E W - B

R19

FIG. 24 Panel Checking Procedures



46-05-15

Electric Moon Roof

4 6 - 0 5 - 1 5

the vehicle and re-arch the roof panel by

using your feet and pushing up on

underside of roof panel to increase the

roof panel arch.

WATER LEAK AT GLASS

MOULDING

A water leak occurring in the area of

the halo m oulding is usually caused by an

NOTE: PROCURE DOUBLE BACK

FOAM TAPE LOCALLY IN

VARIOUS THICKNESSES.

A. IF AN EXCESSIVE CLEARANCE

IS NOTED, AND THE V EHICLE IS

EQUIPPED WITH A VINY L ROOF,

REMOVE FELT SEAL IN THE

AREA TO BE SHIMMED. CARE-

FULLY PEEL THE VINYL MATE-

RIAL AND INSTALL NECESSARY

SHIM ON DOWNSTANDING

FLANGE. RE-INSTALL VIN YL

ROOF COVER OVER SHIM AND

RE-CEMENT FELT SEAL IN

POSITION.

inadequa te seal between the glass and the

metal frame. To correct a leak between

the metal frame and the glass, remove the

sliding panel from the vehicle. Use a clear

silicone sealer—3M Part No. 8551 auto

INSPECT PLAST IC PLUGS

AT EACH END OF THE

PANEL TO INSURE TH AT

THE PLUGS ARE POSITIONED

AND ARE WATER TIGHT.

REMOVE SLIDING

PANEL FROM VEHICLE

AND INSPECT JOINT AT

FOAM SPACER.

I

INSPECT WEATHERSTRIP TO EN-

SURE THAT IT IS PROPERLY

POSI-

TIONED AT REAR OF PANEL AND

THAT A 1/4" TO 3/8" CHANNEL IS

PROVIDED TO CATCH ANY WATER

THAT MAY BY-PASS FELT SEAL.

R1961-A

B. IF THE EXCESSIVE CLEARAN CE

IS NOTED AT THE REAR OF THE

PANEL, PLACE THE SHIM A T THE

FRONT.

FIG. 27 Rubber Seal (Weatherstrip)

Inspection

R1959 A

FIG.

25 Shimming Felt Seal-Full Vinyl

Roof

REMOVE EXISTING SEAL AND

POSITION TRIMMED FELT SEAL

SHIM ONTO THE DOW NSTANDING

FLANG E, RE-CEMENT E XISTING

SEAL IN POSITION.

APPLY SEALER,

IF REQUIRED TO

OBTAIN WATER

TIGHT INSTALLATION.

POSITION SHIM 1/16" BELOW

-* ROOF SURFACE

R1960 A

APPLY BEAD OF CLEAR L CONE

SEALER ALONG FOAM SPACER.

ALLOW SEALER TO SET-UP AND

CHECK FOAM SPACER JOINT TO

ENSURE THAT A WATER TIGHT

SEAL IS OBTAINED.

Ft 1962 A

glass sealer (procure from local glass

repair shop) and apply a bead arou nd the

edge of the metal frame as shown in Fig.

32.

CAUTION: DO NOT ATTEMPT

T O P R Y T H E M E T A L F R A M E

UPWARD TO APPLY THE SEALER,

AS THIS CAN RESULT IN GLASS

BREAKAGE.

ROOF ELECTRICAL

CONNECTIONS

The electrical connections, locations

and circuit schematic are shown in Figs.

33,

34, 35 and 36.

The parts component chart is ihown

in Fig. 32.

jAPPLY BEAD OF CAULKINC

•CORD ALONG JOINT IF TH;

WATER IS LEAKING FROM

GARNISH MOULDINGS ABOVE

SIDE WINDOWS.

K1963-A

F IG . 29 Sealing Module-To-Roof

Panel

INSPECT WATER CHANiNEL

OUTBOARD OF TRACKS FOR

WELD BURN THROUCiHS OR

SHEET METAL CRACKS. SEAL

ANY DISCREPANCY WITH

PAINTABLE PLASTIC SEALER

AND TOUCH-UP.

R1964-A

FIG. 26 Shimming Felt Seal-1/2 Vinyl

Roof

FIG.

28 Applying Sealer to Foam

Spacer

FIG. 30 Inspecting Drain Trough Area



46-05-16

Electric Moon Roof

46-05-1

ROOF REINFORCEMENT

TO FLATTEN OR DE-ARCH

THE ROOF PANEL, APPLY

HAND PRESSURE AT CENTER

OF ROOF OPENING.

REMOVE THE SLIDING PANE L

AND SUN SHADE TO PERFORM I

THIS OPERATION. I

R1965- A

FIG. 31 Overcrowned Roof Panel

PLACE PANEL AT A 45° ANGLE FROM THE HOR IZONTAL SURFACE OF WORK BENCH

AND SEAL MOULDING BY APPLYING CLEAR SILICONE SEALER, PART 3M NO. 8551

CLEAR AUTO GLASS SEALER, OR EQUIV ALENT BETWEEN MOULDING AND GLASS.

REPEAT THIS PROCEDURE FOR ALL REMAINING SIDES.

R1889-A

FIG .

32 Applying Sealer-Glass-To-Frame



46-05-17

Electric Moon Roof

46-0')-17

HEADER WIRE (BLACK)

MOTOR

(BLACK)

EXISTING WIRE (RED)

CIRCUIT BREAKER

HEADER WIRE (BLACK)

CIRCUIT BREAKER

HEADER WIRE (BLACK)

M 8 9 2 - C

FIG. 33 Wiring System Components — Thunderbird and Continental Mark V



46-05-18

Electric Moon Roof

46-05

MOTOR

HEADER WIRE

(BLACK)

TAPE

REFER

TO

VIEWS

A AND B FOR FUSE

CONNECTIONS

FORD

MERCURY

TORINO

COUGAR

AN D

ELITE

RED W/YELLOW

STRIPE

(BLAC

VIEW A

FUSE BOX

LINCOLN CONTINENTAL

WIRE ASSEMBLY

(BLACK)

CIRCUIT BREAKER

(LOCATED ON BRAKE

PEDAL SUPPORT)

HEADER WIRE

(BLACK)

VIEW B

FIG. 34

Wiring System Compo nents—Thunderbird,

Ford,

Mercury,

LTD II,

Cougar

and

Lincoln Continental



46-05-19

Electric Moon Roof

46-05-19

CANDELABRA

CONNECTORS

POWER

RELAY

CONNECTOR

GROMMET

USED ON VEHICLES

WITH MANUAL

TRANSMISSIONS

ON FLOOR MOUNTED

AUTOMATICS

OTHERWISE USE

EXISTING

TRANSMISSION

CABLE GROMMET.

P1943 B

FIG. 35 Wiring System Components—Monarch and Granada



46-05-20

Electric

Moon Roof

46-05

CHASSIS

GROUND

CONNECTOR

(4 REQ'D.)<

SWITCH

3 0

BLACK

R E D

GREEN

MOTOR

CLOSE OPEN

25-AMP FUSE

(IN FUSE PANEL)

TO + POWER

SOURCE

I

I FORD

MERCURY

I LTD II

I THUNDERBIRD

,

COUGAR

_J

L

25-AMP CIRCUIT

BREAKER (LOCATED

ON BRAKE PEDAL

SUPPORT)

TO SPARE ACC. TAKEOFF IN

CENTER OF FUSE PANEL BLOCK

POWER SOURCE

LINCOLN

CONTINENTAL

25-AMP CIRCUIT I

BREAKER (LOCATED |

ON ENGINE SIDE OF

DASH PANEL) I

I

TO + POWER SOURCE •

(POWER WINDOW RELAY '

SOLENOID) I

I 1 1

CONTINENTAL

MARK V

ON ENGINE SIDE OF DASH PANEL)

P TO 25-AMP CIRCUIT

/

BREAKER (LOCATED

\

ON R.H. SHOCK

ABSORBER TOWER)

L

GRANADA

MONARCH

J

+ POWER SOURCE

R 1 9 4

FIG.

36

Circuit Sche matic—Electric Roof



46-05-21

Electric Moon Roof

46-05-21

SEAL ASSY. REAR

- 50928

FILLER

-

REAR

W/S

ALO MOULDING

5 / 8 A 6 6

CABLE AND SLIDE

ASSY. - 502B20

ALTERNATE LIFTER

BRACKET INCLUDED

IN SERVICE KIT

SUN SHADE ASSY.

u

>

V

V

L . H . FRONT TRACK

502L17

HANDLE -

502C34

REAR TRACK RETAINER

PIN - 502B40

TRACK ASSY.

L.H.502C07

R.H.502C06

CABLE AND SLIDE

ASSY.

-

502B21

ALTERNATE L IFTER BRACKET

INCLUDED

IN

SERVICE

KIT

RAMP GUIDE SHOE

-* -FRONT OPENING Si iAL

ASSY.

-

50250

FRONT ADJUSTING

RING/NUT - 502IJ66

FRONT TRACK SHOE

- 502L09

USE WITH M ETAL

SLIDING PANEL

ONLY

PAD - 519B66

R.H. FRONT TRACK

- 5 0 2 L 1 6

TRACK

EXT.

UPPER

CORNER - 502L17

TRACK EXT. LOWER

CORNER

-

502L17

MOTOR

AND

DRIVE

ASSY. 15790

FRONT HEADER

WIRING HARNESS

SWITCH TO-CIRCUIT

BREAKER

R1894-B

FIG. 37 Moon Roof—Exploded View Parts Component Chart



46-11-1 Manual-Sun Roof

46-1

Manual Sun Roof

P A R T

46-11

SUBJECT PAGE

SUBJECT

PAG


ADJUSTMENTS

Cable Alignm ent 11-2

Fore and Aft, Side-To-Side Alignment

of Panel in Roo f Opening 11-2

Roof Sliding Panel Alignment for

Flush Fit 11-1

Roo f Sliding Panel Rear Edge -

Up or Dow n 11-2


Crank Handle and Drive Assem bly 11-3

Drain Hoses 1.1-5

Fro nt Slide 11-5

Guide

Rail,

Slide and Cable System 11-3

Rear Slide and Cable Assem bly 11-5

Rear Slide Tension Spring 11-5

Roo f and Sliding Panel 11-2

Roo f Sliding Panel Fro nt Seal 11-6


The manual sun roof panel slides on

guide rails. It is operated by a crank. The

crank is splined to a shaft and pinion

(Fig. 6) that drives two flexible cables.

Each cable is attached to a slide that

moves on the guide rails. The left and

right rear slides are attached by mounting

brackets to the rear of the sliding panel.

(Figs. 5 and 8). Front guides attached to

the front of the sliding panel and slide on

the left and right guide rails, respectively

(Fig. 4).

CR2853-A

To operate the sliding panel, pu

handle from its stowed position and

handle counterclockwise to open;

clockwise to close.

ADJUSTMENTS

Before making any adjustments,

remove the trim (inner) panel from the

sliding panel for access. Open the sliding

panel about five inches. Disengage the

trim panel from the sliding panel by

pulling the seven trim clips loose (Fig. 3).

Slide the trim panel rear-ward for

stowage. Crank the sliding panel to

close (Fig. 4) .

FRONT SLIDE ADJUSTING NUT

ROOF SLIDING PANEL

ROOF SLIDING PANEL

ALIGNMENT FOR FLUSH FIT

Sliding Panel Front Edge-Up or

Down for Pinto and Bobcat

Both sides may be adjusted, as

necessary.

Loosen the two screws that attach the

front slide assembly to the knurled

adjusting nut at the front of the panel

(Figs. 1 and 4). Turn the adjusting nut

clockwise to lower; counterclockwi

raise. When tightening the two attac

screws, be sure that the front

assembly is perpendicular to the g

rail and that the base of the slide t

does not contact the guide rail (Fig

Sliding Panel Front Edge—Up

Down For Mustang

To adjust the Mustang roof sli

panel loosen the two screws that a

REAR SLIDE ADJUSTING SCREW

ROOF SLIDING PANEL

GUIDE RAIL

SLIDE THROAT BASE

(SHOULD NOT CONTACT

THE GUIDE RAIL)

FRONT SLIDE ASSEMBLY - PINTO AND BOBCAT ONLY

TENSION SPRING IN

APPLIED POSITION

REAR SLIDE ASSEMBLY - PINTO BOBCAT AND MUSTANG

FIG.

1 Roof Sliding Panel Adjustments

R



46-11-2

Manual-Sun Roof

46-11-2

the front slide assembly to the double

bossed tapping plate. Move the tapping

plate rearward to lower the front of the

panel, or forward to raise the panel (on

the Mustang equipped with glass panel,

add shims to raise panel). When the front

edge of the panel is f lush, tighten the

attaching screws into the tapping plate.

Be sure the f ront s l ide assembly is

perpendicular to the guide rail, and that

the base of the s l ide throat does not

contact the guide rail (Fig. 2).

NO TE: The blue slide assembly is for

the driver's side and the white slide

assembly is used on the passenger side.

ROOF SLIDING PANEL REAR

EDGE—UP OR D OW N

Both sides may be adjusted, as

necessary.

Loosen the rear slide adjusting screw

(Figs. 1 and 4), and raise or lower the

sliding panel until f lush with the

stationary roof panel. Tighten the

adjusting screw to hold the correct

position.

FORE AND AFT, SIDE-TO-SIDE

ALIGNMENT OF PANEL IN ROOF

OPENING

This adjustment is automatically

achieved when the sliding panel is

TAPPING PLATE

FRONT SLIDE ASSEMBLY

SCREWS

R1I559-A

FIG. 2 Front Slide Assembly—Mustang Only

attached and adjusted in the full closed

position. See Removal and Installation.

CABLE ALIGNMENT

Cable misalignment can cause the

sl id ing panel to jam on one s ide. To

correct, remove the sliding panel, crank

handle, escutcheon, and drive assembly

as shown in Fig. 6.

Make sure that both cables are

i n

the

front guide rail channels and through the

front retainer, as shown in Fig. 7. Then,

push each rear slide forward until it is

seated firmly against the cable side

cover stops. Install the drive assembly,

escutcheon and crank handle and sliding

panel.


ROOF AND SLIDING PANEL

1. Open the sliding panel five inches

(Fig. 3).

2. Disengage the trim (inner) panel from

the sliding (outer) panel by pulling the

seven trim clips loose (Fig. 3).

3. S l id e th e t r im p an e l to r ea r fo r

stowage, and crank the sliding panel

closed (Fig. 4).

4. Release the rear slide tension springs

(left and right) by rotating them to the

inboard position (Fig. 4).

5.

Detach the sliding panel from both

left and right front slide assemblies (2

screws each side, Fig. 4).

6. Deta ch the sliding panel from the two

rear s l ide assemblies by removing

each slide mounting bracket retainer

from the tabs in the panel (2 screws,

Figs.

4 and 5).

7. Pull the sliding panel forward and out

of the roof panel opening.

8. Before installing the sliding panel, be

sure that the crank handle is rotated

clockwise as far as it will go. Set the

sliding panel in the roof panel opening

an d a t tach i t to th e fo u r s l id e

assemblies (right and left, front and

rear) , as shown in Figs . 4 and 5 .

Rotate the tension springs outboard

TRIM PANEL

(7) CLIPS

FRONT SLIDE ASSEMBLY

V S J S J * ? ?

FIG. 3 Trim Panel-To-Sliding Panel Attachment



46-11-3

Manual-Sun Roof

46-1

and lock them into applied position.

9. Crank the sliding pane l open about

f iv e in ch es , p u l l the t r i m p a n e l

forward, and engage it to the sliding

panel

at the

seven trim clips (Fig.

2).

CRANK HANDLE AND DRIVE

ASSEMBLY

1.

Remove the crank handle from the

drive assembly

and the

escutcheon

from the housing,

as

shown

in

Fig.

6.

2. R e m o v e

the

d r iv e as semb ly

(two

screws).

GUIDE RAIL, SLIDE AND CABLE

SYSTEM

Removal

1. Remove the roof sliding panel and the

crank handle

and

drive assembly.

2.

R e m o v e

the

cable f ront cover

(8

screws), the two cable side covers (3

screws each) , and the cable front

retainer (Fig. 7).

3. Remove the two retaining screws at

the center of the cable front guide rail

(Fig. 7), slide the locating tabs at the

left

and

right ends

of

the front guide

rail from the left and right guide rails,

respectively, and remove the front

guide rail (Fig. 8).

TAPPING PLATE

SLIDING PANEL

REAR SLIDE ANDCABLE

ASSEMBLY

(502B78-9)

MOUNTING BRAC

RETAINER TAB

REAR SLIDE MOUNT

BRACKET (51812

MOUNTING

BRACKET-TO-PANE

RETAINER

(51880)

ADJUSTING SCREW (385035) A \ SCREW (57485

(§|}& 2 REQUIRED

REAR SLIDE ADJUSTING NUT (518A16) ^ ^ S L *

^&*^ R1

FIG. 5

Sliding Panel-To-Rear Slide Attachment—Pinto, Bobcat and Mustang

REAR SLIDE TENSION

SPRING (518A36)

(RELEASED POSITION)

TENSION SPRING APPLIED POSIT ION

FIG. 4

Roof Sliding Panel Assembly (Right Side Shown)

4. Slide

the

cable left

and

right guide

rails from their respect ive rear

retainers and lift them out of the panel

housing (Fig.

8).

The guide rails will

con t a in the rear slide and cable

assemblies. 2.

5. Remove

the

sliding panel trim piece

from

its

stowed position

in the

roof

panel.

6. Remove

the

rear slide

and

cable

assemblies from the guide rails, by

sliding them forward and out (Fig.

8).

Installation 3.

1. In ser t

the

rear s l id e

and

c a b l e

assemblies into

the

guide rails.

The

plast ic rol lers

on

each rear slide

assembly should

be

inboard,

so

that

the r ight

and

lef t s l ide s w il l

be

installed

in the

right

and

left guide

rails, respectively (Fig.

8).

Install the left and right guide rails in

the panel housing, sliding them onto

their respective rear retainer (Fig.

8).

Be sure that

the

gui de rail rear

retainers are engaged in their brackets

at

the

rear

of

the housing assembly,

inside the

roof.

Install

the

front guid e rail

in the

housing, so that the locating tabs on

each

end

engage

the

right

and

left

guide rails (Fig. 8). Then insta

two retaining screws near

the

c

of the front guide rail (Fig.

7).

4. Install

the two

cable side cove

screws each,

Fig. 7), and

pull

rear slide assemblies forward ag

the stops

of

the cable side cove

5. Thread

the

right c able in t

outboard channel o f the left guid

an d

the

left cable into

the

in

channel of the right guide rail (F

6. Seat the cable into the front guid

and install the cable front retain

top

of

the cables

in the

center

o

front guide rail (Figs.

7

and

8)



46-11-4

Manual-Sun Roof

46-111-4

7.

Lubricate the top of each cable at the

front guide rail with ESB-M1C93A

(Ford Part No. 19584 or equivalent)

polyethylene grease. Wipe the excess

grease into the guide rail channels.

8. Make sure that the cable rear slides

are still positioned against the stops

of the cable side covers, and then

install the cable front cover (9 screws,

Fig. 7).

9. Install the drive assembly, the

escutcheon and the crank handle, as

shown in Fig. 6. Make sure that the

rear slides are still positioned at the

stops of the cable side covers.

10. Cycle the cables and rear slides to

make sure that the cable and guide

rail system functions without binding.

11. Install the trim panel by sliding it into

the guide rails from the front. Then,

slide the trim panel to the extreme

rear position.

12.

W ith the rear slide assemblies against

the stops of the side covers and the

slide adjusting links in the vertical

position, place the roof sliding panel

into the roof opening.

13.

Attach the sliding panel to the left

and right rear slide assemblies. To

make this attachment, position each

slide mounting bracket over the

tapping plate holes and between the

retainer tabs in the sliding panel.

Then slide the mounting bracket

retainer into the tabs against the

bracket and secure with two retaining


14. On Pinto and Bobcat only, turn the

sliding panel front adjusting nut

counterclockwise to the mid-position

on each front slide adjusting stud

R 1:547-A

FIG.

6 Crank Handle and Drive Assembly

R 1 5 ^ 8 - A

FIG. 7 Cables and Guide Rails Installed

REAR SLIDE AND CABLE ASSEMBLIES

CABLE LEFT GUIDE RAIL

RIGHT GUIDE

RAIL

REAR RETAINER

(51882)

CABLE FRONT GUIDE RAIL (502A10)

LOCATING TAB

R 154<»-A

FIG. 8 Guide Rail and Cable System



46-11-5

Manual-Sun Roof

46-1

(Fig. 1). For Mustang, position the

front guides midway on the adjusting

ramp (Fig. 2).

15. Engage the left and right front slides

to the left and right guide rails,

respectively, and attach each slide to

its adjusting

nut on the

sliding panel

(2 screws each, Figs. 1 and 4). The

s l i d e a s s e m b l y s h o u l d be

perpendicular

to the

guide rail.

To

avoid binding,

be

sure that

the

base

of the slide throat does not contact the

guide rail (Fig. 1).

Do not

jamb

the

slide

to the

guide rail.

16.

Raise

or

lower

the

sliding panel

to

proper alignment with the roof, as


17.

Lock each rear slide tension spring in

applied position, by ro ta t ing it

outboard and engaging it in the

plastic roller (Fig. 4).

18. Crank the roof sliding panel open

about five inches, pull the trim panel

forward, and engage it to the sliding

panel at the seven trim clips (Fig. 2).

19. Crank

the

sliding panel

to the

closed

position, and check the crank handle

alignment within the escutcheon cup

(Fig. 6). Realign the handle on the

drive shaft, if necessary.

REAR SLIDE AND CABLE

ASSEMBLY

1. Remove the roof sliding panel from

the roof panel, as outlined under Roof

Sliding Panel, steps 1 through 7.

2.

Remove the crank handle and drive

assembly.

3. Remove the guide rail(s), as outlined

under Guide Rail, Slide

and

Cable

System, steps 2 through 6.

4.

Install the rear slide to the guide rail

and

the

guide rail

to the

housing,

as

outlined under Installation, steps 1

through 19.

FRONT SLIDE

1. Remove the trim panel from the roof

sliding panel,

as

described under Roof

Sliding Panel, steps 1 through 3.

2.

Remove the front slide assembly from

the adjusting nut or adjusting ramp,

at the front end of the sliding panel

(2 screws, Fig. 4).

3. When installing the slide, engage it to

the guide rail and attach it to the

adjusting nut or adjusting ramp, on

the

sliding panel. The slide assembly

should be perpendicular to the guide

rail. To avoid binding, be sure that the

base of the slide throat does not

contact the guide rail (Fig. 1).

Do not

jam the slide to the guide rail.

REAR SLIDE TENSION SPRING

1. Remove the trim panel and slide it to

the rear (stowed) position, as outlined

ROOF PANEL

HOUSING ASSEMBLY

FRONT OF CAR

RETAINER AND B

ASSEMBLY

^ ^ ( 3 5 9 1 6 0 - S 2 ) 7 REQUI

NUT

AND

WASHER ASSEMBLY

(45334-S2) 7 REQUIRED

R

FIG. 9 Sliding Panel-To-Roof Panel Attaching Points

under Roof Sliding Panel, steps 1

through

3.

2.

Using a 3/16-inch drill, remove the

rivet that retains the spring to the roof

sliding panel (Fig. 4).

3. Install a new spring washer and

spring with a pop rivet.

SLIDING PANEL HOUSING

ASSEMBLY

1. Crank the roof sliding panel to the

half open position.

2.

Remove the c rank h and le and

escutcheon assembly

(Fig. 6).

3. Remove the headlining retainer and

the headlining, as outlined in Part

45-

41.

4. Disconnect the four d rain hoses (Fig.

10).

5.

Remove the (7) nuts (for Pinto and

Bobcat, (6) nuts for Mustang)that

retain the housing assembly to the

roof panel,

and

lower

the

housing

from the roof (Fig. 9). The

housing

should

be

held

in

position, while

the

retaining nuts

are

being removed.

6 . When in s ta l l ing the h o u s i n g

assembly, tighten the retaining nuts to

a torque of 3 to 7 ft-lbs.

DRAIN HOSES

To replace front drain hose, the

headlining assembly must be lowered at

the windshield header area for access.

Disconnect the hose from the roof front

drain neck (Fig. 10). Remove the

side trim panel for access to

the low

of

the

hose. Attach the replacement

to the lower end of the existing hose

the new hose into place from belo

the existing hose is pulled out at

th

To replace

a

rear drain hose, pu

headlining down from the affected c

of

the

roof panel

for

access.

disconnect the hose from the roof

drain neck (Fig. 10). Remove

the q

trim panel for access to the lower e

the hose. Attach the replacement h

the lower end of the existing hose

remove the retaining clips.

The new

can then be pulled into place from

as the existing hose is pulled out

top. Secure the new hose with

retaining clips before installing

quarter panel.

During regular maintenance, c

the drain hole at each of the four co

of the roof, to see if it is free of fo

material.

Any

hole that

is

plugged

be cleaned out with a flexible ho

smaller diameter, or with air press

ROOF SLIDING PANEL REAR S

1.

Remove

the

roof sliding panel

the roof, as outlined in this Sec

2.

Remove the rear seal from th

vertical flange of the panel, as s

in Fig. 11.

3. Remove the weatherstrip from

rear horizontal flange of the pan

shown

in Fig. 11.



46-11-6

Manual-Sun Roof

4 6 - 1 1 - 6

ROOF SLIDING PANEL FRONT

SEAL

1. Remove the sliding panel housing

assembly, as outlined in this Section.

2. Drill out the blind rivets from th e seal

and remove the seal assembly (Fig.

12).

3. Install the new seal assembly to the

roof panel reinforcement flange. Trim

the seal to the proper length at the

notches in the f lange of the roof

reinforcement.

4.

Pierce rivet holes in the seal assembly.

Use the existing holes in the roof

flange as guides.

5.

Secure the seal, using seven

1/8-inch

blind rivets.

6 . Instal l the s l id ing panel housing

assembly back in the

roof,

as outlined

in this Section.

REAR DRAIN HOSE

REAR HOSE CLIPS

R I S 5 1 - A

FIG. 10 Roof Drainage System

SCREW (55953-S46X)

11 REQUIRED

PLUG BUTTON

(385034)

2 REQUIRED

WEATHERSTRIP

502C12

REAR SEAL ASSEMBLY (518A46)

FIG. 11 Rear Seal Replacement

SLIDING PANEL

FLANGE COVER

(PAINTED AND VINYL- MUSTANG

PAINTED SLIDING PANEL- PINTO)

518A54

R 1552-D



46-11-7

Manual-Sun Roof

46-1

FRONT SEA-L ASSEMBLY

(51884)

SEE VIEW A

SYMMETRICALLY

OPPOSITE TO VIEW A

ROOF PA

ROOF PAN

REINFORCEM

VIEW A

SECTION B-B

FIG.

12 Front Seal and Vinyl Cover Installation

R1



46 -12-1 Manual Sun Roof—Removable

46-12-1

Manual Sun Roof - Removable

REMOVABLE SUN ROOF

The optional removable sun roof is

operated as follows: To open to vent

position, move the release lever as far

forward and upward as it will go. To

close, move the lever to its full rearward

position (Fig. 1).

PANEL REMOVAL

To remove the glass panel, move the

release lever to mid-position. Then

squeeze the attaching links together to

disengage the latching mechanism from

the roof panel. From outside the vehicle,

OPERATION

raise the rear edge of the glass and

remove it by lifting upward and rearward

(Fig. 2).

PANEL STOWAGE

Whenever the glass panel is removed,

it should be stored in the stowage bag

provided (Fig. 3). The glass panel and

sunshade should never be s tored

anywhere else in the vehicle. The stowage

bag consists of two compartments that

can safely accommodate the removable

glass and sun shade.

N2867-A

FIG. 1 Removable Sun Roof Operation

The stowage bag on 2-door models

rests against the rear seat back ai: the

bottom edge and clips to the drain trough

beneath the weatherstrip at the top edge.

On 3-door models it is strapped to the

rear floor on the passenger side of the

vehicle.

PANEL INSTALLATION

To install the glass panel, align the

two hinges at the front of the glass with

the hinge sockets in the roof panel (Fig.

4).

Hinges should be fully seated in iheir

sockets before the rear edge of the panel

is lowered. From inside the vehicle,

squeeze the connecting links together and

insert them in their respective sockets.

Glass can then be locked in position by

actuating the release lever.

N2868-A

FIG.

2 Panel Removal



46-12-2

Manual Sun Roof—Removable

46-1

N2869-A

FIG. 3 Panel Stowage

VIEW

A

N2870

FIG.

4

Panel Installation

REPAIR PROCEDURES

GLASS REPLACEMENT

Remove the hinge brackets from the

broken glass by removing the attaching

screws at the center of each bracket.

Loosen the Allen Set Screws on the latch

mechanism and unscrew the two

attaching bolts to separate from the

broken glass. Be sure to transfer all

sleeves and washers to the new

installation (See Fig. 5).

Recommended attaching torque is 36-

54 in-lbs.

ADJUSTMENT

After the glass panel is installed in the

vehicle

the

latching mechanism

can be

a d j u s t e d

to

o b t a i n o p t i m u m

fit.

Adjustment

is

accomplished

by

moving

the latch sleeves

up or

down

and

locking

them in place with the set screws.

T h e p o r t i o n of the la tch th

attached

to

the roof panel can be a dj

fore

and aft by

loosening

the two 1

bolts

and

repositioning

the

bracket.

WEATHERSTRIP REPLACEMENT

I f wea th er s t r ip p in g is remove

replaced it should be secured as fol

Body opening seal: remove attac

pop-rivets and install new seal w ith

rivets drill-at-assembly.



46-12-3

Manual Sun Roof—Removable

4 6 - 1 2 - 3

HINGE SOCKET

GLASS PANEL

LATCH COVER

N2871-A

FIG.

5 Glass



46 -1 2- 4 Manual Sun Roof—Removable 46 -1

Weatherstrip roof opening: pull off HINGE SOCKET REPLACEMENT the headlining for access. Parts can

and reinstall new part by pushing on (no In order to repla ce the front hing e be removed and replaced in the no

adhesive required). sock ets, it is necessary to locally lower manner (2 attaching screws).



46-20-1

Roof Outside Cover

46-20-1

SUBJECT

Roof Outside Cover

PAGE SUBJECT

REMOVAL

AND

INSTALL ATION MAJOR REPAIR

Roof Outside Cover

- All

Vinyl Roof Material Except

Non-Ensolite Pad

20-1

Levant Type Pattern

Roof Outside Cover

-

General Repair Infor m atio n

W/Ensolite Pad

20-1

Levant Type Pattern Only

P A R T

46-20

PAGE

20-9

20-7

20-7

CR2855-A

REMOVAL

AND

INSTALLATION

ROOF OUTSIDE COVER—NON-

ENSOLITE

PAD

If some

of

the following steps

do not

apply

to the

particular model being

serviced, proceed

to the

next step.

Removal

1. Unpack

the new

cover

and

spread

it

out

to

remove

the

w rinkles.

2. Cover

the

fenders, seats

and

rear

deck.

3. Remove the rear seat cushion and seat

back.

4.

On

models with roof side ornaments,

remove the blind quarter interior trim

panel

for

access

to the

ornament

retaining nuts. Remove

the

orna-

ments. For trim panel removal see

Group

45.

5. Remove the weatherstrips (Group 44)

and

the

exterior mouldings around

the windshield

and

rear window

(Group 43).

In

some cases, part of the

interior garnish moulding

may

have

to

be

r e m o v e d

for

a c c e s s

to

weatherstrip retaining screw(s). Also

remove

the

exterior trim moulding

from

the

ope r a w indow ,

if so

equipped.

6. Remove

the

drip rail mouldings

and

weatherstrips (Groups 44 and 47).

7. Remove

the

side

and

rear belt

mouldings (Group

47).

8. Remove screws that retain

the

cover

at front

and

rear window openings

(one

at

each seam).

9. Remove

the

cover from

the roof.

10. Clean

all

mouldings

and

retainers.

Clean excess sealer from around

the

windshield

and

back window.

Installation

1. With Thunderbird

and

Continental

Mark

V

only—if

the

roof side front

or rear pads are torn

or

damaged, pull

off

the old pad and

clean

the

sheet

metal area with

a

wire brush. Apply

adhesive (19C 525

or

equivalent)

to

the roof sheet metal

and the

under-

side

of a new

pad(s). Position

the

pad(s)

to the top

sheet metal

as

shown in Fig. 2.

2.

Measure

and

mark

the

center

of the

new cover fabric.

3.

Measure

and

mark

the

center

of the

vehicle

roof.

4. Apply adhesive

to the

underside

of

the

new

roof cover assembly between

the center mark

and one of the

outboard seams.

Do not apply

adhesive to those parts of the

assembly which cover the roof sides

and

the

area around

the

door,

windshie ld and back window

openings.

5. Apply adhesive

to the

corresponding

half of the roof. Do not apply adhesive

to

the

roof sides

and the

sheet metal

area around the door, windshield, and

the back window openings.

6. Position

the

cover

to the roof, and

align

the

center marks. Then, cement

the cover

to the roof.

Stretch

out all

wrinkles.

7. Apply adhesive

to the

remaining half

of the roof and cover as described in

Steps

4 and 5.

Position

the

cover

to

the roof

as

described

in

Step

6, and

stretch

out all

wrinkles.

8. Apply adhesive

to the

bod>

and

underside

of the

cover

in the

area

below

the

back window. Position

the

cover

and

remove

any

wrinkles.

9. Apply adhesive

to the

roof sides

and

door openings

and to the

underside of

the cover. Make angle cuts

a: the

corners

as

necessary. Then, stretch

the cover

and

cement

in

place.

10.

Trim

the

roof cover

at the

windshield

and back window openings. Leave

1/

2 inch

of

material

at the

openings

for

cover attachment

in the

wirdow

opening recess.

11. Apply adhesive

to the

back window

opening

and the

underside

of the

roof

cover. Make angle cuts

as

necessary

at

the

c or ne r s

and

cement

the

material

in the

back window opening

recess. Trim

the

cover around

the

moulding retainer weld studs.

12.

Apply adhesive

to the

windshield

opening and

the

underside

of

the roof

cover. Make angle cuts

as

necessary

at

the

c or ne r s

and

cement

the

material

in the

windshield opening

recess. Trim

the

cover around

the

moulding retainer weld studs.

13.

At

each roof rear quarter, locate

and

punch

two

holes

for the

roof side

ornament

on

models

so

equipped.

Install each side ornament with

the

studs entering

the

punched holes;

then, from inside

the

vehicle, install

the retaining nuts on the studs. Apply

sealer around

the

nuts.

14.

Re-install

all

interior trim panels,

garnish mouldings, weatherstrips

and

e x te r io r m ould ings t ha t w e r e

removed before cover replacement.



46-20-2

Roof Outside Cover

46-2

CO^ER ASSEMBLY

APPLY ADHESIVE

TO ENTIRE

PERIMETER OF

ROOF SURFACES

R 1 5 3

F IG .

1 Roof Outside Cover Installation—LTD II, Cougar and Thunderbird



46-20-3

Roof Outside Cover

46-20-3

SEAM

VIEW A

CENTER

PILLAR COVER

COVER

TRIM COVER

.06 MIIM.

VIEW C

TRIM AT REAR

OF BOLT HOLE

SEAM

COVER ASSEMBLY

SCREW

ADHESIVE

COVER

ADHESIVE

VIEW E

ADHESIVE

R1104c

FIG . 2

Roof Outside Cover Installation—Lincoln Continental



46-20-4

Roof Outside Cover

46-2

ADHESIVE

APPLY

ADHESIVE

TO BACK

SIDE OF VINYL

APPLY ADHESIVE

TO ENTIRE PERIMETER

OF ROOF SURFACE

R

FIG. 3 Roof Outside Cover Installation—Granada and Monarch



46-20-5

Roof Outside Cover

46-20-5

COVER ASSEMBLY

ADHESIVE

C5AZ-19C525 -A

TAPE - APPLY

TAPE AROUND Tl -E

ENTIRE PERIMETI-R

ON THE INSIDE

Of

:

TH E

PINCHWELD

A D H E S I V E

F L A N

G E O V E R L A P P IN G

TAPE ON TOP.

MOULDING RETAINER

STUD

ROOF OUTSIDE SIDE PADS

REAR FRONT

VIEW-B B

OPTIONAL OPERA WINDOW

FIG . 4 Roof Outside Cover Installation—(Non-Ensolite Pad)—Thunderbird



46-20-6

Roof Outside Cover

46-2

ADHESIVE

SIDE

PAD

CONTINENTAL MARK V SHOWN

THUNDERBIRD TYPICAL

R194

FIG. 5 Roof Outside Cover Installation—(Ensolite Pad)—Standard Continental Mark V, Optional Thunderbird, Typica

Mustang



46-20-7

Roof Outside Cover

46-20-7

N O T E : Any exterior mouldings

using positive bolt-on fasteners must

be installed prior

to

installation

of

interior trim parts.

15. Clean

the

glass, mouldings,

top and

surrounding area.

ROOF OUTSIDE CO VER —W /

ENSOLITE

PAD

Continental Mark

V

Described—

Thunderbird

and

M u stan g

Simil iar

Removal

1. Unpack

new

cover

and new pad,

spread

out to

remove

the

wrinkles.

2. Cover

the

hood, fenders, rear deck

and seats with protective covers.

3.

Remove rear seat cushion

and

seat

back assemblies (Group

41).

4. Remove upper

and

lower

1/4

trim

panels rig ht

and

left (Group

45).

5. Remove opera windows

and

outside

opera window mouldings.

6. Remove

1/4

window housing right

and left,

to

gain access

to

T-Bolt nuts

that retain

the

outer belt moulding.

7. Remove windshield garnish moulding

and

sun

visors including

sun

visor

brackets.

8. Remove staples

and

pull headliner

down

on

both sides

and

across front

at windshield.

9. Remove T-Bolts nuts retaining

the

halo mouldings along both sides,

across front of roof and across lower

roof panel

at

rear. Lower rear roof

panel T-Bolt nuts

can be

reached

from inside trunk.

10.

Remove

all

roof cover retaining

mouldings

and

rear window outside

mouldings

and

clips (Group

43).

11. Mark

all

seam

and

hole locations.

This will

aid in

lining

up new

cover.

12.

Remove

all

screws

and

clips retaining

cover

to roof.

13.

Remove

the

cover from

roof.

14.

Remove rubber backing from roof

and scrape

off all

excess backing.

15. Repair areas damaged

by

scraping.

16. Grind excess cement

and

padding

from roof area prior

to

priming.

17. Mask area for priming and wipe with

solvent.

18.

Prime entire

top (1st)

coat.

19. Prime entire

top (2nd)

coat.

20. Scuff sand, blow

and

wipe roof area

clean.

Installation

1. Position

all

mouldings

in

place

to

line

up

pad for

proper alignment

of

cover

to mouldings.

NOTE: It is very important that

the mouldings be installed around the

backlite and beltline to properly

position the Ensolite pad before any

cutting is done. If the pad is not

properly positioned to the mouldings,

the cover will have a gap at the

mouldings Fig. 5).

2. Tape

all

m ould ings

to

prevent

spraying glue

on

them.

3.

Spray glue

to

roof

and

pads

and

install

to roof.

Trim excess

pad

4.

Remove tape from mouldings

and

remove mouldings.

5. Remove backing from

pad.

6.

Cut

ope n ing

in pad for

ope r a

windows.

7. Position cover

on top and

inspect

for

proper

fit.

8. Position

and

mark cover

and

roof

area

for

proper alignment.

9. Spray glue

to pad and

cover

and

install cover

to pad.

Loosely install

halo mouldings

and

mark

and

trim

excess cover.

10.

Cut

opening

in

cover

for

opera

windows, trim

and

install outer

retainers.

11.

Cut

holes

in

cover

at

weld studs

and

punch holes

for

retaining screws

and

install screws.

12.

Install retainers

and

clips

and

install

mouldings.

13.

Apply clear silicone sealer in bac klite

opening.

14. I n s t a l l r e a r w i n d o w g a r n i s h

mouldings.

15.

Install halo mouldings.

16. Install

all

interior trim

and

staple

headliner.

17. Remove

all

tape

and

paper.

18.

Clean interior

and

exterior.

MAJOR REPAIR

GENERAL REPAIR INFORMATION

Several materials

are

used

as

vinyl

roofs.

Of

these

the

Levant material

requires

a

separate repair procedure.

The

Levant

type material

can

be identified

by

the grain pattern which

is

shown

in Fig.

8.

If the

texture

is

different than shown

in Fig.

8, use the

repair procedure

for all

except Levant type.

Repairs on White Vinyl

Although repairs

can be

performed

on white vinyl tops,

the

repair

is

more

difficult with white (particularly when

repairing

a cut or

scuff

on the

vinyl

sur f a c e ) . H ow e ve r , w i th c e r t a in

precautions

the

repair

can be

made

to an

acceptable level.

It

is

important that

the

vinyl surface

is thoroughly cleaned before

the

repair

is

made

and

also that excessive heat

be

avoided

to

prevent possible charring

of

the vinyl.

The

recommended cleaning

procedure

and

temperatures

are

outlined

under Repair Procedures.

LEVANT TYPE PATTERN ONLY

A repair

kit is

now available

to

repair

gouged, cut or torn Levant Type Pattern

only Vinyl Roofs.

The

repairs

are

permanent

and

difficult

to

detect.

The

repaired area has the same strength, grain

and color

of the

original roof material.

Levant Type Pattern Grain is shown in

Fig. 8.

Color sprays provided

in

this

kit are

pure liquid vinyl

and

absorb into

the

original roof material.

The

repair

kit

includes six colors of sprays to match

vinyl tops (Black, White, Dark Blue,

Dark Green, Dark Brown

and

Light

Beige).

A complete vinyl

top

repair

kit,

Part

No. VR-1, includes the following: (Fig.

6)

Model 750-HDA electric heat

gun,

heavy duty industrial grade 75O°F.

Pure liquid vinyl aerosol colors,

six

basic

top

color sprays.

Special formula heat curable vinyl

patching compound.

Vinyl prep-conditioner.

Applicator trowel tools.

Scalpel knife.

Grain

- die

compound.

Silicone mold release.

Practice vinyl samples.

The

kit,

Part

No. VR-1, can be

obtained from

a

local automotive parts

supply jobber

or

direct from:

D e t r o i t A u t o b o d y E q u i p m e n t

Company

100 Park Street

Troy, Michigan 48064

Kit Part No. VR-l-LHG, which does

not include the electric heat gun, can also

be obtained.

A model HG-501 heat

gun is

also

suitable

for

repairs

on

Levant type vinyl

R15&9-A

FIG.

6

Vinyl

Top

Repair Kit—VR-1



46-20-8

Roof Outside Cover

46-20

roof material. Do not use any heat gun

of lesser capacity.

General Information

Applying patching compound is a

multiple layer procedure with alter-

nate filling and curing.

On flat or horizontal roof areas, use

a moist sponge (not wet) to cool the

repair area between heat cycles to prevent

the patching compound from setting up

too fast. Cooling is also accomplished by

operating the heat gun on the COLD

position.

On sloped or vertical roof areas, keep

the work area warm so the patch

compound will partially set up as it is

applied to the joint to prevent running

and tear-drop effects.

Sand down high spots with 200 grit

open coat paper, then regrain and re-

spray, or cut out undesirable area and

repeat repair procedure.

If repair is too low, refill, recure,

regrain and spray color.

Keep patching compound away from

the heat gun air stream to prevent

hardening in the jar. Store compound in

a cool place.

Practice Procedure

Use sample vinyl swatches in kit for

practice. Cut a hole or slit in the sample

and glue it to a piece of sheet metal with

trim cement. After trim cement dries,

make practice repa irs in the flat position.

Follow by making practice repairs in the

vertical position.

Instructions On Use Of Heat

Gun

1. Gun is hottest when using shortest

possible heavy duty extension cord.

Beware of drop light cords and long

extension cords with small wires

where the line of voltage drop can

seriously reduce heat output of the

gun.

2.

Gun is hottest when adjustable air

intake louvers are closed. Regraining

p r o c e d u r e s r e q u i r e m a x i m u m

temperature - use closed louvers with

nozzle distance 1 inch from work.

3. Curing each layer of Vinyl Patching

Compound is normally done at 1 inch

nozzle d is tance. Adapt louver

opening to suit rate of cure desired.

4.

Move gun nozzle in circular motion

over repair area (whether curing or

regraining) to get best temperature

distribution at the vinyl surface.

5. Before turning gun OF F, flip switch

from hot to cold for a few seconds to

cool the heater element.

6. Do not drop gun - the ceramic heater

element may fracture.

Vinyl Roof Repair Procedure

1. Make a grain die by following the

Vinyl Grain Pattern Die procedure

which is given in this Part. This die

will be used later to regrain the

repaired area.

2.

If damaged area is small (Fig. 7), use

scalpel knife to cut out loose vinyl

material back to where vinyl material

is securely bonded to roof. Cut out all

fibrous strands. Cut to obtain a clean

edge condition as shown in Fig. 8.

If damaged area is larger, cement

loose material back into place with

trim cement and allow to dry. Cut out

at least 1/16 inch of material on both

sides of the tear line in which to

place the vinyl patching compo und.

3. Clean the area to be repaired with

vinyl prep conditioner by spraying the

conditioner onto a clean cloth and

wiping the area (Fig. 9).

Do not spray

the prep conditioner directly onto the

repair area.

4.

Apply patching compound with

applicator trowel tool as follows

(Refer to Figs. 10 and 11):

Apply the first layer in small

quantities to the metal-vinyl edge

joint to make a root fillet as shown in

Fig. 11. Before curing, wipe off any

excess patch compound above the

joint with a clean dry cloth.

Hold the heat gun approximately 1

inch away from the repair and move

the gun in a circular motion. Curing

takes about 20 seconds and is

complete when the compound turns

from white to translucent. Press down

on the roof material around the joint

with fingers during heat-cure cycles

to keep area flat.

Repeat the procedure of applying

patching compound and heat curing

- always in thin layers. (Refer to Figs.

12 and 13.) Usually three layers are

adequate to complete the job but

larger holes may require four to five

layers.

After heat curing the next-to-last

layer, the joint cross-section will

appear as shown in Fig. 12 and be

warm. Apply patching compound to

obtain a slight build-up above the

vinyl surface as shown in Fig. 13.

R 1 6

FIG. 8 Vinyl Roof Damage After

Trimming

R16

FIG. 9 Cleaning Damaged Area

R 1

FIG.

10 Applying Patching

Compound

NOTE: BEFORE CURING, WIPE OFF ANY

EXCESS PATCH COMPOUND THA T

MAY GET ON ROOF SURFACE.

ROOT FILLE

R 16

R 1600-A

FIG. 7 Typical Vinyl Roof Damage

FIG.

11 Patching Compound—Fir

Layer



46-20-9

Roof Outside Cover 46 -20-9

Wait until this last application turns

to a gel-like consistency (about 10

seconds). DO NOT CURE WITH

HEAT GUN AT THIS STAGE.

Then, draw the side edge of the trowel

tool over the face of the patch area to

strike off the excess build-up to get a

level surface (Fig. 14). Also, remove

any excess compound that may smear

on the vinyl roof material adjacent to

the patch area otherwise it will cure

to the roof material and cause

u n w a n t e d b u i l d - u p on t h e

surrounding area. Joint is now ready

for the final heat cure and regraining

procedure.

5.

Cure this last leveled layer by heating

the patched area for about 30 seconds

at 1 inch nozzle distanc e (always

moving the gun nozzle in a circular

m o t i o n ) u n t i l t h e i m m e d i a t e

surrounding vinyl develops a shiny

glazed appearance. Have grain

pattern die ready in the other hand.

6. Remove heat and immediately press

grain pattern die with force (Fig. 15).

Hold die on repair for at least 10

seconds to obtain a good impression.

7. Cool the repaired area w ith a moist

sponge or

cold

air blast from the gun.

8. Spray vinyl prep conditioner on a

clean cloth and lightly dab the area.

Do not rub.

9. After the repair area has cooled, color

spray with a back and forth sweep to

fog in the vinyl roof color.

Vinyl Grain Pattern Die

A graining die can be made to

duplicate any print desired. It is made by

taking an impression from the vinyl

material in an area adjacent to the repair

or from a piece of scrap having the same

grain.

1. Clean the vinyl material from which

the print will be made with any

suitable mild vinyl cleaner.

2.

Dry the material.

3. Spray a 6 x 8 inch area with Silicone

Mold Release.

4. On a glass surface, place about two

tablespoons of Grain Die Compound

and add seven drops of Fast Set

Liquid Hardener to the compound

(Fig. 16). Mix thoroughly with a stick

or spatula.

5. Scrape the mixture onto the vinyl

material that has been sprayed with

mold release and level out on a 4 x 6

inch area.

6. Cut an 6 x 8 inch piece of vinyl

material of the same grain pattern,

and place it over the compound. Place

the grain side up, fabric side down.

Refer to Fig. 17.

7. Place a flat board (such as 1/2 inch

plywood) on top of the vinyl material

and place a weight on the board.

8. Allow to dry for 20 minutes.

9. Peel off the completed vinyl grain

pattern die and trim edges with

scissors.

10.

Spray the die face with Mold Release

to provide a non-adhering silicone

coated surface. The die can be used

repea ted ly to r epa i r iden t i ca l

patterns. Die should be at room

temperature when making grain on

repair area.

ALL VINYL ROOF MATERIAL

EXCEPT LEVANT TYPE PATTERN

Tools and Mater ia l

The following are the recommended

tools and material required to perform

the various types of repairs on all vinyl

roof material except the LEVANT type.

Before ordering from the sources

listed, it is suggested that local jobbing

shops or radio equipment outlets be

contacted for availability of these items.

Tools

1.

Heat Gun—Model

HG-501...

Source:

Electric Tool & Service Co., 6188

12th St., Detroit, Michigan 48208.

2. Soldering Iron consisting of

1

each):

No. 6100—Imperial Unger Handle...

No .

6102—Imperial Unger Standard

2-wire cord... No. 6202— Imperial

Unger 25-Watt heating cartridge...

No. 6372—Imperial Unger Tip...

PARTIAL F ILL

ROOF

R 1605-A

FIG. 12 Patching Compound—

Intermediate Layer(s)

LAST LAYER OF COMPOUND BEFORE

STRIKING OFF EXCESS BUILD-UP

ROOF

DO NOT CURE WITH HEAT GUN AT THIS STAGE

R 1606- A

FIG. 13 Patching Compound—Last

Layer

Source: Radio Specialties Co., 12775

Lyndon Ave., Detroit, Michigan

48227.

COMPLETE FILL

1607-A

FIG. 14 Leveling Surface

1608-A

FIG.

15 Applying Grain Pattern Die

FIG. 16 Mixing Grain Die Compound

RH510-A

FIG. 17 Place Vinyl Material Ov*r

Die Compound Mixture



46-20-14)

Roof Outside Cover

46-20

3.

Transformer Model

No .

10B Superior

Variable... Bud Metal Box Model No.

C-1606... Source: Radio Specialties

Co.,

12775 Lyndon Ave., Detroit,

Michigan 48227.

4. Hypodermic Syringe 2-1/2 cc with a

No.

BD-18 needle (Plastipakz)...

S o u r c e : A n y m e d i c a l s u p p l y

company.

Materials

1. R u b b e r C e m e n t P i c k - U p

( D RA FCO ) . . . Sour c e : P r oc ur e

locally or Drafting Materials Inc.,

4851 Woodward Ave . , Det roi t ,

Michigan 48201.

2. Abrasive Cellulose Sponge No. 7010

(Scotchbrite Brand 3M) (Surfa Scuff

Sponge)... Source: Procure locally.

3. Vinyl Top Cleaner—P art No. 19526

(or equ ivalent)... Source: Facing Parts

Depot.

4. Vinyl Top Adhesive Part No. 19C525

(or equivalent)... Source: Master

Parts Depot.

5. Vinyl Paint—Spray Can net wt.

5

Oz.

Avd. (or equivalent):

Color Part Number

Black VR-1724-S

White VR-1525-S

Blue VR-19O3-S

Gold VR-1915-S

Parchment VR-1631-A

Brown VR-2045-S

Dulling Agent VR-95F17-S

Class drop ship.

The above colors

are packaged in quantities of (6).

When ordering always select any

combination of (6) colors by Part

Number.

Types of Repair

The following are the various types of

items that can be repaired:

Bubbles

A separation between the vinyl cover

and metal surface due to trapped air (Fig.

18).

Scuffs and Abrasions

Surface damage caused by rubbing

action (Fig. 19).

Major Cuts

A cut which has penetrated through

both the vinyl surface and cloth backing

(Fig. 20).

Wrinkles

A crease or small fold on the surface

of the material. This condition is usually

evident outboard of the bonded seam

(Fig. 21).

Minor Cuts

A sur f a c e c u t w hic h ha s no t

penetrated the cloth backing (Fig. 22).

padded material used on certain models

and body styles (Fig. 23).

Separated Bonded Seam

Seams in which the two pieces of

material have a gap between the sections

(Fig. 24).

Adhesive Smears

These are smears of the type that

normal cleaning will not remove such as

trim cement, drip rail sealer, or the

adhesive which is used for vinyl roof

installation.

These are typical of the kind of items

that are repairable. However, there are

certain considerations regarding the type

R1400-A

FIG.

18 Air Bubble

of repairs to be performed (e.g., wh

repair is to be performed during

delivery, color of vinyl roof invo

location of defect, etc.).

Repair Procedures

Before proceeding with any re

thoroughly clean the vinyl roof

cleaner, Part No. 19526 (or equiva

Use a scrub brush to remove all

imbedded in the graining. Repea

cleaning operation as often as requ

particularly on white vinyl tops.

Scuffs

or

Abrasions

Connect the soldering iron and se

transformer heat range to No. 7 pos

(approximately 225°F).

C le a n the so lde r in g i r on

thoroughly with the abrasive pad.

m u s t be d o n e f r e q u e n t l y w

performing the repair to avoid v

build-up on the tip.

Lightly slide the soldering tip ove

scuff mark several times using s

overlapping strokes until the frayed

has fused to the surface.

The vinyl surface may have

removed by the scuff exposing the

backing. If this is encountered, it wi

necessary to fill in with vinyl as sh

in Fig. 25. This is typical where v

must be added and is accomplishe

FIG.

19 Scuffs or Abrasions

\

Vinyl material that has not been

drawn tight over a sharp bend in the sheet

metal such as around the backlite or over

FIG.

20 Major Cuts



46-20-11

Roof Outside Cover

46-20-11

. < , ' * J

K

(

C l e a n t h e s o l d e r i n g ir o r . t i p

thoroughly with the abrasive pad. This

must be done frequently during the repair

to avoid vinyl build-up on the tip . Lightly

sl ide the so lder ing t ip across the cut

surface using very short strokes (1 /4 inch

or less) until the cu t is covered with vinyl.

Again go over the cut lengthwise with th e

soldering tip to smooth out the su:*face.

The graining effect can be restored by

carefully etching the grain pattern into

1

F IG . 21 Wrinkles

stripping a small quantity of vinyl off a

piece of scrap material with the hot tip

of the solder gun as shown in Fig. 25.

Carefully fill in as required using short

overlapping strokes.

(Several stripping

operations may be required to adequately

fill the scuffed area.)

The graining effect

in the vinyl can be restored by carefully

etching the grain pattern into the vinyl

with the sharp edge of the soldering tip.

The gloss or shiny surface created by the

repair can be removed with the dulling

agent or by spraying the area with liquid

vinyl as shown in Fig. 26. Several color

coats may be required . The las t coat

should be a fog coat to minimize gloss.

R1404-A

F IG . 22 Minor Surface Cut

R 1 4 0 3 - A

This repa ir can be applied to scuffs or

abrasions in most areas of the vinyl top.

Minor Surface Cuts

Connect the soldering gun and set the

transformer heat range to No. 7 position


R14C8-A

F IG . 26 Spraying Repaired Area

R 4 0 6 - A

FIG. 24 Bonded Seam Separation

R1405-A

F IG .

23 Looseness

F IG . 2 5 Stripping and Fil ling Scuffed Area W ith Vinyl



46-20-12

Roof Outside Cover

4 6 - 2 0 -

the vinyl with the sharp edge of the

soldering tip.

If required, the gloss or shine on the

vinyl surface created by the repair can be

removed with the dulling agent and then

spraying the area with liquid vinyl as

shown in Fig. 26. Several color coats of

liquid vinyl may be required. The last

coat should be a fog coat to minimize

gloss.

Major Cuts

Connect the soldering iron and set the



Clean the soldering iron tip with the

abras ive pad. This must be done

frequently during the repair to avoid

vinyl build-up on the tip. If damage is

over an inch long, apply a light coat of

adhesive as shown in Fig. 27. (It is not

necessary to use cement if the cut is over

a padded area.)

Start at the center of the cut and

lightly slide the soldering tip across the

cut surface, as shown in Fig. 28, using

very short strokes (1/4 inch or less) until

the cut is covered with vinyl.

Again go over the cu t lengthwise with

the soldering tip to smooth out the

surface.

The graining can be restored by

carefully etching the grain pattern into

the vinyl with the sharp edge of the

soldering tip.

If required the gloss or shine created

by the repair can be removed with the

dulling agent or by spraying the area with

liquid vinyl as shown in Fig. 26. Several

coats may be required. The last coat

should be a fog coat to minimize gloss.

Bubbles

Generally, an air bubble is caused by

trapped air and can be corrected by

expelling the air with a hypodermic

needle as shown in Fig. 29. It will be

necessary to activate the adhesive under

the vinyl after the air has been expelled

by applying heat with the heat gun until

the vinyl surface is hot to the touch (see

Fig. 30). Then, work the material down

with the fingers as shown in Fig. 29.

To

avoid overheating and possible damage to

the vinyl, hold the heat gun about 10 to

12 inches from the surface and constantly

move the gun in a circular motion. In

some cases where a good bond cannot be

obtained, insert a small amount of

adhesive, Part No. 19C525 or equiva-

lent, under the vinyl material with a

syringe as shown in Fig. 29.

Wrinkles

Do not confuse a wrinkle with a

bubble. Usually a wrinkle has small

radial folds with an excessive amount of

slack material which cannot be displaced

without rearranging the material. The

following repair procedure, for example,

RU0

FIG.

27 Application of Adhesive

R 1 4 1 1

FIG.

28 Fusing Cut with Soldering Iron

describes the correction of a wrinkle at

the front corner.

Partially or completely remove any

mouldings or ornamentation in the

immediate area of the wrinkle.

Pull the vinyl material free from the

roof panel up to the bonded seam and

along the side drip rail for approximately

10 inches.

Clean the surface thoroughly of t

old adhesive. Apply a thin film

adhesive to both the vinyl material a

R1412-A-

R141

FIG.

29 Expelling Air With

Hypodermic Needle

FIG. 30 Applying Heat With Heat

Gu n



46-20-13

Roof Outside Cover

46-20-13

along the drip rail. Allow the adhesive to

air dry for several seconds.

Grasp the material firmly, then draw

the material taut until all wrinkles are

removed as shown in Fig. 31. Fold the

material under the drip rail flange.

Secure the front edge of the material

with as many drive nails as needed to

prevent the material from creeping.

Apply sealer under the drive nail to

prevent possible water leak.

Install the mouldings and

weatherstrips.

Looseness

Loose vinyl roof material usually

occurs at padded areas of the vinyl roof

which is used only in certain body styles.

The following is a typical repair of loose

material at the blind quarter area and

generally applies to other areas such as

around the backlite opening.

Partially or completely remove

mouldings or ornamentation in the

immediate area to be repaired.

Carefully peel the edge of the material

free from the sheet metal.

Clean the metal surface thoroughly of

the old adhesive. Apply a thin film of

adhesive to both the vinyl and metal

surface. Allow the adhesive to air dry for

several seconds.

Grasp the material firmly, then draw

the material taut. Secure the edge of the

material with drive nails or sheet metal

screws as needed to prevent the material

from creeping.

Apply sealer over the drive nails or

sheet metal screws to prevent possible

water leaks. Install the mouldings.

Gap Between Vinyl Top and Moulding

In some instances, vinyl top material

that is to short to be concealed under the

roof moulding can be corrected by

adjusting the moulding or stretching the

material. If it is necessary to stretch the

material, pop rivets must be used to

prevent the vinyl from returning to its

original position. Should there be an

insufficient amount of material to allow

the use of pop rivets, the complete vinyl

top cover must be replaced. To determine

whether there is a sufficient amount of

material, perform the following

procedure:

1. If applicable, loosen the moulding

retainers and reposition the moulding

sufficiently to cover the edge of the

vinyl roof material. Re-torque the

moulding retainers. If the edge of the

vinyl material cannot be covered by

repositioning the moulding, proceed

to Step 2.

2.

Partially or completely remove the

moulding(s) or ornamentation in the

area in which the vinyl roof is too

short or gaps to the moulding(s).

Refer to Group 47 for removal and

R 1 4 1 5 - A

FIG. 31

Correcting Wrinkles

at

Front Corner

installation of exterior mouldings

and/or ornamentation.

3.

Carefully peel the vinyl material free

from the roof panel 4 to 6 inches.

4.

Using Silicone and Wax Remover

(D160-3721-A or equivalent) clean

the sheet metal surface thoroughly,

removing all of the old adhesive.

5.

Apply a thin film of adhesive (D4AZ-

19C525-A or equivalent) to both the

vinyl material and the sheet metal

surface and allow the adhesive to air

dry for several seconds.

6. With a heat gun, apply heat to the

vinyl, then grasp the material firmly

and stretch the material so it can be

installed beneath the moulding(s).

CAUTION: To avoid overheating the

vinyl, hold the heat gun about 12 inches

from the surface and constantly move the

gun in a circular motion.

NOTE: If after stretching the

material, it is evident that pop-rivets can

not be hidden by the mouldings, the vinyl

roof cover will have to be replaced.

However, if it is determined that the pop-

rivets can be used, proceed to Step 7.

7. Drill a sufficient number of 9/64 inch

diameter holes in the edge of the vinyl

to assure that it can be adequately

secured to the roof panel with

3815OO-S (1/8 x 3/8) pop-rivets.

8. Install the necessary pop-rivets and

reinstall the moulding(s) or

ornamentation removed in Step 1.

Separated Bonded Seam

Connect the soldering iron and set the



Clean the soldering iron tip

thoroughly with the abrasive pad. This

must be done frequent ly while

performing the repair to avoid vinyl

build-up on the tip. Start at one end of

the separated seam and insert the

lip

of

the soldering iron between the bonded

seam as shown in Fig. 32. Note the

position of the curved tip. Slowly move

the tip along the underside of the seam

following immediately with the fingers to

press the seam together.

Reverse the soldering iron tip as

shown in Fig. 33 and again slowly move

the tip along the edge of the seam.

This completes the repair and, if

performed correctly, should not require

paint touch-up. If, however, the vinyl

surface outboard of the seam has a glossy

or shiny appearance created by the

repair, the area can be restored :o its

original satin finish with a dulling agent

RU17-A

FIG.

32

Applying Heat

to

Underside

of Bonded Seam



46-20-14

Roof Outside Cover

46-20

or by applying liquid vinyl as shown in

Fig. 26. Several coats may be required.

The last coat should be a fog coat to

minimize gloss.

Adhesive Smears

Adhesive smears can be removed in

most cases, provided this is done

immediately and the adhesive is not

allowed to age on the vinyl roof.

Therefore, it is imperative tha t the clean-

up is performed as soon as possible. Fresh

sealer smears can be removed by rubbing

the smear off with a rubber cement pick-

up block such as the type described in the

list of materials.

R

FIG. 33 Applying Heat to Edge of Bonded Seam



46-30-1

W ood Grain Transfer

46-30-1

Wood Grain Transfer

DESCRIPTION

MODEL APPLICATION

Low Gloss Type

The low-gloss type is used on all

Squire Station Wagons.

High Gloss Type (KUX)

The high-gloss type (KUX) is used on

the Pinto Squire Station Wagon tailgate

only. The following c hart identifies wood

grain usage at the Assembly Plants (Fig.

1).

CR2856A

Assembly

Plant

Metuchen

San Jose

St. Thomas

Code

T

R

X

Wood Grain

Transfer Type

high gloss KUX type

low gloss 3M type

low gloss 3M type

R1936-A

FIG .

1 W o o d Gra in T ran s fe r Usage


PRESSURE SENSITIVE W O O D

GRAIN TRANSFER REPAIR

Low Gloss Type <3M)

It is not necessary to replace the vinyl

wood grain transfer because of blisters,

air bubbles, chips or scratches.

To repair b l is ters or air bubbles ,

pierce the air bubble or blister w ith a pin.

Work the trapped air out of bubble and

press the transfer firmly against the sheet

metal. It may be necessary to preheat the

metal slightly, to soften the adhesive.

For chips or scratches, use touchup

paint to repair the damaged areas. The

available pain ts are shown in Fig . 2 .

Refer to the master parts catalog for

par t numbers .

Color

Highlight Color (Dark Brown)

Solid Background Color (Light Brown)

Black

CR1488 C

FIG. 2 Wood-Grain Transfer Repair

Paints

High Gloss Type (KU X)

Repair procedures are the same as

low gloss type, except for repair in areas

of hem f lange, fuel f i l ler and door

depression.

If the wood-grain transfer lifts off the

sheet metal, check the recessed surface

for pin holes. If holes are evident, ex haust

the trapped air through the holes, ensure

the transfer is adhering to the sheet metal

and then patch the holes with a small

scrap of transfer to create the necessary

v acu u m to h o ld th e t r an s fe r in th e

depression.

If the transfer has lifted off the sheet

metal and holes are not evident, cut a slit

ap p ro x imate ly 1 /4 in ch lo n g in th e

transfer near the edge of the depression

(not in the depression or the vacuum will

be lost) to exhaust the air and adhere the

transfer to the sheet metal.

PRESSURE SENSITIVE W O O D -

GRAIN TRANSFER REPLACEMENT

Low Gloss Type

Removal

1. Remove the wood-grain plastic trim

rail(s) or mouldings.

2. Clean th e surface to be sure it is free

of dirt, oil, wax and/or other foreign

material. Use a clean rag, paper towel

or sponge wet with Silicone and Wax

R e m o v e r ( D L 6 0 - 3 7 2 1 - A o r

e q u i v a l e n t ) .

Be sure the flanges,

corners and any depressions are clean

t o a s s u r e m a x i m u m t r a n s f e r

adhesion.

3.

Repair the panel by metal finishing,

if required.

Installation

1. If the original grained transfer has

been damaged (scratched or cut) or

p a r t i a l l y r e m o v e d d u r i n g m e t a l

finishing, the damaged area should be

s a n d e d s m o o t h a n d t h e o r i g i n a l

transfer film feather-edged with 320-

grit or finer sandpaper.

2. Apply Lacquer Spot Putty (19B542

or equivalent) to the damaged area

with a squeegee or flexible glazing

knife to build up the surface tc the

level of the original film. This should

be done only on a small area. If the

damaged area is large, apply primer

with a spray gun to build up the

surface to the level of the original

film.

3.

Allow the primer or spot putty to dry

thoroughly . Then, sand the pr imer

and the entire grained panel with 320

grit or finer sandpaper. Repeat step 5

if necessary.

4.

If the repair is being made to a coor,

trim the existing transfer film from

the leading and trailing edges of the

panel. Sand the edges of the panel and

the inner surface of the flanges. Use

the same procedure for the trailing

edge of the fender and the leading

edge of the quarter panel.

5. Prep are a wetting solution by mixing

one ounce Liquid Car Wash (19B521

or equivalent) in a pail of warm water.

6. Cut the repair transfer to the desired

size, using care to align the wood

grain with the surrounding panels.

7. Place the transfer face down on a

clean bench or o ther su itab le f lat

surface and pull the paper backing off

the transfer film.

Be careful not to

stretch or tear the transfer Him.

8. Apply the wetting solution liberally to

the tacky side of the transfer and to

the panel being repaired with a rag or

sponge.

It is extreme ly important that

the vehicle panel surface, the transfer

film and the wetting solution all be at

a moderate temperature (at least 65

degrees F.) when performing this

repair.

Live steam, hot water cr an



46-30-2

W oo d Grain Transfer

46-30

electrically heated air blower may be

used to warm the panel. It may also

be used to soften the repair transfer

film to make it conform to the vehicle

panel and to aid in bending the

transfer around the panel edges.

9. Position the transfer film on the

panel. The presence of the wetting

solution will help to prevent the

pressure sensitive adhesive from

sticking to the panel. This permits

moving the transfer film to align the

simulated caulk lines or wood grain

pattern with the adjacent panels.

10. Smooth the transfer film on the panel

with a rag or sponge wet with the

wetting solution to remove large air

pockets.

11. Squeegee the transfer film on the

panel, working from the high point of

a con tour line on the panel. This will

remove the wetting solution from

between the transfer film and the

panel and allow the adhesive on the

film to stick to the panel. Remove any

air or water bubbles as necessary by

pricking them with a pin, and

squeegee.

12. Wrap the transfer film around the

edges of the door and quarter panels

and the trailing edge of the front

fender (as applicable). Apply heat to

the edges and press the transfer film

firmly against the f lange, and

squeegee.

13. Wipe the surface dry with a clean soft

cloth and install the grained plastic

trim rails or mouldings.

High Gloss Type (KU X)

Removal

Use same procedure as for low-g

woodgrain type.

Installation

Use the same procedure as for l

gloss type woodgrain, except in area

hem flange, fuel f i l ler and d

depression. It is imperative tha t suffic

heat (approximately 200°F.) be u

in these areas to prevent transfer f

lifting off the sheet metal. This can

accomplished with a Master Applia

Corp.

Heat Gun (Model HG501

equivalent. To install transfer in d

depression, follow steps in Fig. 3.

PIECE OF

PLASTIC OR

METAL SCALE

PIECE OF PLASTIC

OR METAL SCALE

1. INSURE THE DEPRESSION IS FREE OF MOISTURE.

2. HEAT SHEET META L IN DOOR DEPRESSION AREA

TO APPROXIMATELY 200°F, AND APPLY TRANS-

FER IN NORMAL MANNER.

3. WITH A PIECE OF PLASTIC OR METAL SCALE IN

PLACE AS SHOWN TO ALLOW THE TRAPPED A IR

TO ESCAPE. SO A VACUUM IS CREATED TO HOLD

TRANSFER FIRMLY IN DEPRESSION (DO NOT

PUNCH HOLES IN TRANSF ER). SQUEEGEE THE

TRANSFER FILM INTO PLACE AROUND THE HANDLE.

4.

PRESS THE FILM SECURELY INTO THE SHALLOW

DEPRESSIONS.

5. USING HOT AIR TO MAKE THE FILM PLIA BLE, CARE-

FULLY PRESS THE FILM INTO THE DEEP DEPRESSION-

EXHAUSTING THE TRAPPED AIR TOWARD THE PIECE

OF PLASTIC, WITH THE AIR EXHAUSTED, REMOVE

THE PLASTIC TOOL AND SMOOTH THE FILM.

R1937-A

FIG.

3 High Gloss W ood gra in Transfer Installation



47-00-1

Body Shell, Exterior Trim, Frame and Underbody 47-00

BODY SHELL, EXTERIOR T R IM ,

FRAME AND UNDERBODY


Body She ll, Exterior Tr im , Frame and

Underbody General Service 47-01


Ford and Mercury 47-05

LT D II , Cougar a nd LTD

II

Ranchero 47-06

Lincoln Continental 47-02

GROUP

(70000)

PART TITL E PART N

Maverick and Comet 47

Monarch and Granada 47-

Mustang 47-

Pinto and Bobcat 47

Thunderbi rd 47

CR2008

Body

Shell,

Exterior Trim , Frame

And Underbody General Service

P A R T

47-01

SUBJECT PAGE

G ENERAL INF O RM AT IO N

Body Side Protection Mouldings

(Pressure Sensitive Tape Type) 01-1

General Ho isting Instructions 01-2

Types of Body Sealer 01-1

DIAGNOSIS AND TESTING 01-4

ADJUSTMENTS

Body Al ignment 01-4

SUBJECT PAGE


Frame Al ignment

01-4

Frame Repairs 01-4

Unit ized Body Al ignment 01-4

CLEANING

AND

INSPECTION

Body Maintenance 01-5

Floor Pan Plugs and Grommets

01-5

Rattle Elimination 01-5

Trim 01-5

GENERAL INFORMATION

BODY SIDE PROTECTION

MOULDINGS (PRESSURE

SENSITIVE TAPE TYPE)

To install the optional body side

moulding (Tedlar

or

Urethane), wipe

the

area surface with naphtha

or a

suitable

cleaning solvent to remove all foreign

material. Then, remove protective paper

from pressure sensitive tape on the

mouldings. Position moulding

and

press

firmly to assure adhesion.

CN1842-A

TYPES OF BODY SEALER

Caulking Cord 19560

This sealer has

a

plastic base with

asbestos filler and is commonly know

permagum. It is used on spotweld ho



47-01-2

Body Shell, Exterior Trim, Frame and Underbody General Service

47-01-2

around moulding clips, or between two

surfaces not properly sealed by a gasket.

Apply with a putty knife.

Trim Cement 19C52S

This cement is recommended for

body panel plastic watershield and on

some soft trim installations and also

other vinyl and rubber trim.

Rubber Cement 19552

This quick-drying, strong adhesive

material is designed to hold weather

stripping

on

doors, bodies, deck lids,

cow.1

ventilators and the surrounding metal.

Windows and windshields which are set

in rubber can be sealed effectively against

leakage by flowing cement into the

affected areas.

Clean all grease, dirt, and old sealer

from the surfaces to be cemented and

apply a medium coat of cement to both

surfaces, allow it to dry until tacky, and

press both surfaces firmly together.

Silicon Lubricant 199532

JELLY

and

SPRAY

This lubricant is to be used on the

d o o r a n d m i n i - v e n t w i n d o w

weatherstrips. It is recommended that

silicone lubricant be applied to the

weatherstrips at every lubrication period.

Its use makes the doors easier to close,

avoids weatherstrip squeaks, retards

weatherstrip wear from chafing between

the door glass upper frame and the

weatherstrip, and helps to retain door

window alignment by reducing friction

between the glass frame and rubber

weatherstrip.

GENERAL HOISTING

INSTRUCTIONS

Damage to suspension, exhaust and

steering linkage components may occur

if care is not exercised when positioning

the hoist adapters of 2-post hoists. Place

the adapters under the front suspension

lower arms.

Do not allow the adapters to

contact the steering linkage.

O n t h e L i n c o l n C o n t i n e n t a l ,

Continental Mark V, Thunderbird, Elite

and Cougar, rear suspension lower arms

prevent positioning of fork lifts outboard

of the suspension lower arms. Place fork

lifts under th e axle housing inboard of the

suspension arm brackets.

Do not position hoist pads under

Number

3

crossmember.

Refer to the Owner's Manual when

using the jack supplied w ith the vehicle.

Maver ick , Comet Granada,

Mo narch, Pinto, Bobcat and

Mustang II

The unitized body-frame construction

r e qu i r e s spe c i a l p r e c a u t ions a nd

procedures when the vehicle is jacked up

or hoisted. In some cases, special hoist

adapters must be used as recommended

by hoist manufacturers.

Drive-On Type Hoist

To prevent damage to the underbody,

do not d rive the vehicle onto the drive-on

type hoist without first checking for

possible interference between the upright

f langes of the hoist rai ls and the

underbody. Should there be interference,

the hoist flanges should be modified as

necessary or the approach ramps built up

to provide the needed clearance.

Rail Type—Free Wheeling Hoist

Front

The front adapters or hoist plates

must be carefully positioned in contact

with the lower suspension arms to assure

safe,

accurate lifting.

Rear

The hoist adapters must

be

positioned

to avoid damage to the shock absorbers

when the vehicle is raised. The hoist rails

should be raised slowly and the position

of the adapters checked.

Fork Lif t—Twin Post Hoist

Front

To assure safe hoisting, the front post

adapters must be positioned carefully to

co nta c t the cen ter of the lower

suspension arms (Figs. 1 and 2).

Rear

To prevent damage to the shock

absorbers, the rear forks m ust contact the

axle at points not farther out board than

one inch from the circumference welds

near the differential housing. Carefully

raise the rear post and check the position

of the fork (Figs. 1 and 2).

Floor Jack—Pinto, Bobcat and

Mustang

When using a floor jack, the vehicle

may be raised at several locations. The

F R O N T R A I L T Y P E , F O R K L I F T

O R F L O O R J A C K C O N T A C T A R E A

front of the car may be lifted by

positioning the jack under the center of

the number two crossmember. The front,

as well as either side of

the

rear end. may

be lifted by positioning the floor jack

under the rocker flange at the contact

points used for the jack supplied wilh the

vehicle. To lift both sides of the rear at

once, position the floor jack under the

differential housing.

Floor Jack—Other Models

When a stationary floor jack or a roll

jack is to be used, there are several

specific recommended points of contact.

Either side of the vehicle may be raised

at the front by jack contact at the lower

arm strut connection. Either side of the

front end of the vehicle may also be raised

b y j a c k p r e s s u r e o n t h e f r o n t

crossmember, or on the crossmemter to

which the stabilizer is connected.

Do not

attempt to use jack pressure on either

front or

rear

Maverick, Comet, Granada,

Monarch, Pinto, Bobcat or Mustang

bumpers.

O n C o n t i n e n t a l M a r k V a n d

Thunderbird, position jacks under the

rear axle housing between the suspension

arm brackets and the differential

housing. Do not place jacks under the

suspension arm brackets. To unload ball

joint front suspensions, position jack as

shown in Fig. 3.

Frame Co ntact Ho ist

On frame contact hoists, adapte rs are

necessary to lift the vehicle. The ad apters

must be centered at four contact points

as shown in Fig.

4.

All four contact join ts

must contact the adapters.

REAR FRAME CONTACT AREA

FRONT FRAME CONTACT AREA

smm

M l l l l - l

FIG. 1 Front Hoist Contact Areas

REAR RAIL TYPE, FORK LIFT OR

FLOOR JACK CONTACT AREA M11 12-A

FIG.

2 Rear Hoist Contact Areas



47-01-3


47-01

NOTE : Exercise care when hoisting conv erter(s). On vehicles so equipped, and exhaust system components be

ve hi cle s eq u ip pe d w ith ca ta ly ti c assure necessary clearance between hoist energizing hoist.

FORD/MERCURY

LT D I I/COUGAR

CONTINENTAL MARK V

THUNDERBIRD

LINCOLN CONTINENTAL

PINTO/BOBCAT/MUSTANG

MAVERICK/COMET

GRANADA/MONARCH

FIG. 3 Front Suspension Lift Points for Ball Joint Unloading

D

i

m

e

o

n

A

B

C

D

Car Line

C

o

m

e

21.3

75.8©

82.7©

20.0

22.0

C

o

L

I

22.0

• 8 3 . 4 0

87 .4 ©

25.0

27.5

C

o

n

a

M

a

k

V

24.9

102.9

25.0

26.0

F

d

21.5

97.5

23.0

25.0

L

n

n

C

o

n

a

21.7

103.7

23.5

27.0

M

a

c

21.3

75.8®

82.7©

20.0

22.0

M

e

c

y

21.5

100.5

23.0

25.0

M

u

a

17.5

75.0

12.0

24.0

P

n

o

o

17.5

75.0

12.0

24:0

T

b

d

22.0

83.4

25.0

27.5

G

r

a

M

o

c

21.5

83.5

26.4

26.4

© 2 Door. (2)4 Door.

FIG.

4 Frame Contact Lift Points



47-01-4


4 7 - 0 1 - 4

DIAGNOSIS AND TESTING

Sealer locations should be considered

when checking for dust or water leaks.

The forward motion of the vehicle causes

any unsealed small opening in the lower

section of the body to permit air to be

drawn into the body. Dust will follow any

path taken by the air from the point of

entry into the passenger and luggage

compartments. Opening the ventilator air

ducts will equalize these pressures. Dust

accumulates in the rocker panel, and may

eventually work its way to the kick-up or

the rear body pillar, and follow the

contour of the wheelhouse into the

luggage compartment.

To eliminate dust leakage, determine

the exact point at which the dust enters.

The point of entry is often deceptive, in

that the dust may enter at one point, then

follow the passages formed by interior

trim to another point.

Under certain conditions, water can

enter the body at any point where dust

can enter. Any consideration of water

leakage must take into account all points

covered under dust leaks.

To determine the exact location of a

dust leak, it may be necessary to remove

the following trim from the vehicle:

1. Cowl trim panel.

2.

Quarter trim panel.

3.

Rear seat back and seat cushion.

4.

Luggage compartment floor mats,

spare wheel, and side trim panel.

5.

Center pillar trim on 4-door models.

6. Scuff plates.

After removing the trim, the location

of most leaks will be readily evideni The

entrance of dust is usually indicated by

a pointed shaft of dust or silt. Seal these

leaks, and road test the vehicle on a (dusty

road to make sure that all leaks are

sealed.

After the road tests, check for

indications of a dust pattern around the

door openings, cowl panel, lower part of

the quarter panel, and in the luggage

compartment.

Sometimes leaks can be located by

putting bright lights under the vehicle,

with the above components removed, and

checking the interior of the body oints

and weld lines. The light will show

through where leaks exist.

ADJUSTMENTS

UNITIZED BODY ALIGNMENT

Servicing the unitized body should

present no unusual difficulties or

necessitate additional equipment, other

than required for conventional frame and

body repair. The application of heat and

the use of heavy duty jacks must be

carefully controlled because of the

difference in the gauge of the metal in the

sub-frame of a unitized body and the

stress points developed in a single welded

unit construction. It is possible to pull

damaged areas back into alignment with

the use of l ight-weight jacks and

hydraulic equipment, without heating the

metal.

Rough-out badly damaged areas

before taking measurements for squaring

up a body. If necessary, remove the glass

from the damaged area to prevent

breakage. In severe cases, reinforcement

brackets and other inner construction

may have to be removed or cut to permit

restoration of the outer shell and pillars,

without excessive strain on the parts.

Straighten, install, and secure all such

parts in place, before attempting to align

the body.

In cases of severe or sharp bends, it

may be necessary to use heat. Any

attempt to cold-straighten a severely bent

bracket may cause ruptures of the welds

and may also cause cracks in the bent

part. Never heat the area more than a

dull red.

Checking Underbody for

Misa l ignm ent

The dimensions of the underbody

must be restored in the repair of major

body damage, to provide correct front

and rear wheel geometry. The underbody

dimensions are given in each Part of this

Group for the respective models. All the

dimensions are detailed to the center line

of existing holes in the underbody

assembly. Once the frame and suspension

members are aligned, the balance of the

repair can be performed.

BODY ALIGNMENT

When checking alignment of a badly

damaged body, be sure that all necessary

frame corrections have been made before

attempting to align the body.

Rough out badly damaged areas

before taking measurements for squaring

up a body. Remove the glass to prevent

breakage. In severe cases, reinforcement

brackets and other inner construction

may have to be removed or cut to permit

restoration of the outer shell and pillars

without excessive strain on the parts.

Straighten, install and secure all parts in

place before attempting to align the body.

In cases of severe or sharp bends, it

may be necessary to use heat. Any

attempt to cold-straighten a severely bent

bracket may cause ruptures of the welds

(if any) and may also cause cracks in the

bent part. Never heat the area more than

enough to give a dull red.

Check ing Body for Misal ignm ent

To align or square up a body, take two

opposite diagonal measurements between

the front, center, or rear pillars. Take the

measurements between reference points,

such as crease lines or weld joints which

are diagonally opposite each othe r, on the

two pillars being measured. Since all

measurements should be made from the

bare metal, remove all interior trim from

the checking points.

Do not attempt to correct any serious

m i s a l i g n m e n t w i t h o n e j a c k i n g

operation. This is particularly true if

other sections of the body also require

a l i g n i n g . A l i g n e a c h s e c t i o n

p ropor t iona te ly , un t i l the p roper

dimensions are obtained. If frame

alignment is questionable, refer to the

frame dimensions given in each Part of

this Group for the respective models.

FRAME ALIGNMENT

Frame misalignment can affect front

wheel alignment, body alignment and

the operation of the chassis parts .

Window glass cracks, door and window

opening troubles, and air or water leaks

at the doors are often caused by

improperly tightened body bolts or frame

misalignment.

Before checking frame alignment,

inspect all frame members for cracks,

twists, or bends. Check all welded

connections for cracks. Inspect the bolts

and body support brackets for looseness.

M a k e a n y n e c e s s a r y r e p a i r s o r

replacements.

FRAME REPAIRS

To prevent internal stresses in the

metal, frame straightening should be

limited to parts which are not severely

bent. If heat is needed to straighten a

frame member, keep the temperature

below 1200 degrees F. Excessive heat

may weaken the metal in the frame

members and cause permanent damage.

Electric welding equipment should be

used for all frame welding and heat

should be kept t o a minimum area so that



47-01-5


47-01

the hardness of the metal will not be

affected.

When a reinforcement is to be welded

to a frame side member, run the welds

lengthwise a long the s ide of the

reinforcement.

If a damaged frame member is to be

replaced, use the same method of

attachment as on the original fra

member . New bol ts , r equi red

replacement of parts, should be of

same specifications as the original bo

CLEANING AND INSPECTION

FLOOR PAN PLUGS AND

GROMME TS

Many plugs and grommets are used

in the floor pan and dash panel. The

floor-pan plugs seal the various access

holes. If any plugs are missing or

improperly installed, a dust or water leak

may result. This also applies to the

grommets used on the dash panel. When

dust or water leaks are evident, these

plugs and grommets should be checked

for proper installation.

RATTLE ELIMINATION

Most rattles a re caused by a loose bolt

or screw. Foreign objects such as nuts,

bolts, or small pieces of body deadener in

the door wells, pillars and quarter panels,

are often the source of rattles. Door wells

can be checked by carefully striking the

underside of the door with a rubber

mallet. The impact made by the mallet

will indicate if loose objects are in the

doorwell.

All bolts and screws should be

tightened periodically. In the event that

tightening the bolts and screws, located

on such assemblies as the doors, hood,

and deck lid does not eliminate the

rattles, the trouble is probably caused by

misalignment. If this is the case, follow

t h e a d j u s t m e n t a n d a l i g n m e n t

procedures for these assemblies.

Rattles and squeaks are sometimes

c a u s e d by w e a t h e r s t r i p p i n g a n d

antisqueak material that has slipped out

of position. Apply additional cement or

other adhesive, and install the material in

the proper location, to eliminate this

condition.

TRIM

The bright metal parts of the vehicle

require no special care. Periodic cleaning

will preserve the beauty and life of these

finishes. Wash with clear water, or if the

parts are very dirty use multi-purpose

cleaner (19523 or equivalent). Using a

clean soft cloth or a sponge and water,

rinse and wipe the parts dry. Chrome

Cleaner may be used sparingly to remove

rust or salt corrosion from chrome plated

parts. Do not scour aluminum or chrome

finished parts with steel wool or polish

them with products containing abrasives.

A custom silicone polish (19530 or

equiva lent ) wi l l provide exce l lent

protection for all bright metal parts.

BODY MAINTENANCE

Regular body maintenance preserves

the vehicle's appearance during the life of

the vehicle. The following steps

suggested as a guide for regular bo

maintenance.

1. Vacuum the interior thoroughly

wash the vehicle.

2. Check all openings for water le

and seal where necessary.

3. Cement all loose weatherstrips wh

are still usable.

4.

Replace all door and deck

weatherstrips which are unfit

service.

5. Apply si l icone lubricant to

weatherstripping.

6. Replace all cracked, fogged,

chipped glass.

7. Align the hood, doors, and deck

if necessary.

8. Inspect the windshield wiper bla

and replace them if necessary.

9. Tighten the sill plate and garn

moulding screws.

10.

Clean the seats, door trim panels,

headlining.

11.Touch up or paint chipped

scratched areas.

12. Drain holes located on the under

of each rocker panel, quarter pa

a n d d o o r , s h o u l d b e c l e a

periodically.



47-02-1

Lincoln Continental

47-02-1

Lincoln Continental

P A R T

47-02

SUBJECT PAGE

REMOVAL AND INS TALLATION

Exte rior Mouldings 02-1

Frame Dimensions 02-1

Front Bumper 02-1

SUBJECT PAI3£


Hidden Attachments 0 ;M

Rad iator Grille 02-1

Rear Bump er 02-1

CN2875-A


RADIATOR GRILLE

The radiator grille is attached to the

front of the vehicle with 8 nuts which can

be removed from the front of the grille

(Fig. 1).

FRONT BUMPER

Removal

1. Remove three (3) bolts attaching each

isolator to the bumper reinforcement

and, with an assistant, remove the

bumper and reinforcement from the

ve h ic l e . Be f or e r e m oving the

reinforcement-to-bumper attaching

bolts, the license plate bracket must

be removed first. Remove cooling slot

grille.

2. Remove the reinforcement- to-

bumper attaching bolts, and separate

the reinforcement from the bumper

(Fig. 2). Then, remove the stone

deflector.

3. Remove the bumper guards and pads

f rom the bumper . NOTE: The

bumper pad attaching tabs may be

dest royed upon removal , i f so

equipped. Damage will be avoided by

squeezing the retaining tabs with

pliers unti l tabs can be pushed

through holes in bumper.

4. Remove the license plate mounting

bracket from the bumper.

5. If the reinforcement is to be replaced,

transfer the bumper opening grille

and stone deflector to the new

reinforcement.

Installation

1. Install the bumper gu ards and pads

on the bumper.

2. Position the reinforcement to the

bumper and install the attaching

bolts. Install the cooling slot grille,

stone deflector and licence plate

mounting bracket.

3. Position the bump er and spacers to

the isolators and install the attaching

bolts.

4. Adjust the bumper height so that the

distance from the top edge to the

ground meets the specifications in

Fig. 4. Then, adjust the bumper for

body clearance at the centerline of the

parking lamp so that the vertical and

h o r i z o n t a l b o d y t o b u m p e r

dimensions meet the specifications in

Fig. 4. Tighten the isolator- to-

reinforcement bolts to 35-50 ft-lbs

torque.

REAR BUMPER

Removal





vehicle. Remove the opening shield

and licence plate mounting bracket.

Remove the push-on rub strips.

NOTE: The bumper pad attaching

tabs may be destroyed upon removal, if

so equipped. Damage will be avoided by

squeezing the retaining tabs with pliers

until tabs can be pushed through holes in

bumpers.


bumper attaching bolts (Fig. 3), and

separate the reinforcement from the

bumper.

3.

If the bumper is to be replaced,

transfer the bumper guards and pads

to the new bumper (Fig. 3).


transfer the stone deflector supports

and license plate lamp assembly to the

new reinforcement (Fig. 3).

Installation

1. Position the reinforcement i:o the


bolts. Tighten the bolts to 25-3>i ft-lbs

torque. Install opening shield and

license plate mounting bracket.

Install push-on rub strips.

2. P o s i t i o n t h e b u m p e r a n d

reinforcement to the isolator and

install the attaching bolts.






tail lamp so that the vertical and





torque.

EXTERIOR MOULDINGS






removed to provide access (Figs. 5 and

6). If a weld stud is distorted or broken

off, it should be replaced with an oval

head blind rivet (Part No. 383229 -S).

HIDDEN ATTACHMENTS

Refer to Fig. 7 for hidden positive

attachments placement.

FRAME DIMENSIONS

The Lincoln Contin enta l f rame

dimensions are shown in Fig. 8. The

frame checking and repair procedures are

given in Part 47-01.



47-02-2

Lincoln Continental

47-02

GRILLE

F IG .

1 Grille Installation—Lincoln Continental



47-02-3

Lincoln Continental

47-02-3

/^

FRONT BUMPER

REINFORCEMENT

ASSEMBLY -

17A919

FRONT BUMPER

- 3 8 3 6 1 5

FRONT BUMPER

PAD - 17C949

FRONT BUMPER

GRILLE - 178968

SCREW & WASHER

-5 63 01 (3 PLACES)

FRONT BUMPER PAD

17C881 - R H.

1 7 9 5 0 -

L.H.

INSERT - 17997

(2 PLACES)

BUMPER GUARD

- 17996

(2 PLACES)

SCREW & WASHER

- 385 764 (6 PLACES)

(35-50 FT-LBS TORQUE)

PACER - 1776

(UP TO 2 EACH SIDE)

SPACER - 17C832

(UP TO 3 EACH SIDE)

SCREW & WASHER

- 57052 (2 PLACES)


NUT & RETAINER

- 385485 (2 PLACES)

NUT & RETAINER

-383615 (5 PLACES)

NUT & RETAINER

-45 26 5 (4 PLACES)

— SCREW& WASHER

- 57049 (9 PLACES)

NUT - 357314

(2 PLACES)

LICENSE P LATE

BRACKET - 1 7A385

FRAME - 17A392

SCREW - 5 6301

(3 PLACES)

N1796-H

FIG . 2 Front Bumper Installation—Lincoln Continental



47-02-4

Lincoln Continental

47-02

REAR LAMP

(REF.)

REAR BUMPER

STOP BRACK ET

BOLT 17K755(R.H.)

17B965(L.H.)

REAR BUMPER

OPENING SHIELD

17C857

LICENSE PLATE

FRAME (KIT)

17A392

BUMPER END BRACE

17789 (R.H.)

REAR 17793 (L.H.)

BUMPER

17906

SCREW

25-38 FT-LB

GUARD

17984

PAD

(R.H.

- 17914,

L.H. - 17C996)

N1797

F IG . 3 Rear Bumper Installation—Lincoln Continental



47-02-5

Lincoln Continental

47-02-5

DOOR PARKING LAMP

21.67 ± 1 . 5 0

TOP OF BUMPER

TO GROUND

1.00

+

.5 0

- . 0 0

DEFLECTOR FRONT

BUMPER STONE END

BUMPER - FRONT

FRONT BUMPER

BUMPER REAR

LAMP ASSY. REAR

22.60 ± 1.50

TOP OF BUMPER

TO GROUND

REAR BUMPER

N2750-B

F IG .

4 Bumper Adjustment

Specifications—Lincoln

Continental



p

[T.

3

n

9

|

I'

I

o

VIEW A

ORNAMENT

N U T -

366121

NAME PLATE

- 138124

VIEW

B

SCREW - 56904

NUT

-

374046

S C R E W - 5 6 9 0 3

V IEW D

VIEW E

N2751-B



F

G

6

E

e

o

S

d

M

d

n

n

a

a

o

—

L

n

n

C

n

a



47-02-8

Lincoln Continental

47-0

F IG U R E -1 V IE W

MOULDING

- 6 0 5 1 7 C 4 4

RETAINER

71291B66

MOULDING

- 6520550

V I E W - D

N2860

FIG . 7 Hidden Attachments



FRAME AND BODY MOUNTS

1977 LINCOLN CONTINENTAL

7100394 FOR NO. 6 BODY MOUNT

2 REQ'D.

20 30 FT LB

NO.

FLATS

WITHIN 15

C

OF POSITION

SHOWN

NO .

1A BODY MOUNT R.H

NO.

1 A BODY MOUNT L.H

F" BODY MOUNT

9.07

NO. 6 BODY MOUNT

O.

3 BODY MOUNT

NO.

4 BODY MOUNT

6200157

2 REQ'D.

6200346

2 REQ'D.

BREAK OFF TOP

OF STUD AFTER

= IS TORQUED IN P

- ..60 IUSE TOP FRAME SURFACES AT «

• NO. 2 BODY MOUNTS

# B 0

DY MOUNTS AND K 4 BODY MOUNTS

NO . 5 BODY MOUNT

WITHIN AN AREA 1.75 R OF BODY MOUNT HOLE C,

(OR WITHIN .50 OF OUTSIDE PERIMETER

OF ABSORBER) AS LOCATING SURFACES FOR

SHIMMING OPERATION

SECTION G

NO.

6 BODY MOUNT

380618-S2

15-22 FT-LB

2 REQ'D.

FOR NO. 1A BODY MOUNT

1 40 FOR NO. 2 BODY MOUNT

34977S2

20-30 FT-LB

2 REQ'D.

383423-S2

2 REQ'D.

34979-S100

2 REQ'D.

35-45 FT-LB

SECTION D

NO .

3 BODY MOUNT

SECTION B

NO.

2 BODY MOUNT

1.02 MAX.

SHIMSTACK

387675-S100

2 REQ'D.

20-30 FT-LB

6500396 -2 REQ'D.

ABSORBER AND RETAINER ASSY

MUST BE ASSEMBLED WITH

FLATS AS SHOWN.

TAB IN

BODY (REF.)

SECTION E

NO.

4 BODY MOUNT

S REQ'D. I337673-S2

6500396 - ASSY

2 REQ'D.

6500154

2 REQ'D.

IDENTIFICATION WHITE

384294-S2

6200163

387676-S

.442 THICK SHIM, USE

ONE IF SHIM STACK IS

.565 OR MORE

6500145

.082 THICK

USE AS REQ'D.

387677-S

.082 THICK SPLIT SHIM

A MAX. OF 2 SPLIT SHIMS

TO BE USED AT EACH MOUNT

SPLIT SHIMS MUST BE INSTALLED

ON THE BOTTOM OF THE STACK

WITH THE TAB OF THE SHIMS

POINTING FORWARD.

387673-S2

387096-S 2

AS REQ'D.

OPT.

A MAX. OF 2 SHIMS IS

TO BE USED AT EACH

OF THE NO. 4 BODY MOUNT

SECTION A

*F"

BODY MOUNT

2 REQ'D.

I387675-S100

35-50 FT-LB

2 REQ'D.

SECTION C

TYPICAL 2 PLACES

NO. 1A BODY MOUNT

SECTION H

NO.

5 BODY MOUNT

BODY BOLTS AT NO. 1A. NO. 4. NO. 5 AND NO. 6

BODY MOUNTS HAVE LOCKING COMPOUND ON

THREADS. IF BOLTS ARE REMOVED A NEW

BOLT MUST BE INSTALLED.

N 1 3 2 1

FIG. 8 Frame Dimensions—Lincoln Continental



474)3-1

Continental Mark V

47-0

Continental MarkV

P A R T

47-03

SUBJECT PAGE


Exterior Mouldings

03-2

Frame Dimensions

03-3

Front Bumper , 03-2

SUBJECT

PA


Radiator Grille

03

Rear Bumper

03


RADIATOR GRILLE

Removal

1. Remove

13

radiator upper shield

attaching screws

and

remove

the

shield.

2.

Remove two nuts retaining each side

of the grille to the grille opening lower

panel (Fig. 1).

3. Remove two bolts attaching each side

of

the

grille to the g rille outer su pport

panels (Fig.

1).

4. Remove one bolt attaching the top

center

of

the grille

to

the hood latch

support, and remove the grille.

Installation

1. Transfer

the

grille ornament

bracket and clips to a new grille

grille is to be replaced.

2. Position the grille assembly

gr i l le opening. Ins ta l l

th

retaining nuts

and

five atta

screws finger tight.

NUT

&

WASHER

-45334(21 PLACE

NOTED:

A

G R I L L E - 8 2 0 0

B R A C K E T - 8 A 0 2 2

N170

FIG.

1

Grille Installation—Continental Mark

V



47-03-2

Continental Mark V

47-03-2

BOLT AND WASHER

57049«

SHIELD

17D808

U-NUT

383613

BUMPER

17750

N1710-I

FIG. 2 Front Bumper Installation—Continental Mark V

3.

Align the grille with the hood, grille

opening lower panel and the bumper.

Then, tighten the retaining nuts and

attaching bolts securely.

4.

Install the radiator upper shield.

FRONT BUMPER

Removal

1. Remove six bolts (three on each side)

a t t a c h ing the i so l a to r t o t he

reinforcement assembly (Fig. 2).

R e m o v e t h e b u m p e r a n d

reinforcement assembly from the

vehicle.

2. Remove the reinforcement assembly,

bumper guards and license bracket

pads (twelve bolts, seven nuts and two

screws) from the bumper.


tabs may be destroyed upon removal,

if so equipped. Damage will be

avoided by squeezing the retaining

tabs with pliers until tabs can be

pushed through holes in bumper.

Remove the stone deflectors.

Installation



bolts. Tighten the bolts to 25-38 ft-lbs

torque. Install opening shield and

license plate mounting bracket.

Install pads to bumper assembly (Fig.

2). Install bumper guards to bumper

and tighten attaching bolts 25-38 ft-

lbs.

torque.


reinforcement to the isolator and


3.

Adjust the bumper height so that the








Fig. 4 (zero clearance at sight shield).

Tighten the isolator-to-reinforcement

bolts to 35-50 ft-lbs torque.

REAR BUMPER

Removal

1. Remove three bolts attaching each

isolator to the reinforcement and,

with an assistant, remove the bumper

and reinforcement from the vehicle.



the reinforcement from the bumper

(Fig. 3).

3.


transfer the bumper guards and the

pads to the new bumper (Fig. 3).







Installation


bumper, and install the attaching

bolts (Fig. 3). Install the bumper

guards to the bumper. Tighten the



reinforcement to the isolator with the

shim(s) between the isolator and

reinforcement (Fig. 3). Install the

three attaching bolts at each isolator.


distance from the top edge to ihe



body clearance at the centerline of :he

tail lamp so that the vertical and



Fig. 4. Tighten the isolator- 10-

reinforcement bolts to 35-50 ft- bs

torque.

EXTERIOR MOULDINGS

NOTE: Determine position of

positive fasteners to preclude possible

damages.

Before removing the exte r ior






47-03-3

Continental Mark V

47-0

compar tment tr im panel must f ir s t be

removed

to

provide access (Figs.

5, 6

an d

7) .

If a

weld stud

is

distorted

or

broken

off, it should be replaced with an oval

head blind rivet (Part No. 383229-S).

FRAME DIMENSIONS

The Continental Mark V frame

dimensions are shown in Fig. 8. The

frame checking and repair procedures are

given in Part 47-01.

S P A C E R - 1 7 C 9 7 7

(AS REQUIRED)

SCREW & LOCKWASHER

- 385764

(6

PLACES)


NU T & WASHER

- 376785

(4

PLACES)


SCREW & WASHER

- 57048 (4 PLACES)


ISOLATOR (RE

U-NUT

45265

(8 PLACES)

P A D -

17K867

(2 PLACES)

PAD - 17914

(2 PLACES)

G U A R D - 1 7 8 9 4

NU T

&

W A S H E R - 5 7 0 4 8

(4 PLACES)


N1712

F IG . 3 Rear Bumper Installation—Continental Mark V

TURN LAMP

REAR BUMPER

FRONT BUMPER

24.04

± 1.50 - 1975

2 3 . 7 9 ± 1 . 5 0 - 1 9 7 6

TOP OF BUMPER

TO

GROUND

REAR BUMPER

FIG. 4

Bumper Adjustment Specifications—Continental Mark

V



47-03-4

Continental Mark V

47-03-4

FIGURE 1

V I E W - A

VIEW B

VIEW G

VIEW- H

VIEW I

VIEW J

N1714-O

FIG . 5 Exterior Side and Rear Moulding Installation—Continental Mark V



47-03-5


N274

FIG.

6 Exterior Side Moulding Installation—Continental Mark V

T

ORNAM ENT - DC078

N U T - 3 8 6 1 2 1

V I E W - A

PLATE - 138124

VIEW

MOULDING - 16A702

VIEW - C

N2748-B

FIG.

7 Front Ornamentation—Continental Mark V




1977 MARK V

17.10

,C_

OF FRAME

BODY MOUNT

NO.

6 BODY MOUNT

1@b

1@5

<22:5 1 @

1@5

6200 163

2 REQD.

RADIATOR SUPPORT REF. \ /

• 34979-S100

2 REQD.

35-45 FT-LB

387676-S

.450 THICK AS REQD.

MAX. OF 2 PER MOUNT

6500145

^

.090 THICK SPLIT SHIM AS REQD.

A MAX. OF 2 SPLIT SHIMS IS TO BE

USED

AT

EACH MOUNT. SPLIT SHIMS

MUST

BE

INSTALLED

ON

BOTTOM

OF THE SHIM STACK WITH THE TAB

OF THE SHIMS POINTING FORWARD

.70 - NOMINAL SHIM STACK

1.00

-

MAXIMUM SHIM STACK

387677-S

.090 THICK AS REQD.

6500396

2 REQD. COLOR CODE - WHITE "

6500155

2 REQ D. COLOR CODE - WHITE "

385163-S2

2 REQD 7/16-14

NUT

55-70 FT-LB BODY PART

4 REQD.

SECTION A FLOOR PAN '

"F " BODY MOUNT REF.

v

FRAME-

REF.

PROJECTION ON ABSORBER MUST

ENGAGE IN SLOT OF FRAME HOLE.

SECTION B

NO. 1 & IB BODY MOUNTS

BODY REF.

6500396

2 REQD.

COLOR CODE-

YELLOW

FRAME REF

NUT-BODY PART

2 REQD.

SHEET METAL

REF.

6500155

2 REQD.

COLOR CODE

-

RED

SECTION E

NO. 5 BODY MOUNT

SECTION G

NO. 2 BODY MOUNT

NUT-BODY PART

2 REQD.

^387675-S100

2 REQD

^S 35-50 FT-LB

1 ^ F L O O R PAN

WR F

387675-S100

4 REQD.

35-50 FT-LB

6500396

4 REQD.

COLOR CODE

-

RED

6500155

4 REQD.

COLOR CODE - RED

NUT-BODY PART

2 REQD.

6500155

2 REQD.

COLOR CODE

GREEN

SHEET METAL

REF.

6500396

2 REQD.

COLOR CODE

6500155 S J ^ a N YELLOW

2 REQD.

y

LLUJ 387674-S2

COLOR CODE-

2 REQD.

R E D

SECTION F

NO. 6 BODY MOUNT

2 REQD.

COLOR CODE-GREEN

FRAME REF.

SECTION C

NO. 3 BODY MOUNT

R2050-A

FIG.

8 Frame Dimensions—Continental Mark V



47-04-1

Thunderbird

47-0

Thunderbird

P A R T

47-04

SUBJECT PAGE


Exterior Mouldings

04-2

Frame Dimensions

04-2

Front Bumper

04-1

SUBJECT

PAG

REMOVAL AND INSTALLATION (Cont'd.)

Radiator Grille

04-

Rear Bumper

04-


REMOVAL OF GRILLE ASSEMBLY

To r emove the r ad ia to r g r i l l e

assembly, remove the ten nut and conical

washer assemblies from the back side of

the grille opening panel. Pull the rad iator

grille assembly forward until all locating

pins and studs are clear of the grille

opening panel.

REMOVAL OF RADIATOR GRILLE

FROM ASSEMBLY

1. Remove the two spring legs from the

notches on the bottom of the grille.

Remove the two screws at the hinges

and lift up and forward.

2. To remove the spring from the

surrounding moulding, remove the

three screws and rectangular washer.

NUT & WASHER

- 45334 (NOTED A)

(12 PLACES)

INNER HEAD LAMP

( 4

.

6

FT-LBS. TORQUE)

( R E F )

PANEL ASSY.

- 8 1 9 0

ORNAMENT ASSY.

- 8B343

N1791-F

FIG.

1 Radiator Gril le—T hunde rbird

CN4029-A

INSTALLATION

1. Place spring in the notches on

moulding. Bend on legs

rearward.

2. Attach screw and rectangular w

at the center bars.

3.

Attach the two outboard screw

rectangular washer.

4. Set the grille into the mould

Attach hinge and secure with

screws.

5. Snap spring leg into notches.

INSTALLATION OF ASSEMBLY

1. Place grille to front face of the A

grille assembly utilizing the loc

pins.

2. Secure grille assembly with ten

and conical washer assemblies.

FRONT BUMPER

1.

Remove the bumper from the ve

(six bolts) and remove the bum

and bumper guard- to-reinforce

attachments (five bolts and four

Fig. 2).

2. Remove the pad assemblies. NO

The bumper pad attaching tabs

be destroyed upon removal, i

equipped. Damage will be avoide

squeezing the retaining tabs

pliers until tabs can be pus

through holes in bumper.

3. Transfer the license plate and br

assembly to the new bumper if

bumper is to be replaced.

4.

Install the pad assemblies.



47-04-2

Thunderbird

47-04-2

SCREW AN D WASHER

56950

(3 PLACES)

SCREW AND LOCKWASHER

385107

(6 PLACES)

35-50 FT. LBS. TOR.)

NUT AND WASHER

376785

(10 PLACES)

(18 23 FT. LBS. TOR.)

NUT AND RETAINER

45265

(2 PLACES)

ISOL ATOR

< (REF )

SPACER

77C832

(AS NEIEDED)

NUT AND RETAINER

45265

(4 PLACES)

SCREW AND WASHER

56950

(10 PLACES)

BRACKET

17A385

BOLT

381169

(10 PLACES)

SCREW AND WASHER

57048

(2 PLACES)

FIG.

2 Front Bumper—Thunderbird

N1790-G



47-04-3

Thunderbird

47-0

5.

Position the bumper assembly

to the

vehicle and install the attaching bolts

snug (Fig.

2).



ground meets the specification in Fig.

3. Then, adjust the bumper for body

clearance at the centerline of the


h o r i z o n t a l b o d y

to

b u m p e r


Fig.

3.

Tighten

the

isolator-

to-

reinforcement bolts

to

35-50 ft-lbs

torque.

REAR BUMPER

1. Disconnect the license light wire from

under the vehicle.

2.

With an assistant, remove three bolts

attaching the reinforcement

to

each

isolator, and remove the bumper and

reinforcement from the vehicle (Fig.

4).

3.

Remove

the

re inforcement-

to-


the reinforcement from the bumper.

4.


transfer the bumper guards, pads and

license plate bracket

to the new

bumper. NOTE: The bumper

pad

attaching tabs may be destroyed upon

removal, if so equipped. Damage will

be avoided by squeezing the retaining



5.

Assemble the reinforcement to the


bolts.

6 . P o s i t i o n the b u m p e r and

reinforcement

to the

isolators

and



distance from

the top

edge

to the

ground meets the specification in Fig.

3.

Then, adjust the bumper

for

body

clearance at the centerline of the tail

l amp

so

t h a t

the

ve r t i ca l

and

h o r i z o n t a l b o d y to b u m p e r


Fig.

3.

Tighten

the

isolator-

to-


torque.

8. Connect the license light under the

vehicle.

EXTERIOR MOULDINGS

Befo re r emov ing the e x t e r i o r


the type

of

retainer used whether

a

respective door, quarter

or

luggage


removed

to

provide access (Figs.

5, 6

and 7). If a weld stud is distorted or

broken off, it should be replaced with an

oval head blind rivet (Part No. 383229-

S).

FRAME DIMENSIONS

The Thunderbird frame dimensions

are shown in Fig. 8. The frame checking

and repair procedures are given in Part

47-01.

2.96

GO.

-FRONT BUMPER

V 21.66 ±1.5 0 TO

BUMPER TO GR

EXT. ASSY.

PNL. OUTER

+ .38

- 3 8 V

1.25

DEFL. REAR BMPR

STONE END

BUMPER REAR

V 2 1 . 9 1

±

1.50 TOP

BUMPER TO GR

FIG. 3

Bumper Adjustment

Specifications—Thunder



47-04-4

Thunderbird

47-04-4

STONE DEFLECTOR

- 17808

SCREW & WASHER

- 384783

(7 PLACES)

VIEW A

SCREW

&

WASHER

- 384283

(8 PLACES)

M1182-K

FIG .

4

Rear Bumper Reinforcement Installation—Thunderbird

FIG. 5 Exterior Side Moulding Instal lation

—

Thunderbi rd

N2 / 45-A



47-04-5

Thunderbird

47-

FIG. 6 Optional Exterior Side Moulding Installation - Thunderbird



47-04-6

Thunderbird

47-04-6

FIG. 7 Optional Exterior Side Moulding Installation — Thunderbird

N2394-C




1977 THUNDERBIRD

1.25

'F "

BODY MOUNT

RETAINER ASSY. BODY PART

2 REQ'D.

6500396

2 REQ'D.

COLOR CODE

-

BLUE

6500155

f

2 REQ 'D .

COLOR CODE

BLUE

NUT-BODY PART

*

2 REQ'D.

SHEET METAL

REF.

I

C_OF FRAME

FLOOR PAN REF

FRAME REF

387674-S2

2 R E Q ' D .

387675-S100

2REO/ D.

35-50 FT-

SECTION C

NO.

3 BODY MOUNT

NO.

2C BODY MOUNT

/ * N O .

2 BODY MOUNT

SHEET METAL

REF.

6200 163

2 REQ'D.

RADIATOR SUPPORT REF.

SECTION E

NO. 5

BODY MOUNT

.70 - NOMINAL SHIM STACK

1.00 - MAXIMUM SHIM STACK

^387675-S1OO

/ , 2 REQ'D.

NUT-BODY PART

2 REQ'D.

=E=-^ 387677-S

.090 THICK AS REQ'D.

6500396

2 REQ'D. COLOR CODE - VIOLET

6500155

2 REQ'D . COLOR CODE - VIOLET

385163-S2

SECTION

G

NO.

2 BODY MOUNT - 4 DR. ONLY - 2 REQ'D.

NO.

1C BODY MOUNT - 2 DR. ONLY - 2 REQ'D.

NO.


RETAINER ASSY.

BODY PARTS

2 REQ'D.

SHEET METAL REF

387675-S100

4 REQ'D.

\ / 3 5- 5 0 FT-L B

ECTION A

BODY MOUNT

387676-S

.450 THICK AS REQ'D

MAX. OF 1 PER MOUNT

6500145

.090 THICK SPLIT SHIM AS REQ'D

A MAX. OF

2

SPLIT SHIMS IS TO

BE

USED AT EACH MOUNT. SPLIT SHIMS

MUST BE INSTALLED ON BOTTOM


OF THE SHIMS POINTING FORWARD.

\ ^ j 35-50 FT-LB

FLOOR

PAN

65003396

2 REQ'D.

COLOR CODE

GREEN

6200145

2 REQ'D.

SECTION

F

NO . 6

BODY MOUNT

2 REQ'D.


ENGAGE

IN

SLOT OF FRAME HOLE.

SECTION B

NO.

1 & 1B BODY MOUNTS

SECTION D

NO.

4 BODY MOUNT

H.D. SEDAN ONLY

R1794-E

F I G . 9 FrGme Dimensions—Thunderbird



47-05-1

Ford and Mercury

47-05 -1

Ford and Mercury

P A R T

47-05

SUBJECT PAGE


Exterior Mou ldings

05-7

Frame Dimensions 05-2

Radiator Grille 05-1

SUBJECT

PAGE

REMOVAL AND INSTAL LATION (Cont'd .)

Rear Bu mp er, Sedan

05 4

Rear Bumper, Station Wagon 05 7

CN2877A


RADIATOR GRILLE

Ford High and Low Series Center

Grille

The radiator grille is attached to the

front of the vehicle with six screws which

can be removed from the front of the

grille (Figs. 1 and 2). To install, simply

reverse the procedure.

RADIATOR GRILLE

Mercury High Series

Center G rille

1. Remove seven radiator center grille


the center grille from the vehicle.

2.

Position the center grille to the

veh ic le , and in s ta l l the seven

attaching screws.

Headlamp Moulding Assembly

(Mercury Only )

Removal

1. Open headlamp door and remove six

self-threading nuts that secure the

moulding to the door.

2. Close

the

door

and

remove

the

moulding assembly.

Installation

1. Position

the

m o u l d i n g

on the

headlamp door.

2.

Open the door and install six self-

threading nuts securing the moulding

to the door.

Headlamp Door Ornament

Removal

1. Open the headlamp door and remove

th e two self-threading nuts that

secure

the

ornament

to the

door.

2.

Close the door and remove ornament.

Installation

1. Position ornament on headlamp.

2.

Open door and install the two self-

threading nuts that secure the

ornament

to the

door.

Ford

Low

Series Headlight Doors

1. Remove two (2) upper bright screws

and lift door

out of

lower attaching

access notches in grille open panel

(Fig. 2).

2.

Position lower headlight door tabs

into notches in grille opening panel,

rotate door upward and rearward to

flush fit and install attaching bright

screws.

FRONT BUMPER

Ford

Removal

1. Remove six bolts (three on each side),

attaching the reinforcement to the

isolator (Fig.

5).

2. Remove

the

bumper assembly from

the vehicle. Remember to replace the

spacers between reinforcement and

mounting plate

(if

so equipped).

3. Remove the bumper guards (two

nuts).

4. Remove the re inforcement- to-

bumper (thirteen bolts and six nuts).

5.

Remove the license plate and bracket

assembly.

NOTE:

The

bumper

pad

attaching tabs may be destroyed upon

removal,

if so

equipped. Damage may

be avoided by squeezing the retaining



Installation

1. Install the license plate and bracket.

Install three new bumper pads, if so

equipped.

2.

Install the reinforcement assembly to

the bumper (Fig. 4). Torque nuts to

17-23 ft-lbs.

3. Install the bumper guards. Install 3

new bumper pads, if so equipped.

4. Position

the

bumper assembly

to the


snug.





body clearance

at

the centerline of the


h o r i z o n t a l b o d y to b u m p e r




torque.

Mercury

Removal

1. Remove six i s o la to r - to -bumper

reinforcement bolts and remove the

bumper assembly (Fig. 5).

2.

Remove the pad assemblies from the

bumper

(if

so equipped).

3. Remove the bumper guards.

4.

Remove the license plate and bracket

and remove the reinforcemen t from

the bumper (Fig. 5).



47-05-2

Ford and M ercury

47-05

HEADLAMP

HOUSING

ASSEMBLY

HEADLAMP COVER

TRIM

HEADLAMP

COVER

BAR

STONE DEFLECTOR

(CENTER)

HOOD LATC

SUPPORT

ASSEMBLY

HOOD LATC

SUPPORT

BRACE

GRILLE CENTER

MOUNTING BRACKE

N2535-C

F I G .

1 Radia tor Grille Installa tion - Ford High Series

NUT& RETAINER

45263 ( 2 PLACES )

SCREW & WASHER 57031

( 7-11 FT. LBS. TORQUE )

NUT & WASHER

45334 ( 10 PLACES )

( 3-6 FT. LBS. TORQUE )

SCREW & WASHER

57030 (4 PLACES )

7-11 FT. LBS. TORQUE )

WASHER & SEALER ASSY.

381923

(LOWER 3 STUDS EACH SIDE )

EXTENSION ASSY.

16A168( 2 PLACES)

NUT & RETAINER/

^*

45267 { 4 PLACES ) < ^

NUT 45257

(4 PLACES)

SCREW 55 974

(4 PLACES)

SCREW & WASHER

57030 (4 PLACES )

( 7-11 F T . LBS.

TORQUE)

DOOR ASSY.

13045 ( R. H.

13043 ( L. H. )

SCREW 56904 ( 4 PLACES )

(8-20 IN. LBS. TORQUE)

GRILLE 8150

SCREW 56904 ( 2 PLACES )

( 8-20 IN. LBS. TORQUE ) "

N

FIG.

2 Radiator Grille Installation—Ford Low Series



47-05-3

Ford and Mercury

47-05-3

HEADLAMP

COVER MOTOR

NOTE: SHIELD NOT USED

IN 1976

HEADLAMP

COVER

GRILLE

N2585-B

FIG.

3 Radiator Grille Installation—Mercury High Series

ISOLATOR ASSY-17C882

60-90 FT.-LBS.

385966 NUT AND

RET. 3 REQ'D. EA

TO FRONT OF BODY

REINFORCEMENT-17A919

385107 SCREW WASHER

3 REQ'D. EA. SD.

35-50 FT.-LBS.

FRAME

17C832

—l Ab

, V- REQ'D.

ISOLATOR-17C882

376785-S2 NUT AND WASHER ASSY.

2 REQ'D. EA. SD. 17-23 FT-LBS

-REINFORCEMENT-17A919

377687-S2 NUT AND

RETAINER 1 REQ'D.

EA . SD .

57G49-S2

SCREW AND

WASHER 2

REG'D.

EA .

SD .

25-38

FT-LBS

/-""36785-S;: NUT

1

REQ 'D. IEA. SD.

1 7 - 2 3 FT.-LBS.

2 REQ'D. L.H. SIDE

57048^52 SCREW AND

1 R

E Q : D .

R.H. SIDE

WASHER ASSY 25-38 FT-LBS

BOLT

1 REQ'D. EA. SD.

387169-S100

M 2 7 7 - O

FIG. 4 Front Bumper Installation—Ford



47-05-4

Ford and Mercury

47-05-

FRAME

ISOLATOR ASSEMBLY

17C882

56404-S2 3 REQ'D. EA. SD.

60-90 FT-LBS

REINFORCEMENT-17 A9 19 385107 SCREW AND

WASHER ASSEMBLY

3 REQ'D. EA. SD.

35-50 FT.-LBS.

REINFORCEMENT ASSEMBLY -17A919

376785-S2 NUT AND

WASHER ASSEMBLY

4 REQ'D. TORQUE

17-23 FT. LBS.

45265-S2 NUT AND RETAINER

1 REQ'D. |

45265-S2 NUT AND RETAINER

1 REQ'D. EACH SIDE

57049 SCREW AND

WASHER 2 R EQ'D.

EA. SD. 25-38 FT.-LB

J •

3 7 6 7 85 -S2NUI AN

WASHER ASSY. 1

REQ'D. EA. SD.

57048-S2 SCREW AND WASHER

1 REQ'D. 25-38 FT-LBS

57048 SCREW AND

WASHER 2 REQ'D.

L.H.SIDE

R.

H.SIDE

• ^ . 4 5 2 6 5 N U T

AND RET.

2 REQ'D. EA.SD.

387169-S100

BOL

1 REQ'D. EA. SD

N1751

FIG.

5 Front Bumper Installation—Mercury

Installation

Remember

to replace the spacers

between the bumper reinforcement and

isolator m ounting

face (if so equipped).

1.

Install the

reinforcement, license

plate and bracket to the bumper

assembly (Fig. 5).

2. Install the bumper guards.

3. Install the pad assemblies to the

bumper

(if so equipped).

4.

Position the bumper assembly to tHe

isolators and install the attaching

bolts snug.

5.











torque.

REAR BUMPER

Ford Except Stat ion Wagon

Removal

1. Open the luggage compartment and

disconnect the license light wire at the

connector.

2.

Remove three bolts (each side)

attaching the reinforcement to the

isolator and remove the bumper

assembly (Fig. 7).

3.

Remove ten bolts and four nuts and

remove the reinforcement assembly

(Fig. 7).

4.

Remove the bumper guards.

NOTE: The bumper pads attaching

tabs will be destroyed upon removal.

5.

Transfer the license plate and bracket

assembly to a new bumper if the

bumper is to be replaced.

Installation

1. Install the three new pads and

bumper guards (four bolts) to the

bumper, if so equipped.

2. Install the reinforcement to the

bumper assembly (ten bolts and four

nuts).

3.

Position the bumper assembly to the

isolators and install the attaching

bolts snug (Fig. 7). Replace spacers

reinforce men t- to- isolato r ( if so

equipped).

4.






tail lamp, so that the vertical and





torque.

5. Connect the license light wire to the

connector. ,

Mercury Except Station Wagon

Removal

1. Disconnect the license light wire fro

the connector and push the wire a

grommet through the lower panel

2. Remove three bolts (each sid

attaching the reinforcement to

isolator and remove the bump

assembly (Fig. 8).

3.

Remove the license plate and brac

assembly.

4. Remove six bumper to reinforcem

bolts.

5. Remove the three pad assemblies

so equipped.

6. Remove the bumper guards (fo

bolts) and separate the bump

assembly from the reinforcement.

Installation

1. Install the pads and bumper guards

the bumper. Install the retaining n

to the reinforcement. Assemble

bumper to the reinforcement with

attaching bolts.

2. Install the license plate bracket a

license plate to the bumper.

3.

Position the bumper assembly to

vehicle and install the isolator-

reinforcement bolts snug. Repl

spacers between reinforcement a

isolator face plate (if so equipped)

4. Adjust the bumper height so that

distance from the top edge to



47-05-5

Ford and M ercury 47-05-5

3.09 -• .41

- .34

PARKING

x

LAMP

D E F L E C T O R "

CAR AT 35.30'

FRONT —

BUMPER

FROM (£OF BUMPER

FORD

.75 +

1

21.91 ±

TOP OF

TO GR(

.6 0

.0 0

1.50

BUMPER

DUND

HEAD LAMP

DEFLECTOR

22.33+ 1.50

TOP OF BUM

:

E R

TO GROUND

FRONT

BUMPER

MERCURY AND CANADIAN MARQUIS

FRONT BUMPER

DEFLECTOR

REAR

-

BUMPER

CAR AT 34.39" FROM £ OF BUMPER

FORD

22.47 ± 1.50

TOP OF BUMPER

TO GROUND

MOULDING

\

-* •

^ ^

DEFLECTOR

REAR -*

BUMPER

>2.87 + .50

/ - .25

r

30 + .60

- . 0 0

22.52 ± 1.50

TOP OF

BUMPER

TO GROUND

MERCURY CAR AT 35.84" FROM <£ OF BUMPER

DOOR-REAR

LAMP

22.67 ± 1.50

TOP OF

BUMPER

TO GROUND

DEFLECTOR

STATION WAGON AT 35.00" FROM

q_

OF BUMPER

FORD

DEFLECTOR

STATION W AGON AT 35 .00" FROM <£ OF BUMPER

MERCURY

REAR BUMPER

N2586-C

F IG .

6 Bumper Adjustment Specifications—Ford, Mercury



47 -05-6

Ford and Mercury

47-05

384695 NUT AND

WASHER ASSY. 2

REQ'D.

EA. SD.

17-23 FT.-LBS.

BUMPER OPENING

SHIELD-17C857


BUMPER

377687 NUT AND

RETAINER ASSY.

1 REQ 'D. EA. SD.

57048 SCREW AND

WASHER ASSY 1

EA. SD. 25-38 FT-LB

57048 SCREW AND

WASHER ASSY. 2

REQ'D.

EA. SD.

25-38 FT.-LBS.

REAR LICENSE

BRKT. 13406

57049-S2 SCREW AND

WASHER ASSY 2 REQ'D.

25-38 FT-LB

385107 SCREW AND WASHER

ASSY. 1 REQ'D. EA. SD.

FIG . 7 Rear Bumper Installation—Ford Except Station W ag on

385764 SCREW A ND WASHER

ASSY. 2 REQ 'D. EA. SD.

30-55 FT.-LBS.

N1757-


BUMPER OPENING SHIELD-17C857

376785 - NUT AND

. WASHER ASSY.

/ 2 REQ'D. EA. SD. REINFORCEMENT

5 7 0 4 8 - S C R E W

AND WASHER

1 REQ'D. EA. SD.

25-38 FT-LB

3 8 7 1 6 9 - B O L T

2 REQ 'D. EA. SD.

REAR LICENSE BRACKET-13406

385764-S2 SCREW AN D WASHER

ASSY 2 REQ'D. EACH SIDE

35-50 FT-LB

N1568

FIG . 8 Rear Bumper Installation—M ercury Except Station W ag on



47-05-7

Ford and Mercury

47-05-7



body clearance at the centerline of

the tail lamp, so that the vertical

and horizontal body to bumper




torque.

5. Position the license plate wire

through the lower panel, seat the

grommet and connect the wire to the

connector.

Ford and Mercury Station

Wagon

Removal

1. Open the tailgate, disconnect the

license lights at the connectors and

push

the

grommets and w ires through

the lower panel and remove the

license lights.

2. Remove the license plate from the

bumper.

3. Remove three bolts attaching the

bumper assembly to the isolators, and

remove the bumper (Fig. 9).

4.

Remove nine bolts and four nuts,

bumper-to-reinforcement (Fig. 9).

5. Remove the bumper guards.

NOTE:

The bumper pads attaching tabs will

be destroyed upon removal.

6. Transfer the bumper bolts and

retainers and license bracket to a new

bumper if the bumper is to be

replaced.

Installation

1. Install four new pads and the bumper

guards to the bumper if so equipped.


bumper and install the attaching bolts

and nuts (Fig. 9).

3. Position the bumper assembly to the

vehicle and install the isolator- to-

reinforcement bolts snug. Replace the

spacers between reinforcement and

isolator face plate (if so equipped).

4.






tail lamp, so that the vertical and





torque.

5.

Install the license lights, position the

wires through the lower panel, seat

the grommets and connect the wires

to the connectors.

EXTERIOR MOULDINGS

Befo re r emov ing the ex te r io r





removed to provide access (Figs. 10

through 18). If a weld stud is distorted

or broken off, it should be replaced with

an oval head blind rivet (Pan: No.

383229-S).

FRAME DIMENSIONS

The Ford and Mercury sedan and

station wagon frame dimensions are

shown in Figs. 19 and 20. The frame

checking and repair procedures are given

in Part 47-01.

BUMPER GUARD

- 17984

BUMPER - 17906

4 5 3 4 4 - N U T A N D

CONICAL WASHER

2 REQ'D. 12-18 FT-LB

STONE DEFLECTOR SUPPORT

- 17D836 1 REQ'D. EA. SD .

3 7 7 6 8 7 - N U T A N D

RETAINER 1 REQ'D.

EA.SD.

REINFORCEMENT- 17A946

57048 1 REQ'D. EA.SD .

25-38 FT-LBS

376785

5 REQ'D.

17-23 FT-LBS

REAR BUMPER

OPENING S HI EL D- 17C857

SPACER - AS REQ'D.

17A761

17C977

SCREW AND WASHER

ASSY.

-

385107

3

REQ'D. EA.

SD .

35-50 FT-LBS

N1570-K

FIG.

9 Rear Bumper Installation—Ford and Mercury Station W ag on



47-05-8

Ford and Mercury

47-0

C k-

N258

FIG. 10 Exterior Side Moulding Installation—Ford



47-05-9

Ford and Mercury

47-05-9

2-D00R

4-D00R AND STATION WAGON

igh^--^

N2SII8-A

FIG. 11 Exterior Side Moulding Installation—Ford



47-05-10

Ford and Mercury

47-05-

© 0®

N258

FIG. 12 Exterior Moulding Installation—Ford



47-05-11

Ford and M ercury

47-05-11

N2590-A

F IG .

13 Rear Moulding Installation—Ford



47-05-12

Ford and Mercury

47-05-1

FRONT STATION WAGON-TYPICAL

REAR SQUIRE STATION WAGON

LEFT HAND SIDE SHOWN

RIGHT HAND SIDE

TYPICAL EXCEPT AS

SHOWN

VIEW A

REAR CUSTOM AND LTD STATION WAGON

LEFT HAND SIDE SHOWN

VIEW A

RIGHT HAND SIDE TY PICAL

EXCEPT AS SHOWN

£.—

@(HH)@©

FIG.

14

Exterior Side Mouldings—Ford Station W agon

N2 5 0



FIG. 15 Exterior Side Moulding Installat ion—Mercury

N1472-J



47-05-14

Ford and Mercury

47-05-

STATION WAGON

RIGHTSIDE

4-DOOR

©

©

N25

F IG .

16 Exterior Rear Side Moulding Installation—Mercury



47-05-15

Ford and Mercury

47-05-15

N2591-A

F IG .

17 Optional Exterior Side Moulding Installation—Mercury (with Fender Skirts)



47-05-16

Ford and Mercury

47-05

N2

FIG.

18 Exterior Rear Ornamentation—Mercury



FRAME

A ND

BODY MOUNTS

1977 FORD & MERCURY SEDAN

5A10 3 2 R

COLOR CO

BROWN

NO. 1 BO DY M O UNT*

NO. 1B BODY MOUNT

F

f l

F

NO. 6 BODY MOUNT

O. 4 BODY MOUNT

I

NO.

5 BODY MOUNT

T*NO. 3A BODY MOUNT

F" BODY MOUNT

VIEW Y

USE TOP FRAME SURFACES AT

M

1

BODY MOUNTS ANDtt 4 BODY MOUNTS

WITHIN AN AREA 1.75 R OF BODY MOUNT HOLE (OR WITHIN AN

AREA (OR WITHIN .50 OF OUTSIDE PERIMETER OF ABSORBER)

AS LOCATING SURFACES FOR SHIMMING OPERATION

3.23

6200346

,2REQ 'D .

SECTION F

NO. 6 BODY MOUNT

150 FORD

?53 MERCURY

V I E W Z

NO. 3A BODY MOUNT

R.H. SIDE SAME AS L.H.

SIDE EXCEPT AS SHOWN

SECTION C

NO. 3A BODY MOUNT

RAD. SUPPORT REF

6500145

.082 MIN. THK. IF REQ'D.

MAX. OF 6 PER MOUNT

386168-S2

4 REQ'D.

40-50 FT. LB

34978-S2

4 REG'D.

20-30 FT. LB.

REAR OF VEHICLE

325162-S2

2 REQ'D.

55-70 FT. LB.

SECTION E

NO. 5 BODY MOUNT

387673-S2

387096-S2

AS REQ'D.

OPT.

A MAX. OF 2 SHIMS IS

TO BE USED AT EACH

OF THE NO. 4 BODY M OUNTS

SECTION A

"F " BODY MOUNT

AL L BODY MOUNT HEIGHT

LOCATING DIMENSIONS ARE

REF. ONLY

HOLE IN SHIMS MUST BE

ALIGNED TO FLAT ON

RETAINER TO ALLOW

SHIM REMOVAL AS SHOWN.

V I E W Y

"F " BODY MOUNT

62001A42

2 REQ'D.

SECTION D

NO. 4 BODY MOUNT

Y~J \386179-S2

V= ) 4 REQ'D.

SECTION B

NO. 1 AND 1B BODY MOUNTS

•BODY BOLTS AT NO. 4 AND NO. 6 BODY MOUNTS

HAVE LOCKING COMPOUND ON THREADS. IF

BOLTS ARE REMOVED A NEW BOLT MUST BE

INSTALLED.

FIG. 19 Frame Dimensions — Ford and Me rcury — Sedan

N2



FRAME AND BODY MOUN TS

1977 FORD & MERCURY STATION WAGON

NUT 7/16-14

BODY PART

NO.

1 BO DY M O UN T*_

NO.

1B BODY MOUNT

NO. 6 BODY MOUNT

NO. 5 BODY MOUNT

I I

NO.

4 BODY MOUNT (REF.)

NO.

3B BODY MOUNT

I

NO.

3A BODY MOUNT

G

NO. 2 BODY MOUNT

#4-5.15

" F "

BODY MOUNT

VIEWX

USE TOP FRAME SURFACES AT

H 1 W|CIAI

V

BODY MOUNTS ANDH 4 BODY Vlt w Y

.92

NO. 3B MOUNT

I i/

BODY MOUNTS AND

H

4 BODY

MOUNTSWITHIN AN AREA 1.75 R OF BODY

MOUNT HOLE q_ (OR WITHIN .50 OF| |

OUTSIDE PERIMETER OF

ABSORBER)

il.S6

SECTION F

NO.

6 BODY MOUNT

NO.

3A BODY MOUNT

1.12 i t ';|

7100394

2 REQD.

20-30 FT-LB

8097 ^

2 R E Q ' D .

(20)

COLOR CODE -

GREEN

NO. 3A BODY M OUNT

V /

SECTION G FOR

NO.

2 BODY MOUNT

R.H. SIDE SAME AS L.H.

SIDE EXCEPT AS SHOWN

SECTION

H

NO.

3

BODY MOUNT SECTION

C

NO .

3 BODY MOUNT

6500163

2 REQ'D.

RADIATOR SUPPORT REF.

NCTE:

USE GUIDE PINS 5ZF 13306 OVER STUD AND ABSORBER

387330-S100

2 REQ'D.

20-30 FT-LB

SHOULDER OF THE NO. 1 LEFT AND RIG HT BODY MO UNT

TO INSURE THAT THE BODY IS CENTERED WHEN DECKED.

82 MIN. TH K. IF REQ'D

6 PER MOUNT

SECTION D

NO.

3B BODY MOUNT

4978-S2

4 REQ'D.

20-30 FT

398168-S2

4 REQ'D.

40-50 FT-LB

6500154

COLOR CODE -WHITE

SECTION A

F BODY MOUNT

SECTION B

NO.

1 AND IB BODY MOUNT

5A1O3

2 REQ'D.

COLOR CODE -WHITE

— REAR OF V E H I C L E - •

HOLE IN SHIMS MUST BE ALIGNED TO

FLAT ON RETAINER TO ALLOW SHIM

REMOVAL AS SHOWN.

V I E W X

"F "

BODY MOUNT

SECTION E

NO .

5 BODY MOUNT

ALL BODY MOUNT HEIGHT AND LOCATING

DIMENSIONS ARE REF. ONLY

BODY BOLTS AT 3B AND 6 BODY MOUNTS

HAVE LOCKING COMPOUND ON THREADS.

IF BOLTS ARE REMOVED A NEW BOLT

MUST BE INSTALLED.

N2640-E

F I G .

20

Frame Dimensions — Ford

and

Mercury — Station W agon



47-06-1

LTD II, Cougar and Ranchero

47-06-1

LTD II, Cougar and LTD II Ranchero

P A R T

47-06

SUBJECT PAGE SUBJECT PAGE


Exterio r Mouldings 06-3

Frame Dime nsions 06-6

Front Bumpe r 06-1

Radiator Gri l le 06-1


Rear Bum per, Ranchero 06-2

Rear Bum per, Sedan and Wagon 06-1

Underbo dy Dimensions 06-ti

CN4028A


RADIATOR GRILLE

LTD II and LTD II Ranchero

Removal

1. Remove screws attaching each

headlight door, lean forward to

disengage from locating pins and lift

away from the grille panels (Fig. 1).

2. Remove seven grille retaining nu ts

and one screw, and remove the grille

assembly (Fig. 1).

Installation

1. If the grille is to be replaced, transfer

the parking lights and emblem to the

new grille.

2. Position the grille assembly to the

vehicle and install the seven grille

retaining nuts and screws.

3.

Install the parking l ight socket

assemblies to the parking lights.

4. Place the headlight housing on

locating tabs and install the two

attaching screws to retain each

moulding.

Cougar

Removal

1. To remove grille, open the hood and

detach the six nut and washer

assemblies that attach it to the grille

opening panel (Fig. 2).

2. To remove headlamp doors, unscrew

the eight attaching screws and lift

from grille opening panel (Fig. 2).

3.

To remove grille opening panel, open

hood and detach the 12 nut and

washer assemblies (Fig. 2). Lift the

panel away. The panel may be

removed with the headlamp doors

and grille attached.

Installation

1. Locate studs on grille opening panel

with appropriate holes and 'set' into

place . At tach nut and washer

assemblies and torque to 4 to 6 ft-lbs.

2. Install headlamp doors with eight

screws each.

3.

L o c a t e s t u d s o n g r i l l e w i t h

appropriate holes in grille opening

panel. 'Set' studs into place and install

nut and washer assemblies with 4-6 ft-

lbs torque.

Hood Ornament

See Fig. 3 for installation procedure

for LTD II and Cougar (all models).

FRONT BUMPER

LTD II and Cougar

Removal

1. Remove three bolts attaching the

bumper re inforcement to each

isolator, and remove the bumper

assembly from the vehicle (Fig. 4).

2. Remove three screws attaching th e

stone deflector to the reinforcement,

and remove the stone deflector.

3.

R e m o v e th e s t o n e d e f l e c t o r

insulator(s) (Figs. 5 and 6).

4. Remove the reinforcement, end

braces and license plate mounting


5. Remove the bumper guards (4 bolts),

and the pads from the bumper.







Installation

1. Install the bumper guards on the

bumper.

2. Position the pads to the bumper and

push firmly at each attachment until

seated.

3.

Install the reinforcement, end braces

and license plate mounting b racket on

the bumper. Tighten bolts and nuts to

specified torque.

4. Install the front stone deflector

insulator(s) (Figs. 5 and 6).

5. Install the stone deflector on the

reinforcement.

6. Position the bumper assembly and

shims to the isolators, and install the

attaching bolts.




Figs. 7 and 8. The n, adjust the

bumper for body clearance so thai the

vertical and horizontal body to

b u m p e r d i m e n s i o n s m e e t t h e

specific ation s in Figs . 7 and 8.

Tighten the isolator- to-reinforcement


8. Lift up on the end deflector(s) and

install two-way tape. Then press

down on the end deflector(s) to

achieve a flush fit.

REAR BUMPER

All Models Except Ranchero

1. Disconnect the license light wires at

the connector. Push the grommet out



47-06-2


47-0

NUT & WASHER

- 45334

(6 PLACES)

(7-11 FT-LB TORQUE)

HEADLAMP DOOR -

13052 (R.H.)

13064 (L.H.)

P A N E L - 8 1 9 0

SCREW -

56904

(7 PLACES)

(8-20 FT-LB TORQUE)

GRILLE - 8150

N

F IG .

1 Radiator Grille—LTD II and LTD II Ranchero

NUT & WASHER

- 45334

(6 PLACES)

(4-6 FT-LB TORQUE)

HEADLAMP DOORS

13052 (R.H.)

13064 (L.H.)

SCREW- 56000

(8 PLACES)

NUT& WASHER

- 45334

(6 PLACES)

(4-6 FT-LB TORQUE)

G R I L L E - 8 2 0 0

N2504-C

F IG . 2 Radiator Gri l le—Cougar

of the lower back panel on s

models.

2.

Remove the reinforcement,

brackets and license bracket (S

only) from bumper (Figs. 9 and

NOTE: The bumper pad attac

tabs may be destroyed upon rem

if so equipped. Damage wi

avoided by squeezing the reta

tabs with pliers until tabs ca

pushed through holes in bumpe

3. If the bumper is to be repl

transfer the bumper guards, pad

license plate light to the new bu

4.

Ins ta l l the re inforcement ,

brackets and license bracket (S

only) on the bumper.

5.

Position the bumper assembly

spacers to the isolators, and insta

attaching bolts.

6. Adjust the bumper height so tha

distance from the top edge to

ground meets the specification

Figs. 7 and 8. The n, adjust

bumper for body clearance a

centerline of the tail lamp so tha

vertical and horizontal bod

b u m p e r d i m e n s i o n s m e e t

specific ations in Figs. 7 an

Tighten the isolator- to-reinforce




47-06-3


47-06-3

FOR LTD II ONLY

ORNAMENT -

8B343

VIEW - B

N1789-F

FIG.

3 Ornament Assemblies—Cougar and LTD II (all models)

7.

Connec t the license light wire. Seat

the wire grommet in the lower back

panel on sedan models.

Ranchero

1.

Disconnect the license plate lighi at

the connectors and remove the light

from the bumper.

2. R emo v e th e b o l t s a t tach in g th e

bumper arms to the frame rails and


3.

I f the bumper is to be replaced ,

transfer all parts to the new bumper.

4. To in s ta l l , p o s i t io n th e b u mp er

assembly to the vehicle frame and

install the attaching bolts finger ti^ht.

5.

A d j u s t t h e b u m p e r f o r a g o o d

appearance and tighten the attaching

bolts to specification (Fig. 11).

6. Install the license plate light, and

connect the wire at the connector.

EXTERIOR MOULDINGS

B e f o r e r e m o v i n g t h e e x t e r i o r



r esp ec t iv e d o o r , q u ar te r o r lu g g ag e


removed to provide access (Fig. 12). If a

weld stud is distorted or broken off, it

should be replaced with an oval head

blind rivet (Part No. 383229-S). Refer to

General Information (Part 47-01) for

installation of Pressure Sensitive Tape

Type (Bodyside Protection Mouldings).

REINFORCEMENT

- 1 7 A 3 8 5

SCREW & LOCK WASHER

-38 51 07 (3 PLACES)

(35-50

FT-LB TORQUE)

PAD -

17C881 (R.H.)

17C950(L.H.)

ISOLATOR - 17C882

SPACER -

17832 (UP TO 3)

NUT & RETAINER

-45265 (7 PLACES)

SCREWS WASHER

-387359 (7 PLACES)

GUARD ASSY

-

17996

SCREW & WASHER

-5 704 8 (2 PLACES)

N402(iA

FIG. 4 Front Bumper—LTD II and Cougar



47-06-4


47-0

DEFLECTOR

- 17779

SCREW & WASHER

- 56950

(3

PLACES)

V I E W B C

REINFORCEMENT

R E F

GRILLE

17B968

SCREW

&

WASHER

- 56920

(5

PLACES)

J f

v

v

i

BRACKET

- 1 7 D 9 0 4 /

TO

N U T -

45268

\

SHOWN

1 §

NU T -

42564

it?

IN POSITION

^ ^ ^ - B R A C E

X ^ 1 7D 8 54

\

ft

VIEW

-^SCREWS WAS

- 384931

V I E

' SCREW

&

WAS

V I E W

F I G 5

Front Stone Reflector—Cougar

REINFORCEMENT

(REF.)

^ ^

C L I P -

45268

|

B R A C K E T -

17D904

^ S P R I N G

^ ^ L ^

0 P

S C R E W -

56950

V I E W - A

SCREW & WASHER

\\ \

^ l l \ \ \

VIEWB

SCREW

&

WASHER

fe_ \ ^

-57032

NUT - *^

42564 VIEW-C

N4028-A

F I G 6 Front Stone Reflector—LTD



47-06-5 LTD II , Cou gar a nd Ranchero

47-06-5

PARKING LAMP

G.O.P.

BUMPER FRONT (REF.)

21.44 1 1 .5 0- MODELS

5 3 , 6 5 , 7 1

20.70 FOR MODEL 97

TOP OF BUMPER TO GROUND

GRILLE

BUMPER

VIEW- AA

MOULDING

1.251.25

FRONT BUMPER

TRIM FLANGE

REAR LAMP BEZEL

2.121.38

STONE DEFLECTOR END'

BUMPER REAR-

21.67 1 1.50 MODELS

53 , 65

TOP OF BUMPER

TO GROUND

OUARTER PANEL

MOULDING

1.251.25

REAR BUMPER

TRIM FLANGE

VIEW-D

•

TAIL LAMP BEZEL

2.20 + .50

- . 2 5

1

•QUARTER PANEL

t

TO FRT.

OF VEH.

I

V I E W - E

•BUMPER REAR

L.H. SHOWN

STATION WAGON ONLY

3 .151 .38

21.44 1 1.50 MODELS 53, 65 & 71


VIEW F

STATION WAGON ONLY

N2593-C

FIG. 7 Front Bumper Adju stme nt Specificat ions - LTD II and Cougar



47-06-6


47-0

FRAME DIMENSIONS

The Cougar and Ranchero fr

dimensions are shown in Figs. 25

26 . The underbody checking

#

and

pair procedures are given in Part

47

UNDERBODY DIMENSIONS

T h e C o u g a r

and

R a n c h

underbody dim ensions are shown in

25

and 26. The

u n d erb o d y ch ec

and repair procedures are give

Part 4 7 - 0 1 .

N2594-C

FIG. 8 Rear Bumper Adjustment Specifications—Cougar XR7



4 7 - 0 6 - 7


47-06-7

SPACER ASSY.

- 17C977

SPACER - 17A761

BOLT (35-50 FT-LB TORQUE)

ISOLATOR 17C884-5

FRAME

TO FRONT OF BODY

CLIP

3REQ'D

END BRACKET

17A881

REINFORCEMENT

- 17A946

SHIELD

17C857

1976 ONLY

U-NUT-

45265

(6 PLACES) SCREW & WASHER

- 57049 (2 PLACES)

TO FRONT OF BODY

NUT & WASHER

- 387685


BRACKET

- 17A881

ANTI-RATTLER

- 370677

(2 PLACES)

BRACKET

- 13406

B O L T -

387169

SCREW & WASHER

- 57049 (4 PLACES)

BOLT


SCREW & WASHER

- 57030 (2 PLACES)

CENTER PAD-17C997

TO FRONT OF BODY

P A D - 1 7 A 4 6 5

G U A R D - 1 7 9 8 4

PAD-17914 (R IGHT)

17C996(LEFT)

N1787-H

FIG.

9 Rear Bumper Installation—A ll Models Except Station Wa go n and Ranchero



47-06-8


47-06


END BRACKET-17A881-2

BOLK25-38 FT-LB TORQUE)

C L I P 3 R E O / D .

ISOLATOR-17C884-5

•BOLTI60-90 FT-LB TORQUE)


NUT(17-23 FT-LB TORQUE)

REINFORCEMENT

VIEW A

BUMPE

NUT AND RETAINER

377687-S2

BOLTI25-38 FT-LB TORQUE)

BUMPER-17906

BOLT

TORQUE 25-38 FT-LB

TO FRONT OF BODY

PAD-17A807

PAD-17914(RIGHT)

17C997ILEFT)

GUARD-17984

N1786

FIG. 10 Rear Bumper Instal lat ion—Station W ag on



47-06-9 LTD II, Cougar and Ranchero

47-06-9

AR M

17C870

SLEEVE BUMPER

386634

NUT& WASHER

- 384695


(REF.)

FRAME ASSY.

WASHER

-

44347

SPACER -

17924 (2 PLACES)

REINFORCEMENT

- 17C890

O L T -

383465 (2 PLACES)


SCREW - 57048


BUMPER -

17906

VIEW

(REF.)

FRAME ASSY

N16<:3-E

FIG. 1 1

Rear Bum per—R anchero

N2595-B

FIG. 12 Exterior Side Moulding Instal lation - LTD II



47-06-10

LTD II , Cougar and Ranchero

47-06

MODEL 65

FIGURE 1

, _ .

t ^

q > r z> —

MODEL 53-71 (MODEL 65 - SIMILAR FIGURE -

N2

FIG.

13 Exterior Side Moulding Installat ion - LTD



4 7 - 0 6 - 1 1


47-06-11

FIGURE 1

MODEL 65

FIGURE 3

MODEL 53D-K AND 65D-K ONLY

= ; ©

FIGURE 2

MODEL 53SHOWN

MODEL 71 TYPICAL

FIGURE 4

MODEL 53B AND 65B ONLY

N2597-B

FIG.

14 Exterior Moulding - LTD II



47-06-12


47-06

RANCHERO AND STATION WAGON

FIGURE

1

STATION WAGON

FIGURE

2

©

STATION WAGON

FIGURE

3

STATION WAGON

STATION WAGON

FIGURE

4

SHOWN

TYPICAL

FIGURE

5

N2

FIG. 15 Side Moulding Installation - LTD II



47-06-13

LTD

II,

Cougar

and

Ranchero

4 7 - 0 6 - 1 3

RANCHERO

RANCHERO

MODEL 97D

&

97R O NLY

MODEL 97K ONLY

STATION WAGON

FIGURE 3

©

FIG. 16

Rear Exterior M oulding Installat ion and Orname ntat ion

—

LTD

II



47-06-14


47-06-

®

F I G U R E - 1

FIGURE

2

TU-TONE F IGURE-3

FIGURE

-4

FIGURE

-5

L J Y

FIG. 17

Exterior Moulding Installation

- LTD II

and Ranchero



47-06-15


47-06-15

MODEL

65

FIGURE

-2

MODEL 53

FIGURE 3

N2763-B

FIG. 18 Exterior Side Moulding Installation — Cougar



47-06-16


47-06-1

SE

FIG. 19 Exterior Side Moulding Installation — Cougar

FIGURE

- 1

(T)YPICAL

( T )

SHOWN

MODEL 53 SHOWN - MODEL 71 TYPICAL FIGURE - 1

FIGURE

- 2

0©0©

II h

©

N2762-

FIG. 20 Exterior Side Moulding Installation - Cougar



47-06-17

LTD II , Cougar and Ranchero

47-06-17

©

©

* s

©

©

©

©

©

D

N27(.3-B

FIG.

21 Exterior Side Moulding Installat ion

—

Cougar Station Wagon



47-06-18


47-06-

FIGURE - 1

FIGURE 2

N2764

F I G . 22 Exterior Side Moulding Instal lat ion — Cougar Station Wagon

FIGURE 1

®

N276

F I G .

23 Exterior Rear Moulding Instal lat ion — Cougar Squire Station Wagon



47-06-19

LTD II , Coug ar an d Ranchero

47-06-19

N2?66-B

FIG. 24 Rear Exterio r Mou lding Installation - Cougar XR7




1977 LTDII. COUGAR & 2 DOOR & 4 DOOR

1.25

NO. 1 BODY MOUNT

NO.

1B BODY MOUNT

NO. IC BODY MOUN T

,<£ OF FRAME

FLOOR PAN REF.

1 0

FRAME REF

387674-S2

2 REQ 'D.

387675-S100

2 REQ 'D.

35-50 FT-L

RETAINER ASSY. BODY PART

2 REQ 'D.

2 REQ 'D.

COLOR CODE -

BLUE

6500155

2 REQ 'D.

COLOR CODE

BLUE

ECTION C

NO . 3

BODY MOUNT

'F " BODY MOUNT

NO. 6 BODY MOUNT

387675-S100

2 REQ'D.

35-50 FT-LB

0

6500396

2 REQ'D.

NUT-BODY PART

2 REQ 'D.

6200 163

2 REQ 'D.

RADIATOR SUPPORT REF

387676-S


MAX. OF 1 PER MOUNT

6500145

.090 THICK SPLIT SHIM AS REQ'D.

A MAX. OF 2 SPLIT SHIMS IS TO BE

USED AT EACH MOUNT. SPLIT SHIMS

MUST BE INSTALLED ON BOTTOM


OF THE SHIMS POINTING FORWARD.

SHEET METAL

REF..

SHEET METAL

REF.

F RAM E REF .

.70 - NOMINA L SHIM STACK

1.00 - MAXIMUM SHIM STACK

387677-S


6500396


6500155


385163-S2

2 REQ 'D.

55-70 FT-LB

SECTION E

NO . 5 BODY MOUNT

SECTION A

'F "

BODY MOUNT

5B097

SECTION G

NO . 2 BODY MOUNT 4 DR. ONLY - 2 REQ'D.

NO .


NO. 2C BODY MOUNT - 4 DR. ONLY - 2 REQ'D.

RETAINER ASSY.

BODY PARTS

2 REQ'D.

SHEET M ET AL REF .

FRAME REF. '

NUT-BODY PART

2 REQ'D.

6500396

2 REQ 'D.

COLOR CODE

387674-S2

2 REQ 'D.

SECTION F

NO. 6 BODY MOUNT

387675 S100

2 REQ 'D.

35-50 FT-LB

FLOOR PAN

65003396

2 REQ 'D.

COLOR CODE

GREEN

6200145

2 REQ 'D.

GREEN



SECTION B

NO. 1 & 1B BODY MO UNTS

6500155

2 REQ 'D.

' ^ 3 8 7 6 7 4 - 8 2

2 REQ 'D.

SECTION D

NO.

4 BODY MOUNT

H.D.SEDANONLY

N17S8-H

FIG.

25 Frame Dimensions - Sedan - LTD II and Cougar



FRAME

AND

BODY MOU NTS

1977 LTD II & COUGAR STATION WAGON

C_OF FRAME

" F "

BODY MOUNT

NUT-BODY PAR

2REQ 'D .

SHEET ME

REF.

RADIATOR

SUPPORT REF.

6500145

.450 THICK AS

REQ'D. MAX.

OF

1 PER MOUNT

6500145

.090 THICK SPLIT SHIM

AS REQ'D.

A

MAX.

OF

2 SPLIT SHIMS

IS TO BE

USED

AT

EACH MOUNT

SPLIT SHIMS MUST BE

INSTALLED

ON

BOTTOM OF THE SHIM

STACK WITH THE TAB

OF THE SHIMS POINT-

ING FORWARD.

34979-S100

2 REQ'D.

35-45 FT-LB

.70-NOMINAL SHIM STACK

1.00-MAXIMUMSHIM STACK

387677-S


6500396

2 REQ'D. COLOR CODE

FRAME

REF.

6500155

2 REQ'D. COLOR CODE

385163-S2

2 REQ'D.

55-70 FT-LB

SECTION A

' BODY MOUNT

FRAME REF

387674-S2

2 REQ'D.

SECTION E

NO. 5 BODY MOUNT

VIO L ET

FLOOR

PAN REF

FRAME '

REF.

SECTION

G

NO. 2 AN D 2C BODY MOUNT

VIOLET

7/16-14 NUT

BODY PART

4 REQ'D.

NUT-BODY PART

2 REQ'D.

387674-S2

4 REQ'D.

SECTION

C

NO. 3 BODY MOUNT

387675-S100

2 REQ D.

35-50 FT-LB

387675-S100

2 REQ D.

35-50 FT-LB

FLOOR

^ /REF.

387674-S2

2 REQD.

SECTION

F

NO. 6 BODY MOUNT

6500396

2 REQ'D.

COLOR CODE

GREEN

145

2 REQ'D.



SECTION B

NO. 1 AND 1B BODY MOUNTS

N13

F I G . 26

Frame Dimensions

-

Tor ino

and

Cougar Station Wagon

and

Ranchero



47-08-1

Maverick and Comet

47-0

Maverick and Comet

P A R T

47-08

SUBJECT PAGE

REMOVAL AND IN STALLATION

Exterior Mouldings 08-2

Front Bumper 08-2


SUBJECT

PAGE

REMOVAL AND INSTALLATION (Con t'd .)

Rear Bump er 08-2

Underbody Dimensions 08-2

CN2874-A


RADIATOR GRILLE

Maver ick and Comet

Removal

1. Comet— Open the hood and remove

the two retaining screws in the center

COMET

of the grille and one snap rivet at each

end of the grille (Fig. 1).

2. M a v e r i c k — O p e n t h e h o o d a n d

remove two screws at the top center

of the grille, and one screw behind the

grille at the center (Fig. 1). Remove

the snap rivet at each upper corn

the grille.

Disconnect the parking light wir

the multiple connectors. Remov

t wo met a l s crews at t ach in g

parking light ground wires at

SCREW-55929

FIG.

1 Radiator Grille—Maverick Shown—Comet Similar



47-08-2

Maverick and Comet

47-08-2

radiator support. Remove the parking

light bracket attaching screws, and

remove the grille and parking lights.

4. Remove the parking lights and grille

mounting brackets from the grille.

5. Center bar: spread snap-on fingers

and remove.

Installation

1. If a new grille is being installed,

transfer the lower locating pin

grommets to the new grille.

2. Position the parking lights and grille

mounting brackets to the grille.

Install the two retaining nuts for each

parking light and support.

3.

Position the grille assembly to the

vehicle. Be sure the lower locating

pins are inserted^ into the stone

deflector's grommets.

4.

Connect the parking light wire

connectors and install the two screws

attaching the parking light ground

wires to the radiator support.

5.

Install the two center grille support

retaining screws (Comet) or three

screws (Maverick), and the grille end

to mounting bracket's snap rivets.

FRONT BUMPER

Maver ick and Comet

Removal

1. Raise the front of the vehicle.

2.

Remove six bolts attaching the

bumper assembly to the isolators and


3. Remove the license plate and bracket

assembly.

4.


stone deflector to the reinforcement.

(Comet Only).

5.

Remove the reinforcement assembly

from the bumper.

Installation

1. If a new bumper is installed, transfer

the bumper guards (Fig. 2). Attach

the license plate retaining nuts to the

bumper.

2.

Position the reinforcement to the

bumper and install the attaching bolts

and nuts.

3. Position the stone deflector to the

re in fo rcemen t and in s ta l l the

attaching screws. (Comet Only).

4.

Install the license plate and bracket

assembly.

5.

Position the bumper assembly to the


snug.


distance from the top edge of the



body clearance so that the vertical


dimensions meet specifications in Fig.

4 .

T i g h t e n t h e i s o l a t o r - t o -

reinforcement attaching bolts to 35-

50 ft-lbs torque. Tighten absorber

to underbody mounting bolts to

90-120 ft-lbs torque.

REAR BUMPER

Maver ick and Comet

Removal

1. Disconnect the license plate lamp

wiring at the socket behind the

reinforcement.

2. Remove four bolts attaching the

reinforcement to the isolators, and

remove the bumper assembly.

3. Remove the license bracket from the

b u m p e r . R e m o v e t w o s c r e w s

retaining the license plate light to the

bumper and remove the light.

4. Remove the nuts and bolts attaching

the reinforcment to the bumper, and

separate the reinforcement and

bumper guards (if so equipped) from


Installation

1. Position the reinforcement and

bumper guards (if so equipped) to the

bumper, and install the bolts and

nuts. Tighten nuts to specification

given in Fig. 3.

2.

Install the license bracket on bumper,

and tighten bolts to specification (Fig.

3).

Position the license plate light to

the bumper and install the two

attaching screws.

3.

Position bumper assembly to the

isolator and install the attaching

bolts.


4.




Fig. 4. Then adjust the bumper for

body clearance at the centerline :>f the

ta i l lamp so tha t the ve r t ical

dimension meets the specifications in

Fig. 4. Tighten the isolator-to-


torque.

5. Reconnect the license plate lamp

w i r i n g a t t h e s o c k e t b e h i n d

reinforcement.

EXTERIOR MOULDINGS

Befo re r emov ing the ex te r io r






through 11). If a weld stud is distorted

or broken off, it should be replaced with

an oval head blind rivet (Part No.

383229-S). Refer to G eneral Information

(Part 47-01) for installation of Pressure

Sens i t ive Tape Type (Body Side

Protection Mouldings).


The Maverick and Com et under body

dimensions are shown in Fig. 14 The

u n d e r b o d y c h e c k i n g a n d r e p a i r

procedures are given in Part

47-01.

BUMPER OPENING

SHIELD-17D808(R IGHT)

17D823(LEFT)

STONE DEFLECTOR

(COMET SHOWN 17779

PAD17A465

-CENTER PAD-

17C949

BUMPER-17757

M 7 7 8 - D

FIG. 2 Front Bumper Installation—Maverick and Comet



47-08-3

Maverick and Comet

47-0

SPACER -17C97 7

17A761

N2399-F

F IG .

3 Rear Bumper Instal lat ion—Maverick and Comet

BUM

TOP

OF

BUMPER

TO GROUND

21.36+ 1.50

FRONT BUMPER AT 27.20"

FROMCENTERLINE

TAIL -LAMP

4.05

+

.35

- . 2 5 M A V E R I C K

3.93 +

.35

- . 25 COMET

3.09+.25 COME

3.28

+

.25

- .25 MAVE

BUMPER

REAR BUMPER

N2

F IG . 4 Bumper Adjustment

Specif ications—Maverick

Comet



47-08-4

Maverick and Comet

47-08-4

FIG. 5 Exterior Side Mouldings—Maverick—2-Door Model

N: 400-C

; / /

N2759-C

FIG. 6 Exterior Side Moulding Installat ion—Maverick—4-Door Model



47-08-5

Maverick and Comet 47 -0

N

F IG .

7 Exterior Side Mouldings—Comet



47-08-6

Maverick and Comet 47-08-6

v

" ' " - ^ .

®

N2 »05-C

FIG.

8

Optional Exterior Side Mouldings—Maverick

and

Comet



47-08-7

Maverick and Comet

47-0

F IG . 9 Optional Exterior Side Mouldings—Pressure Sensitive Tape Installation—Maverick and Comet

F IG . 10 Opt ional Roof Side Mouldings—Maver ick and Comet—2-Door Model



47-08-8

Maverick and Comet

47-08-8

(A) SHOWN

C§) TYPICAL

© SHOWN

(B) TYPICAL

SHOWN

CF) TYPICAL

N2403-C

FIG. 11 Exterior Rear Mouldings—Maverick and Comet



M.C.H. IN MEMBER-FLOOR SIDE REAR

M.C.H. I N EXTENSION FRONT SIDE MEMBER

HOLE IN MEMBER - FRONT

FLOOR SIDE C R O S S # 2

26 52

C.H.

IN MEMBER-FLOOR SIDE REAR

13.59-

26.90A 30.10

A ) FRONT BUMPER-ARM REAR MOUNTING HOLE (M.C.H.)

OUTSIDE OF MEMBER-FR ONT SIDE OUTER

FRONT MOUNTING HOLE INSIDE OF

ADAPT ER-FRO NT SUSPENSION LOWER ARM

43:69

PLAN VIEW

NOTE: ALL PLAN VIEW DIMENSIONS SHOULD BE PROJECTED

DOWNWARD & MEASURED ON A SURFACE W HICH IS

PARALLEL TO SIDE VIEW BASELINE.

DIAGONAL DIMENSIONS MUST BE EQUAL.

DIMENSIONS UNDER 100" HAVE A TO LERANCE OF + .06

DIMENSIONS OVER 100" HAVE A TOLERANCE OF + .12

C ) UPPER STEERING GEAR MO UNTING

HOLE L.H. (M.C.H.) INSIDE OF

MEMBER-FRONT SIDE INNER

D ) UPPER IDLE R-A RM BRACKET MOUNTING

HOLE R.H. SIDE (M.C.H.) INSIDE OF

MEMBER-FRONT SIDE INNER

REAR SPRING FRONT HANGER HOLE IN

MEMBER-FLOOR SIDE REAR

REAR SPRING REAR HANGER HOLE

IN MEMBER-FLOOR SIDE REAR

BASELINE

SIDE VIEW

116.95 2 DR.

123.85 4 DR.

M.C.H. = MASTER CONTROL HOLE

C.H.

= CONTROL HOLE

N

FIG. 12 Underbody Dimensions—Maverick and Comet



47-09-1 Pinto and Bobcat

47-09-1

Pinto and Bobcat

P A R T

47-09

SUBJECT PAGE

REMOVAL AND INS TALLATIO N

Exterior Mouldings 09-2

Front Bumper 09-1

Rad iator Grille 09-1

SUBJECT

PAGE

REMOVAL AND INSTA LLATIO N (Con t 'd . )

Rear Bum per 09-2

Underbo dy Dimensions 09-3


CN2876-A

RADIATOR GRILLE

Pinto

Removal

1. Open the hood and remove the two

parking lamp bulb and socke t

assemblies from the parking lamps by

r o t a t i n g t h e b u l b s o c k e t s

counterclockwise and pulling them

out of the lamp assembly.

2. Remove six grille attaching screws

(Fig. 1), and remove the grille.

3.

If the grille is to be replaced, remove

two screws attaching each parking

lamp to the grille and install them on

the replacement grille.

4. Replace any damaged clip nuts or

retainers.

Installation

1. Position the grille to the vehicle and

install the six attaching screws

loosely.

2.

Align the grille for a good appearance

and tighten the six attaching screws.

3.

Position the parking lamp bulb and

socket assemblies in the parking

la m ps , a nd r o t a t e t he soc ke t

clockwise to lock into place in the

parking lamp.

4. Check the operation of the parking

lamps and turn signals.

Bobcat

Removal

1. Open the hood and remove one screw

from the top of the grille, which

a t taches to the radia tor gr i l le

mounting bracket (Fig. 2).

2. Remove one attaching screw that

attaches to the hood latch support

bracket, located at the bottom center

of the grille.

3.

Remove four attaching screws, two

on each side of the grille, that attach

to the parking lamp housing, and

remove grille from car.

Installation

1. Position grille in vehicle and install

four screws, two on each side, loosely.

2.

3.

Install lower attaching screw and

upper attaching screw, loosely.

Adjust grille to obtain a 0.532-inch

uniform gap between the sight shield

and grille, and a similar uniform gap

between the hood moulding and the

top of the grille, then, tighten the

upper and lower attaching screws.

SCREW & WASHER

- 57030

SCREW- 56904

(5 PLACES) '

BRACKET

8A036

RADIATOR GRILLE

- 8 2 0 0

FIG. 1 Radiator Gri l le—Pinto



47-09-2

Pinto and Bobcat

47-0

4. Tighten the four screws, two on each

side of the grille.

FRONT BUMPER

Removal

1. Remove the isolator-to-reinforcement

bolts

and

screws

and

remove

the

bumper assembly from the vehicle

(Fig.

3).

Installation

1. Transfer the bumper guards, pads and

license plate bracket

to a new

bumper if the bumper is being

replaced (Fig.

3).

2.

To

install , position

the

bumper

assembly to the isolators and install

the attaching bolts and retaining nuts

snug.



ground meets

the

specifications

in



and horizontal body

to

bumper


Fig.

5.

Tighten the isolator-to-bumper

bolts

to

35-50 ft-lbs torque.

REAR BUMPER

Removal

1. Remove two license light attaching

screws and disconnect license plate

lamp wiring from socket behind

bumper.

2. Remove two bolts attaching each


and remove the bum per assembly

(Fig. 4).

3.

If the

bumper

is to be

replaced,

transfer the bumper guards, pads and

license bracke t

to

the new bumper.

4.

Inspect the isolators for fluid leakage.

If leakage is found, replace the

isolator(s).

Installation

1. Ins ta l l

the

l icense p la te lamp

assembly.

2. Position the bumper assembly

to

the

isolators

and

install

the

attaching

bolts.

3.


distance from

the top

edge

to the


Fig.

5.

Then, adjust the bumper

for

body clearance

so

that

the

vertical



Fig.

5.

Tighten

the

isolator-

to-


torque.

4.

Connect the license lamp to the body

wiring.

EXTERIOR MOULDINGS

Befo re r emov ing the e x t e r i o r


the type of retaine r used whe ther a

respective door, quarter

or

luggage



through 15). If a weld stud is dis

or broken

off, it

should be replace

an oval head blind rivet (Par

383229-S).

GRILLE

SCREW

FIG.

2

Radiator Grille—Bobcat

N2

SCREW & WAS

- 385222

(35-50 FT-LB T

(4 PLACES)

SCREW & WAS

- 57049

(25-38 FT-LB T

(2 PLACES)

N U T - 4 5 2 6 5

(2 PLACES)

P A D - 1 7 A 4 6 5 G U A RD ( RP O)

(2 PLACES, ]™*™

SCREW & WASHER

- 57049


(2 PLACES)

N

FIG.

3 Front Bumper Installation

—

Pinto and Bobcat



47-09-3

Pinto and Bobcat

47-09-3

P A D -

17A465

LICENSE PLATE

F R A M E - 1 7 A 3 9 4

V I E W - C

^ . - 3 5 8 1 5 9

in

^ ^ ^ B R A C K E T -

1 13406

SCREW & WASHER

- 3 1 5 2 7

N2197-F

FIG.

4 Rear Bumper Installation—Pinto and Bobcat


The Pinto and Bobcat underbody repair procedures are given in Part

dimensions are shown in Figs. 16 and

47-01.

17. The underbody checking and



47-09-4

Pinto and Bobcat

47-09

BOBCAT PINTO

FRT. FENDER

FRT. BUMPER

BOBCAT

- . 2 5

BOBCAT

DEFLECTOR

PINTO

^ . 6 4

+ .25

- .25 PINTO

DEFL.

1.06

* , i PINTO

— H | -* — O V E R L A P

DEFL.

20.62

+ 1.25

FRT. BUMPER

BOBCAT

-1 .2 5 ^ « FRT. BUMPER


T PINTO

BOBCAT

4.53

BOBCAT

GRILLE

DEFL.

PINTO

1.38

PINTO

3.93

RR. BUMPER

(SEDAN)

PINTO

+ .34

- . 1 6

PINTO

1.42

+ .38

- . 2 5

RR. BUMPER,

(SEDAN)

1.00 OVER LAP

+ 1.25

- 1 . 2 5

TO GROUND

R R . B U M P E R - H

(SEDAN

TAIL LAMP ASSY REAR

1.00 OVER LAP

DEFL

21.34 ±1.25

RR. BUMPER

(STA. WAGON)

REAR BUMPER

(STA. WAGON)

(SEDAN)

PANEL REAR

QUARTER

PANEL RR.QTR.

1.171.25

REAR BUMPER **j(

(STA. WAGON)

N2754-D

F IG .

5 Bumper Adjustment Specifications—Pinto and Bobcat



47-09-5

Pinto and Bobcat

47-09-5

FIG. 6 Front Fender and Hood Exterior Moulding Installation—Bobcat

M2755-A

F IG . 7 Front Fender Exterior Moulding Instal lat ion—Bobcat Station W ag on



47-09-6

Pinto and Bobcat

47-0

N2

F IG .

8 Optional Vinyl Insert Exterior Side Moulding Installation—Pinto and Bobcat

N2194-C

F IG . 9 Optional Body Side Exterior Moulding Instal lat ion—Pinto and Bobcat Sedan



47-09-7

Pinto and Bobcat

47 -09 -7

"FORD" LETTERS

©

©

FIG. 10 Front Fender and Hood Exterior Moulding Installation—Pinto

N2I93-C

FIG. 11 Roof-Outside Rear Exterior Moulding Installation



47-09-8

Pinto and Bobcat

47-09

F IG . 12 Belt-Door W indo w and Qu arter Exterior Moulding Instal lat ion—Pinto and Bobcat Station W ag on

F IG .

13 Body Quarter and Rear Exterior Moulding Installat ion—Pinto S tation W ag on



47-09-9

Pinto and Bobcat

47-09-9

N:>757-A

FIG. 14 Body Quarte r and Rear Extension Moulding Installation—Bo bcat Station W ag on

N2758-B

FIG.

15 Rear Exterior Moulding Installation—Pinto and Bobcat



C.H.

IN PAN-FRONT FLOOR

HOLE IN REINFORCEMENT-REAR FLOOR

SIDE MEMBER MOUNTING BRACKET

M. C. H. TOP HOLES

OF FRONT SUSPENSION

NO . 2CROSSMEMBER

107.18

A ) F RONT BUMPER-ARM REAR MOUNT ING HOLE

OUTSIDE OF MEMBER-FRONT SIDE OUTER

NOTE: ALL PLAN VIEW DIMENSIO NS SHOULD BE PROJECTED

DOWNWARD & MEASURED ON A SURFACE WHICH IS

PARALLEL TO SIDE VIEW BASELINE .


DIMENSIONS UNDER 100" HAVE A TOLERANCE OF + .06

DIMENSIONS OVER 10 0" HAVE A TOLERANCE OF + .12

.C.H. OUTSIDE OF MEMBER-FRONT SIDE OUTER

TOP HOLE OF SUSPENSION HOUSING-IN

REINFORCEMENT-FRONT SHOCK ABSORBER

MOUNTING HOUSING


BRACKET-REAR SPRING FRONT

E ) M.C.H. OUTSIDE OF MEMBER-FRONT SIDE OUTER

M.C.H. = MASTER CONTR OL HOLE

C.H.

= CONTROL HOLE

BASELINE

SIDE VIEW

N2121

FIG.

16 Underbody Dimensions—Sedan—Pinto and Bobcat



C.H.

IN PAN-FRONT FLOOR

( p ) FRONT INNER HOLE IN PLATE-REAR SPRING REAR

V

- ^ TAPPING (FOR MOUNTING SPRING SHACKLE)

M. C. H. TOP HOLES OF

FRONT SUSPENSION

NO . 2 CROSS MEMBER

107.18

28.08A

-10-

FRONT BUMPER-ARM REAR MOUNTING HOLE

OUTSIDE OF MEMBER FRONT SIDE OUTER

D ) M .C.H. OUTSIDE OF MEMBER-FRONT SIDE OUTER

B ) TOP HOLE OF SUSPENSION HOUSING-IN

REINFORCEMENT-FRONT SHOCK ABSORBER

MOUNTING HOUSE

M.C.H. OUTSIDE OF MEMBER

FRONT SIDE OUTER



PARALLEL TO SIDE VIEW BASELINE .


DIMENSIONS UNDER 100" HAVE A TOLERANCE OF ± .06

DIMENSIONS OVER 100" HAVE A TOLERANCE OF +.12


BRACKET-REAR SPRING FRONT

J L

i n

T

8.00

.51 .7 6 -

-1

RASE LINE

N 2 6 3 8

M.C.H. = MASTER CONTROL HOLE

v

* - ^

SIDE VIEW

FIG. 17 Underbody Dimensions—Station Wagons—Pinto and Bobcat

65.40

117.16



47-10-1

Mustang 47-1

Mustang

P A R T

47-10

S U B J E C T

PAGE

REMOVAL AND INS TALLATION

Exte rior Mou ldings 10-4

Front Bumper 10-1

SUBJECT PAGE


Rad iator Grille 10-

Rear Bum per 10-

Underbody Dimensions 10-4


RADIATOR GRILLE

Removal

1. Open the hood and remove the two

parking l ight bulb and socke t

assemblies from the parking lights by

r o t a t i n g t h e b u l b s o c k e t s

counterclockwise and pulling them

out of the light body.

2. Remove seven grille attaching screws

(Fig. 1), and remove the grille.

Installation

1. If the grille is to be replaced, transfer

the

parking light bodies to the new

grille

(2 screws each).

2. Posit ion the gri l le to the gri l le

opening panel and install the seven

attaching screws.

HEADLAMP DOOR

3. Position the bulb sockets to the

parking lights, and rotate the bulb

socket clockwise to lock it into place.

BUMPER—FRONT AND REAR

Removal

1. Remove four bolts attaching the

bumper assembly reinforcement to

the isolators and remove the bumper

from the vehicle.

2. Remove the reinforcement retaining

nuts and bolts (Figs. 2 and 3), and

separate the reinforcement from the

bumper.

Installation

1. If the bumper is to be replaced,

transfer the bumper guards and

GRILLE

CN2878-A

moulding (if

so

equipped) to the

bumper.

2. Inspect the isolators for fluid lea

If leakage is found, replace

isolator (Figs. 2 and 3).

3. Position the reinforcement to

bumper and install the retaining

and bolts. Tighten the bolt

specification (Figs. 2 and 3).

4. Position the bumper assembly t

isolator and install the attac

bolts.

5. Adjust the bumper height so tha

distance from the top edge to gr

meets the specifications in Fi

Then, adjust the bumper for b

clearance so that the horizontal

GRILLE OPENING

P A N E L - 8 1 9 0

DEFLECTOR

N17

FIG. 1 Radiator Grille Installation—Mustang



47-10-2

Mustang 47 -110-2

VIEW A (BOLT 35-50 FT-LB TORQUE)

FIG.

2 Front Bumper Installation—Mustang



47-10-3

Mustang

47-10

GUARD

REINFORCEMENT

BUMPER

REINFORCEMENT

BUMPER

BOLT

(25-38 FT-LB TORQUE)-" V IEW A

(SPACER REINFORCEMENT

IF REQUIRED)

BOLT


ISOLATOR

VIEWB

•

BUMPER ASS EMBLY

ISOLATOR

VIEWC

BOLT


GUARD

NU T

(6-11 FT-LB

TORQUE

VIEW D N1387-

FIG. 3 Rear Bumper Installation—Mustang



4 7 - 1 0 - 4

Mustang

4 7 - 1 0 - 4

HEADLAMP DOOR MOULDING

FRONT BUMPER AT

26.20

FROM Q. OF BUMPER

PANEL

LOWER BACK

EXTENSION - QUART ER

PANEL LOWER REAR

BUMPER

22.09 + 1.25

- 1.50

TOP OF BUMPER

TO GROUND

REAR BUMPER AT 30.00"

FROM

L

OF BUMPER

N2724-B

F I G 4 Bumper Adjustment

Specif ications—Mustang

to bumper dimensions meet the

specifications in Fig. 4. Tighten the

isolator-to-reinforcement bolts to 35-

50 ft-lbs torque.

Bumper Guard Rub Strips

Do not remove the bumper guard(s)

to replace the bumper guard rub strip(s).

Refer to S teps 1 and 2 (Fig . 5) for

removal procedures.

Installation

1. Partially insert new spring clips (if

needed) into holes in guards.

2 . Engage "Tee Bars" on back of rub

strip into the head of the clips.

3 .

Drive the rub strip down with a sharp

blow of a

soft-face

m allet over the top

clip,

and then the bottom clip.

Front and Rear Bumper Rub

Strips

Removal

1. Remove the bump er assembly from

the isolators.

2 .

Place the bum per assembly on a clean

work bench to protect the painted

surface while removing the rub strips.

3 . Remove the bum per guards (if so

equipped).

4 . From the back side, remove two nuts

(one at each end) attaching the end

rub strip sections.

5. Using a hammer, drive the metal

spring clips outward. Do this only on

the rub strip to be replaced.

6. From the front of the bumper, use a

screwdriver to pry off the damaged

rub strip. Protect the surface with

masking tape before using the

screwdriver so as not to damage the

surface of the bumper.

Installation

1. Insert spring clips in holes in bumper.

If 386787 clips are used, insert the

long tip to full depth using a light

mallet. If 387044 clips are used, insert

by hand and only to the depth of the

barbs.

2 . Insert retainer(s) at end of rub strip,

placing threaded end(s) in hoie(s) in

bumper, while inserting rub stiip into

pocket in end of bumper.

3 . Engage the "Tee Bars" on back of rub

strip(s) into the heads of the spring

clips.

4 . Drive the rub strip(s) down with a

sharp blow of a soft-face mallet over

each spring clip.

5.

Install the end retaining nuts.

6. Install the bumper guards (if so

equipped) and tighten the retaining

nuts 6-11 ft-lbs torque.

7 . Install the reinforcement to the

bumper if it was removed and tighten

the retaining bolts and nuts to

specification (Figs. 2 and 3).

8. Install the bumper to the isolator,

adjust the bumper height (Fig. 4) and

tighten isolator-to-reinforcement

bolts 35-50 ft-lbs torque.

EXTERIOR MOULDINGS







through 9). If a weld stud is distorted or

broken off, it should be replaced with an

oval head blind riv et (383229-S). Refer to

General Information (Part 47-01) for

installation of Pressure Sensitive Tape

Type (Body Side Protection Mouldings).


The Mustang u nder body dimensions

are shown in Fig. 10. The under body

checking dimensions are given in Pa rt 4 7 -

0 1 .



47-10-5

Mustang

47-10

PRY RUB STRIP AWAY

FROM BUMPER GUARD

CAUTION: PRY SCREW-

DRIVER IN THE

DIRECTION OF ARROW

TO PREVENT DAMAGE

TO BUMPER GUARD

APPLY

PROTECTIVE

TAPE

RUB STRIP

FRONT AND REAR

BUMPER GUARD

BUMPER GUARD RUB STRIP REMOV AL

RETAINER - FRONT BUMPER

RUB STRIP REAR TYPICA L

VIEW A

CLIP-386786

FRONT BUMPER CLIP-386 787

RUB STRIP OPTIONAL

REAR TYPICAL

VIEW B

RUB STRI

FRONT BUMPER AND RUB STRIPS

SHOWN-REAR TYPICAL

N27

FIG. 5 Front Bumper Rub Strips Removal—Rear Similar



47-10-6

Mustang

47 10-6

FIG.

6 Front and Rear Moulding Installation— Mustang

N 2 7 2 6 A

F IG .

7 Exterior Side Moulding Installation—Mustang



47-10-7

Mustang 47-10

A

C E F G H i

F IG .

8 Exterior Side Moulding Installation—Mustang



47-10-8

Mustang 47-10-8

V I E W B

TO SECURE MOULDING ASSEMBLY,

PROVIDE HOLE WITH DRILL POINT

SCREW (ITEM-F) USING MOULDING

ASSEMBLY HOLE AS TEMPLATE.

V I E W C

N272I8-B

FIG. 9 Exterior Side Moulding Installation—Mustang



C.H. IN PAN-FRONT FLOOR-

M C H

- TOP HOLES OF

ASSY - FRONT

SUSPENSION No. 2 CROSS

31.75A

\FRONT BUMPER-ISOLATOR ASSY MOUNTING HOLE

'OUTSIDE OF MEMBER-FRONT SIDE OUTER

(M C.H. OUTSIDE OF MEMBER-FRONT SIDE INNER

vTOP HOLE OF SUSPENSION HOUSING- IN

(REINFORCEMENT-FRONT SHOCK ABSORBER

MOUNTING HOUSING



PARALLEL TO SIDE VIEW BASE LINE

DIAGONAL DIMENSIONS MUST BE EQUAL

DIMENSIONS UNDER 100" HAVE A TOLERANCE OF ±.06

DIMENSIONS

OVER

100" HAVE A TOLERANCE OF

±.12

42.8

M C H .

OUTSIDE OF MEMBER

FRONT SIDE OUTER

M C H .

MASTER CONTROL HOLE

C.H.

CONTROL HOLE

FIG. 10 Underbody Dimensions—Mustang

2508B



47-11-1

Monarch

and

Granada

47-11-1

Monarch

and

Granada

P A R T

47-11

SUBJECT PAGE

REMOVAL

AND

INSTALLATION

Exterior M ouldings 11-2

Front Bumper

11-1


SUBJECT

PAGE

REMOVAL

AND

INSTALLATION (Con t'd .)

Rear Bumper

11-1

Underbody Dimensions

11-2

CN2883-A

REMOVAL

AND

INSTALLATION

RADIATOR GRILLE

Granada

Removal

1. Remove radiator grille assembly

o u t e r u p p e r and ou t e r l ow e r

attachments.

2. Open hood and remove the four self-

threading nuts that hold the radiator

grille assembly to the radiator grille

opening panel.

(Fig. 1).

3.

Remove the radiator grille assembly.

4.

Remove

the

seven self-threading nuts

that retain

the

plastic grille texture

to

die cast grille surround moulding.

Installation

1.

Position the grille texture to the

radiator grille surround moulding by

s e c u r i n g l o c a t i n g pin on the

moulding, in the sized hole in the

grille and install the seven self-

threading nuts.

2. Install the radiator grille assembly to

the radiator grille opening panel and

secure with four self threading nuts

and four screws and J nuts.

Monarch

Removal

1.

Remove attachments to the radiator

grille.

2. Remove the radiator grille.

Installation

1. Position the radiator grille to the

radiator grille opening panel and

make the center upper attachment.

2. Make upper inboard attachments.

3.

Install the lower center attachment.

FRONT BUMPER

Removal





vehicle.

2. Remove the re inforcement- to-«

bumper

and end

bracket

to

bumper

attaching bolts and separate the

reinforcement from

the

bumper

and

end bracket (Fig. 3).

3.

Remove the bumper guards and pads

from

the

bumper.

4. Remove the license plate mounting



remove

the

sight shield attaching

bolts and remove the top sight shield

a n d c o o l i n g d u c t s f r o m the

reinforcement.

Installation

1. Install

the

bumper guards

and

pads

on the bumper. Install the license

plate bracket.

2. Position the cooling ducts and sight

shields

to the

reinforcement

and

install attaching bolts.

3.

Position bumper

end

brace between

bumper and reinforcement and install

bumper attaching bolts.

4. Install the bump er center stone

deflector to reinforcement.

5. Position the bumper and spacers to

the isolators and install the attaching

bolts.







h o r i z o n t a l b o d y

to

b u m p e r




torque.

7. Lift up the end sight shields. Apply

2-way tape to the center shield,

remove top protective backing and

press down firmly on end shield to

obtain

a

flush

fit.

REAR BUMPER

Removal

1. Disconnect

the

license plate lamp

wire from the underbody harness.

2.

Remove

two

bolts at taching

the

reinforcement to each isolator, and

remove the bumper assembly.

3.

Remove the license bracket from the

b u m p e r . R e m o v e two s c r e w s

retaining license plate light to the

reinforcement and remove the light.

4.

Remove

the

nuts

and

bolts attaching

the reinforcement to the bumper, and

separa te

the

reinforcement

and

bumper guards

(if

so equipped) from


Installation

1. Position the reinforcement and

bumper guards

(if

equipped),

to the

bumper and install the bolts and nu ts.

Tighten nuts to specification given in

Fig. 4.

NOTE : Reinstallation of the end

bracke ts is opt iona l . If the end

brackets are not installed and the

bum pe r has holes provided for



47-11-2

Monarch and Granada

47-1

SCREW

18-43 IN-LB

TORQUE

SLOTS FOR

LOCATING

PINS

N2

FIG.

1 Grille Installation—Granada

attaching the brackets, install the

bolts and nuts into the holes.

2. Install the license bracket on bumper,

and tighten bolts to specification (Fig.

4) . Install the license light to the

reinforcement (two screws). Route

the wire through the hole in the back

of the reinforcement.

3.

Position bumper assembly to the

isolator and install the attaching

bolts.










torque.

EXTERIOR MOULDINGS







9). If a weld stud is distorted or br

off, it should be replaced with an

head blind rivet (Part No. 38322

Refer to General Information (Par

01) for installation of Pressure Sens

Tape Type (Body Side Protec

Mouldings).


T h e G r a n a d a a n d M o n a

underbody dimensions are shown in

10. The underbody checking and r

procedures are given in Part 47-01



47 11 3

Monarch and Granada

47-11-3

HEADLAMP

DOOR

PARKING LAMP

GRILLE

MOULDING

VIEW-A

VIEW-B

HEADLAMP

DOOR

STONE DEFLECTOR

END

C L I P -

386450-S100

GRILLE

PANEL

- 8 1 9 0

VIEW-C

N25J9 B

FIG. 2 Grille Installation—Monarch



47-11-4

Monarch and Granada 47 -11

STONE

DEFLECTOR

END

(GRANADA)

SCREW

25-38 FT-LB

TORQUE STONE DEFLECTOR

END (MONARCH)

LICENSE PLATE

BRACKET

GUARD

AND RUB STRIP

N253

F IG . 3 Front Bumper Instal lat ion—Granada and Monarch



47 -11-5 Monarch and Granada

47-11-5

B O L T T O R Q U E -

40-60 FT-LB

ISOLATOR

BOLT TORQUE

25-38 FT-LB

DEFLECTOR

ASSEMBLY

END(REF.)

GUARD

BOLT TORQUE

17-23 FT-LB

BOLT TORQUE

25-38 FT-LB

N2738-C

FIG . 4 Rear Bumper Installation—Granada and Monarch



47-11-6

Monarch and Granada 47 -1

3.19+ .50

- . 2 5 G R A N A D A

2.40 + .50

- .25 MONARCH

GRANADA

MONARCH .91 ± .25

FRONT BUMPER

TOP O F

BUMPER

TO GROUND

21.58 ±1.50

FRONT BUMPER

STONE DEFLECTOR

TOP OF

BUMPER

TO GROUND

21.94

± 1 . 5 0

REAR BUMPER AT 19.00'

FROMQ. OF BUMPER

. \

N2739-C

F IG .

5 Bumper Adjustment

Specif icat ions—Granada and

Monarch

N27

F IG .

6 Exterior Side Moulding Installation—Granada Shown—Monarch Typical



47-11-7

Monarch and Granada

47-11-7

N2741-A

FIG.

7 Exterior Side Moulding Installation—Granada Shown—Monarch Typical

FIG. 8 Exterior Side Moulding Installation—Granada Shown—Monarch Typical



47-11-8

Monarch and Granada

47-1

NOTE: ONE PIECE ASSY. FOR 1976

N

FIG.

9 Rear Exterior Moulding Instal lat ion—Granada Shown—Monarch Typical



M.C.H. EXTENSION FRONT SIDE MEMBER

HOLE IN MEMBER FRONT FLOOR SIDE CROSS N2 2

M.C.H. IN MEMBER-FLOOR SIDE REAR

^ S ~ ^ j f S_r- •

,C.H.

IN MEMBER-FLOOR

SIDE REAR

0.00

1 2 6 . 9 0 - 1975

127.51 - 1976

NOTES:

ALL PLAN VIEW DIMENSIONS SHOULD BE PROJECTED

DOWNWARD &MEASURED ON A SURFACE WHICH IS

PARALLEL TO SIDE VIEW BASE LINE

DIAGONAL DIMENSIONS MUST BE EQUAL

DIMENSIONS UNDER 100" HAVE A TOLERANCE OF + 6

DIMENSIONS OVER 100" HAVE A TOLERANCE OF+ .12

MC.H.= MASTER CONTROL HOLE

C.H.= CONTROLHOLE

10.03

FRONT SPRING REAR HANGER HOLE

IN MEMBER - FLOOR SIDE REAR

REAR SPRING REAR HANGER HOLE

IN MEMBER - FLOOR SIDE REAR

M.C.H. IN MEMBER

FRONT SIDE INNER

FRONT MOUNTING HOLE INSIDE OF

ADAPTOR-FRONT SUSPENSION LOWER ARM

UPPER STEERING GEAR MO UNTING HOLE L.H. (M.C.H. )

INSIDE OF MEMBER-FRONT SIDE INNER

123.85

H

-

SIDE

"

2 DR A ND 4 DR GRANADA AND M ONARCH


FIG. 10 Underbody Dimensions—Granada and Monarch

N2549-C



DECIMAL

AND

METRIC EQUIVALENTS

Fractions

1/64

1/32

3/64

1/16

5/64

3/32

7/64

1/8

9/64

5/32

11/64

3/16

13/64

7/32

15/64

1/4

17/64

9/32

19/64

5/16

21/64

11/32

23/64

3/8

25/64

13/32

27/64

7 /16

29/64

15/32

31 /64

1/2

Decimal In .

.015625

.03125

.046875

.0625

.078125

.09375

.109375

.125

.140625

.15625

.171875

.1875

.203125

.21875

.234375

.250

.265625

.28125

.296875

.3125

.328125

.34375

.359375

.375

.390625

.40625

.421875

.4375

.453125

.46875

.484375

.500

Metric M M .

.39688

.79375

1.19062

1.58750

1.98437

2.38125

2.77812

3.1750

3.57187

3.96875

4.36562

4.76250

5.15937

5.55625

5.95312

6.35000

6.74687

7.14375

7.54062

7.93750

8.33437

8.73125

9.12812

9.52500

9.92187

10.31875

10.71562

11.11250

11.50937

11.90625

12.30312

12.70000

Fractions

33/64

17/32

35/64

9/16

36/64

19/32

39/64

5/8

41/64

21/32

43/64

11/16

45/64

23/32

47/64

3/4

49/64

25/32

51/64

13/16

53/64

27/32

55/64

7/8

57/64

29/32

59/64

15/16

61/64

31/32

63/64

1

Decimal In .

.515625

.53125

.546875

.5625

.578125

.59375

.609375

.625

.640625

.65625

.671875

.6875

.703125

.71875

.734375

.750

.765625

.78125

.796875

.8125

.828125

.84375

.859375

.875

.890625

.90625

.921875

.9375

.953125

.96875

.984375

1.00

Metric M

13.0968

13.4937

13.8906

14.287

14.6843

15.0812

15.4781

15.8750

16.2718

16.6687

17.0656

17.462

17.8593

18.256

18.653

19.050

19.446

19.843

20.240

20.637

21.034

21.431

21.828

22.225

22.621

23.018

23.415

23.812

24.209

24.606

25.003

25.400



Multiply

Inch

Foot

Yard

Mile

Inch2

Foot2

Yard2

Inch3

Quart

Gallon

Yard3

Pound

Ton

Ton

Kilogram

Ounce

Pound

Degree Fahrenheit

by

LENGTH

25.4

0.304 8

0.914 4

1.609

A

t r

A

AREA

645.2

6.45

0.092 9

0.836

1

VOLUME

16 387.

16.387

0.016 4

0.946

4

3.785

4

0.764

6

MASS

0.453

6

907.18

0.907

FORCE

9.807

0.278

0

4.448

TEMPERATURE

(t°F-32)t 1.8

METRIC-ENGLISH

to get equivalent

number o f:

millimetres

(mm)

metres

(m )

metres

kilometres (km)

millimetres2 (mm2)

centimetres2 (cm2)

metres2

(m2)

metres2

mm3

CIT)3

litres (1 )

litres

litres

metres3 (m3)

kilograms (kg)

kilograms (kg)

tonne

(t)

newtons(N)

newtons

newtons

degree Celsius

CONVERSION TABLE

Multiply

Foot/sec2

Inch/sec2

Pound-inch

Pound-foot

Horsepower

Inches o f water

Pounds/sq. in.

BTU

Foot-pound

Kilowatt-hour

Foot candle

Miles/gal

Gal/mile

Miles/hour

by

ACCELERATION

0.304 8

0.025 4

TORQUE

0.112 98

1.355 8

POWER

0.746

PRESSURE

OR

STRESS

0.249 1

6.895

ENERGY OR WORK

1 055 .

1.355 8

3 600 000.

or 3.6 x 106

LIGHT

1.076 4

FUEL PERFORMANCE

0.425

1

2.352

7

VELOCITY

1.609 3

to get equivalent

number of:

metre/sec2 (m/s2)

metre/sec2

newton-metres (N

newton-metres

kilowatts (kW)

kilopascals (kPa)

kilopascals

joules (J)

joules

joules (J = one W's

Iumens/metre2 (Im

kilometres/litre (k

litres/kilometre (I

kilometres/hr.

(k



CO

C

< o

o

Dear Shop Manual User:

The Ford Mo tor Com pany wants yo ur Sho p Manuals to be as useful as possible.

In form at ion that y ou prov ide on th is pre-addressed and prepa id fo rm wi l l be an impo r tant par t

o f our fu ture p lann ing.

Did you f ind any errors or i tems not covered in this manual?

Name of Shop Manual Year

Section and Page

I

& Suggestions fo r imp rov ing manuals.

Documents

1977 Ford Car Shop Manual Volume 4 Body