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Copyright 2006, Forel Publishing Company, LLC, Woodbridge, Virginia
All Rights Reserved. No part of this book may be used or reproduced in any manner
whatsoever without written permission of Forel Publishing Company, LLC. For
information write to Forel Publishing Company, LLC, 3999 Peregrine Ridge Ct.,
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,
GROUP INDEX
VEHIa! IDENTIFICATION
BRAKES
..
D
SUSPEN~ON, STEERING, WHEfIS AND TIRES D
ENGINE
B
1m!
FALCON IGNITION SYSTEM
FUEL SYSTEM
0
II!)
EXHAUST SYSTEM
1m
mI
INTERMEDIATE CHARGING SYSTEM
STARTING SYSTEM
Ikl
IC:I
~SERVICE PUBLICATIONS
1" 1
GROUP
Vehicle Iclentification
I
FIG . 3- Couga r Identification FIG. 4-Mustang Iden ti fication
Number l ocatio n Num ber Location
VEHICLE WARRANTY NUMBER OFFICIAL VEHICLE IDENTIFICATION NUMBERS
The vehicle warranty number is the first li ne al numbers and le tters appearing Th e officia l Vehicle identification Numbe rs for titles and reg istration purposes
on the Warranty Plat e (Fig. l). The first number indicates the model year. The are stamped in the following locations:
letter follo wing the model year number indicates the manufacturing assembly
plant. The neIt two numbers designate the Body Serial Code followed by a Mercury, Comet (Intermediate-size), Fairlane, Falcon - On the top surface of
letter expressing the Engine Code. The group of si x digits remai ning on the the radiatur and front fender apro n support (near the radia tor fill cap) Fig. 2.
first line indicate the Consecutive Unit Number.
Couga r - On the top upper flange of the left front fender apron (Fig. 3).
VEHICLE DATA MUSTANG - On the top upper ftange of the teft hont fendel 'plOn ( f ig. 4).
The veh icle data appears on the second or lower line on the Warranty Plate.
The first two number s and a lett er iden tify the Body Style. A letter or anum
ber appea rs next ind ica ting the Ext erior Paint Colo r followed by a nu mber
letter combination designating the Interior Trim. To the right of this code aj}
pears the Da te Code ind ica ting the date the car was manufactured. A two-digit MODEL YEAR CODE
number ne xt designates the distr ict in which the car was ordered and may
appear in conjunctio n with a Domestic Spec ia l Order or Foreign Special Order
number wh en applica ble . The fina l two spaces in dicate the Rear Axle Ratio
(numbers for regu lar ax les, leUers fo r lock ingtypes) and the Transmission type The number 7 designates 1967 .
(numbers for manual, lett ers for automatic ).
1-2 GROUP 1-Vehicle Identification
BODY SERIAL AND STYLE CODES BODY SERIAL AND STYLE CODES-(continued)
FAIRLANE
The twodigit numeral which follows the assembly plant code identifies
the body series. This twodigit number is used in conjunction with the Body Body Body
Style Code, in the Vehicle Date, which consists of a two-digit number with Serial Style
a letter suffix. The following chart lists the Body Serial Codes, Body Style Code Code Body Type Model
Codes and the model.
31 54A 4Door Sedan I Fairlane
30 62A 2Door Sedan I
MERCURY -COMET (I NTERMEDIA TE-S IZE)
34 54B 4Door Sedan I Fairlane 500
33 62B 2Door Sedan .1
Body Body 35 63B 2Door Hardtop I'
Serial Style 36 76B 2Door Convertible I
Code Code Body Type Model
40 63C 2Door Hardtop 2 Fairlane 500XL
02 54A 4Door Sedan j Comet 202 41 76C 2Door Convertible 2
01 62A 2Door Sedan (1
42 63D 2Door Hardtop 2' Fairlane 500GT
OS 54B 4.Door Sedan 1 Comet Capri 43 76D 2Door Convertible'
07 63B 2Door Hardtop 1
TRANSMISSION CODES
DISTRICT CODES (DSO)
Code Type
1.............................................................................................3Speed Manual Units built on a Domestic Special Order, Foreign Special Order, or other spe
2.............................................................................................Overdrive cial orders will have the complete order number in this space. Also to appear
3.............................................................................................3Speed Manual in this space is the two-digit code number of the ~istrict which ordered the
5 .............................................................................................4Speed Manual unit. If the unit is a regular production unit, only the District code number
W............................................................................................Automatic (C4) will appear.
U.............................................................................................Automatic (C6)
FORD
Code Code
Lettl!f' Letter
A........................................... Atlanta L................................... Michigan Truck MERCURY
B...........................Oakville (Canada) N............................................... Norfolk
C.................................Ontario Truck P..........................................Twin Cities
o............................................. Oallas R.............................................San Jose Code District Code District
E..........................................Mahwah S...........................................Pilot Plant
F......................................... Oearborn T............................................ Metuchen 11 ...................Boston 34 ................... 0etroit
G...........................................Chicago U............................................ Louisville 16 ................... Philadelphia 41 ................... Chicago
H............................................. Lorain W................................................Wayne 15 ................... New York 42 ................... St. Louis
J..................................... Los Angeles Y.................................................Wixom 17 ...................Washington 46 .................. .T win Cities
K..................................... Kansas City Z............................................. St. Louis 21 .................. .Atlanta 51 ................... 0enver
22 ................... 0allas 52 ................... Los Angeles
23 ...................Jacksonville 53 ................... 0akland
26 ................... Memphis 54 ...................Seattle
31 ................... Buffalo 84 ................... Home Office Reserve
32 ...................Cincinnati
33 ...................Cleveland 90 ................... Export
1-4 GROUP 1-Vehicle Identification
M-3O.J
Code M-32J Color Code Trim Schemes
A..................................... 1724A ...................................... Black 8G .................................. .Ivy Gold Vinyl
B. .................................. .1734A ...................................... Lt. Aqua 8K .................................. .AQua Vinyl
f.:::::::::::::::::::::::::::::::::::::::::::~~:t~ ::::::::::::::::::::::::::::::::::::::~i~e ~~r.e
Met.
8U .................................. Parchment Vinyl W/Black
9A .................................. Black Cloth and Black Vinyl
K. ................................... 1903A ......................................Ok. Blue Met. 9B .................................. Ok. Blue Cloth and Ok. Blue Vinyl
M................................... 1619-A ......................................White 90 .................................. Ok. Red Cloth and Ok. Red Vinyl
Q................................... 1624A ......................................Med. Blue Met. 9K .................................. .AQua Cloth and Aqua Vinyl
T. ................................... .2008A ......................................Red 9U .................................. Parchment Cloth and Parchment Vinyl W/Black
V.................................... 2066A ...................................... Bronze Met. FA .................................. Parchment Vinyl W/Black
~.::::::::::::::::::::::::::::::::::::::::::l~~t~ ::::::::::::::::::::::::::::::::::::::~:~o~~e~et. FB .................................. Parchment Vinyl W/Blue
FO .................................. Parchment Vinyl WIRed
y .....................................2039A ...................................... Ok. Green Met. FG .................................. Parchment Vinyl W/lvy Gold
Z. ................................... .1 915A ......................................Med. Gold Met. FK................................. Parchment Vinyl W/Aqua
2 . ................................... 1633A ......................................Yellow GA .................................. Black Vinyl W/Parchment
Brakes
i 2
PART 2-1 PAGE PART 2-3 PAGE
Genera I Brake Serv ice .. . . 2-1 Specifications ..... ...... 3-34
PART 2-2
Brake System ... .. ......... .. .. .. 2-9
BRAKE SYSTEM TESTS the conditi o n may be caused by a BRAKE P EDAL FRE E
defect ive s witc h. grounded s witc h wires HEIGHT AND TRAVEL
o r the dirrerential pressure va lve is not MEASU R EME NTS
BRAKE FLU ID LEVEL
ce nte red . Cent rali ze t he differential
AND HYDRA U LI C S YS TEM
press ure va lve as o utlined under H y-
d rau li c S ys te m Bleeding a nd Cen- W ith the e ngi ne running for full
I. Always check the flu id level In tra liz ing of the Diffe rentia l Va lve in p o wer b rake opera t io n, meas ure the
the brake master cy linde r rese rv oirs this sect ion o f the manual. If the brake peda t free he ight , and check
befo re pcr ro rming the les t procedures. warning light remains on. chec k the the bra ke ped a l travel with the use
If the fluid level is not w ithi n 1/ 4 to s wi tch connecto r and wi re fo r a of the Brake Pedal P ress ure Gauge ,
1/2 in ch o f the top of the ma s ter cy l- grou nded co nditi on and rep air o r Too l WRE- 500-50 as follows:
inder reservo irs. add the spe c ifi ed brake repl ace the wire assembly. If the
fl uid. Add Rotunda Brake F tuid - co nditi on o f the wi re is good , rep lace Brake Pe dal Free
Ext ra Hea vy Dut y - Pa rt Numbe r the b rake warning lamp sw itch.
Hei ght Me asurem en t
C 6A Z -19 542-A (ESA - M 6C25- A ) o r
2. Turn the ignition s wi tc h to the
eq ui va lent for all di sc brak e appli ca-
start pos ition. If the brake warn ing
tion s and Rotunda Brak e Fluid - I. Inse rt a slende r, s harp po inted
lamp docs not light , c heck the lig ht
I-!cavy Duty - Part Numbe r B7AZ- prod throug h the ca rpel a nd so und
a nd wiring fo r defects and replace
19542-A, R- I03-A o r equi va lent deadncr to th e das h panel meta l a nd
o r repai r wiring.
for power drum or s ta ndard drum meas ure the di s tan ce to the brake
appli c<lli ons. T he di sc bra ke ext ra 3 . If the..: brake warnin g lam p docs pe da l (F ig. I).
heavy duty brake fluid is co lored not li g ht when a press ure differe nt- 2. If the pos iti o n of the pedal is
blue for identification purposes. Do ial conditi o n ex is ts in the b ra ke sys- nll t within s peci ficat ion. check the
not mix low te mpe ratu re brake flu id s tem . th e warning lamp may be brake pedal lin kage for miss ing
with t he specified di sc bra ke fluid . burned o ut . the warning lam p bu s hings o r loose attachin g bolt s
s wit ch is inoperative or the s wit c h to and rep la ce them . if requi red .
D U AL MASTER CY LI NDE R la mp wirin g ha s an open ci rc ui t.
IIRAKE S YSTEM C hec k the bulb and rep lace it , if re - 3. If the ped a l free height is still
quired . C he c k the s wit ch t o lamp wi res o ut of s pec ific;Hion , c heck the b rake
fo r an o pen c irc uit and repair or re pedal booster push rod (if so equipped)
I. Turn the ignition switc h t o the pla ce the m, if requ ired . If the warn - o r mas ter cy li nder to be sure the co r-
ACe or ON position. If the li gh t on in g lamp s titl docs not lig ht , rep lace rec t pa rts are ins ta ll ed. Replace the
the brake warning lamp remain s o n, the s wit c h. defective part s as necessary.
2-2 GROUP 2-Brakes
POW E R BR A K E
FUNCTI ONA LT EST
be required to hold the pedal in the applied position . Then, chec k the opera- tion of those resolved in the Brake Sys-
applied position. If no action is fell , tion of the brake link age when the tem Tests and brake chatter. To check
the vacuum booster system is not parking brake con trols are moved to for brake chatte r o r s urge, app ly the
lunctioning. the released position. These c hecks bra ke s li ghtly at 50 mph . For each
shou ld indicate whether the manual of the symptoms en co untered, check
LO C KED WHEEL BRAKE parking brake con trol linkage is op- and eliminate the ca uses which are
erating properly or require s repair listed in Fi gs . II and 12.
Should one of the wheel brakes be o r adjustment due to in abi lity of the
locked and the car must be moved , parking brake to hold agai nst mod - If the road test revea ls one or morc
open the bleeder sc rew long enough erate veh icle move ment. prob lem co nd itions li sted in Figs. II
to let out a few drops of brake fluid. and 12, cor rect all malfunctions of
This bleeding operation will release ROAD TEST the vacuum system, bra ke booster
the brakes bur will not correct the and hyd r<lu li c sys tem prior to re-
ca use of trouble. A road tesl sho uld only be con- moving br<lke drum s. brake c<l lipcrs
ducled when ttN.' operator is sure Ihe (if so equipped), brake shoes and
PARKING BRAKE brakes will stol) the vehicle. linin gs or backing plates.
During a road tesl, apply the ve-
Visuall y check the operation of the hicles brakes at a road speed of 20
parking brake link age as the park- mph for all problem co nd itions listed
ing brake controls arc moved to the in Fi gs. II and 12 with the excep-
MUSTANG - COUGAR
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74'l775 ,(;.alE ASSEMBLY 33798-58
2A6G.l 7- 10 La.FT.
EQ UALIZER _iA602
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ALL MODELS EXCEPT
SPRING-2A651 I
CONVER T! BlE NUT-3392358
PARKING
eRA KE CA3LE
MlO CONDUIT *'
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ASSE M(3l Y-2853 \
PR ING_2M5 1 ; CABlE ASSE MBLY
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EQUAllZER - 2A602
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CONvERTIBLE ONLY HI553-A
CampbellEnterprises.com
PART 2-1-General Brake Service 2-7
Trouble Symptoms
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FIG. 11-- Front Wheel Disc Brake Trouble Symptoms and Possible Causes
2-8 GROUP 2-B ra ke s
Trouble Symptoms
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FIG. 12- Drum Brake and General System Trol..ble Symptoms and Possible Causes
2-9
DISC BRAKES
PUSH ROD
VALVE PISTON HAS MOVED TO LOW PRESSURE AREA. VALVE PISTON IS CENTRALIZED.
WARNING LAMP SWITCH PLUNGER IS DEPRESSED, ~ BRAKE FLUID PRIMARY AND SECONDARY SYSTEM
LIGHTING THE BRAKE WARNING LAMP PRESSURES ARE EQUALIZED H1471A
FIG. 4-Pressure Differential Valve and Brake Warning Lamp Switch Operation
2-12 GROUP 2-Brake s
PISTON
SHOE ----r:--li'l--_
LIN ING ----t"11'
PISTON SE AL _ _ _.>-c=-,--~U
CALIPER DUST
BOOT RET AIN ER
CALIPER
CYLINDER BORE HOUSING