1965 Ford Thunderbird Shop Manual. EAN: 978-1-60371-015-2. ISBN: 1-60371-
015-9. Forel Publishing Company, LLC. 3999 Peregrine Ridge Ct. Woodbridge ...
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1965
FORD
SHOP MA
Copyright © 2009, 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., Woodbridge, VA 22192
1965 Ford Thunderbird Shop Manual EAN: 978-1-60371-015-2 ISBN: 1-60371-015-9 Forel Publishing Company, LLC 3999 Peregrine Ridge Ct. Woodbridge, VA 22192 Email address:
[email protected] Website: http://www.ForelPublishing.com
This publication contains material that is reproduced and distributed under a license from Ford Motor Company. No further reproduction or distribution of the Ford Motor Company material is allowed without the express written permission of Ford Motor Company.
Note from the Editor This product was created from the original Ford Motor Company’s publication. Every effort has been made to use the original scanned images, however, due to the condition of the material; some pages have been modified to remove imperfections.
Disclaimer Although every effort was made to ensure the accuracy of this book, no representations or warranties of any kind are made concerning the accuracy, completeness or suitability of the information, either expressed or implied. As a result, the information contained within this book should be used as general information only. The author and Forel Publishing Company, LLC shall have neither liability nor responsibility to any person or entity with respect to any loss or damage caused, or alleged to be caused, directly or indirectly by the information contained in this book. Further, the publisher and author are not engaged in rendering legal or other professional services. If legal, mechanical, electrical, or other expert assistance is required, the services of a competent professional should be sought.
GROUP INDEX VEHICLE IDENTIFICATION BRAKES SUSPENSION-STEERING-WHEELS & TIRES
REAR AXLE CLUTCH -DR I VELINE
MANUAL TRANSMISSION (Not
Applicable)
AUTOMATIC TRANSMISSION
ENGINE IGNITION SYSTEM
.
,SK
FUEL SYSTEM 0
COOUNG
;
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5T0I,
CHAJfcGtHG
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VINtlUTING-rKATIW^
Bto>~rm, S1ATS Htv SOn IRIM-CONVIRTIBII W
p
MAINTENANCE SCHEDULE MAINTENANCE OPERATIONS LUBRICATION CHARTS
INDEX SERVICE
FORD
DEPARTMENT
DIVISION
(^g^MOTOR FIRST PRINTING
1964
FORD MOTOR
SEPTEMBER.
COMPANY.
SPECIFICATIONS AND SPECIAL SERVICE TOOLS AT END OF EACH GROUP
COMPANY
1964
DEARBORN, MICHIGAN
Reproduced under License # 5008 from Ford Motor
Company May -
2000
FOREWORD
This shop complete
the Service Technician
manual provides
information for the
proper
with
servicing of the
1965 Thunderbird
The information is work
being
frequently
grouped
performed,
such
according to the type of as
diagnosis
performed adjustments and
adjustments,
overhaul,
mended special
Refer to the
etc.
testing,
and
repairs, in-vehicle
Specifications
recom
and
tools are included.
opposite page
for important
vehicle
identi
fication data.
The descriptions in
effect at
ing.
the time this
The Ford Motor
discontinue or
and specifications
design,
w
models
at
in this
manual were
manual was approved
Company
any time,
reserves
for
the
print
right
to
or change specifications
ithout notice and without incurring obligation.
SERVICE
DEPARTMENT
FORD MOTOR COMPANY
1-1
GROUP
VEHICLE IDENTIFICATION DATE CODE
EXTERIOR PAINT COLOR (WHITE BODY STYLE
AXLE RATIO CODE
26TH DAY AUGUST)
(3.00:1 AXLE
I
NTERIORTRIM
(2 DOOR LANDAU)
(WHITE VINYL)
RATIO)
TRANSMISSION CODE (3-SPEED DUAL
RANGE AUTOMATIC)
DETROIT DISTRICT
1
-\
i
BODY// COLOR)) TRIIVUJDATE/V
63B
I
1
UAXL E IITRANS
dso/
N
20'
My
33
26H
6
VEHICLE WARRANTY NUMBER
IEWS MANUFACTURED JNDER UNITED STATES D
-QPEICftN
PaA\NTS AND PATENT APPLICATIONS
A P\\ODl\VT OF
MODEL YEAR
(1965)
ASSEMBLY PLANT
(WIXOM) BODY SERIAL CODE (2-DOOR
\^ord
COMPAN'
MOTOR
CONSECUTIVE UNIT NUMBER
"^ENGINE CODE (8 CYL. 390 CID ENGINE)
LANDAU)
M1087-C
Fig. 1 -Thunderbird Warranty Plate a Thunderbird Warranty plate. The warranty plate is to the rear (lock) face of the left door. The official Vehicle Identification Number for title and registration purposes is stamped on the hood support top surface to the right of the hood lock plate (Fig. 2). Do not use the Vehicle Warranty Number which appears on the warranty plate for title or registration purposes.
letter for an Equa-Lock axle. The last code in the data is the Transmission Code and consists of one number. The that follow, list in detail the various vehicle data codes.
Figure 1 illustrates
a conventional axle or a
attached
vehicle
charts
VEHICLE WARRANTY NUMBER warranty number is the second line of numbers and letters the Warranty Plate(Fig. 1). The first number indicates the model year. The letter following the model year indicates the assembly plant at which the car was manufactured. The next two numbers designate the Body Serial Code. The letter following the Body Serial Code designates the Engine Code. The remaining numbers indicate the Consecutive Unit Number. The charts that follow, list the various Vehicle Warranty Number codes.
The
vehicle
appearing
on
BODY SERIAL AND STYLE CODES The two-digit
follows the assembly plant code identifies This two-digit number is used in conjunction with the Body Style Code in the Vehicle Data, which consists of a two-digit number with a letter suffix. The following chart lists the Body Serial codes, Body Style codes and the body type. the
body
Body Serial
Body Style
Code
Code
81
63D 63A 76A 63B
M1088-B
83... 85
Identification Fig. 2 Number Location -Vehicle
VEHICLE DATA The vehicle data appears in a line across the top of the warranty plate (Fig. 1). The first two letters and a number identify the Body Style. The following one or two letters identify the Exterior Paint Color. The next code consisting of two numbers, or a letter and a number, identifies the Interior Trim. The Date Code showing the date the car was manufactured, follows the Trim Code and consists of two numbers and a letter. The next code gives the district in which the car was ordered and consists of two numbers. The next to the last code is the Axle Ratio Code and is designated by a number for
numeral which
series.
87
Body Type 2-Door Landau Special 2-Door Hardtop Convertible 2-Door Landau
EXTERIOR PAINT COLOR CODES
Code A B c
G
M-32-J Number 1724-A 1450-A 1736-A 1446-A 1226-A 1743-A.
Color Black Dk. Turq. Met.
Med. Ivy Gold Met. Med. Silver Mink Met. Lt. Blue Lt. Ivy Gold
VEHICLE IDENTIFICATION EXTERIOR PAINT COLOR CODES (Continued) 1544-A 1515-A .
P
DISTRICT CODES
Dk. Blue Met. Red White Platinum
1619-A 921-A 1738-A 1624-A 1879-A 1744-A 1631-A 1070-A 1555-A 1632-A 1630-A 1734-A
a Domestic Special Order, Foreign Special Order, or Pre-Approved Order have the complete order number recorded in this space. Also appearing in this space is the two digit code number of the District which ordered the unit. If the unit is regular production, only the District code number will appear.
Thunderbirds built to
Palomino Met. Med. Blue Met. Dk. Ivy Green Met. Dk. Grey Met. Lt. Beige Med. Turq. Met. Rose Beige Met.
.....
Maroon Met. Med. Beige Met. Lt. Aqua
INTERIOR TRIM CODES Code
Trim Schemes Silver Mink Cloth and Vinyl Silver Mink (W Headrest) Cloth
11 41 12 42 16 46 19 49 20 50 21 51 22. 52 24 54 25 55 26. 56 27 57 28 29 59 30 60 32 62 33 63 35 65 36 66 39 69
DATE The of
code
the
letters
.
and
Vinyl
Blue Cloth and Vinyl Blue(W Headrest) Cloth and Vinyl Black Cloth and Vinyl Black (W, Headrest) Cloth and Vinyl Palomino Cloth and Vinyl Palomino (W Headrest) Cloth and Vinyl White Vinyl White (W Headrest) Vinyl Lt. Silver Mink Met. Vinyl Lt. Silver Mink Met. (W Headrest) Vinyl Lt. Blue Met. Vinyl Lt. Blue Met. (W Headrest) Vinyl Lt. Beige Met. Vinyl Lt. Beige Met. (W Headrest) Vinyl Red Vinyl Red(W Headrest) Vinyl Black Vinyl Black (W Headrest) Vinyl Lt. Aqua Metallic Vinyl Lt. Aqua Metallic (W Headrest) Vinyl Lt. Gold Metallic (W Headrest) Vinyl Med. Palomino Vinyl Med. Palomino (W Headrest) Vinyl White Pearl Leather White Pearl (W Headrest) Leather Lt. Blue (Low Met.) Leather Lt. Blue (Low Met.) (W Headrest) Leather Burgundy Leather
..
...
month when
are
to be
the Thunderbird
by
a numeral
was completed.
used if model production exceeds
12
The
March April
E. F G.
May July August September October November December
...
...H.
J
K. .
.
L M
Kansas City Omaha St. Louis Dallas Houston
Charlotte Philadelphia Jacksonville Richmond Washington Cincinnati
Cleveland Detroit
34 35
Indianapolis
36
Louisville Chicago Fargo Rockford Twin Cities
Lansing
AXLE
Memphis
74 81
83 84 85
89 90-99
New Orleans Oklahoma City Los Angeles San Jose Salt Lake City Seattle Ford of Canada Government Home Office Reserve American Red Cross Transportation Services Export
RATIO CODE Ratio
TRANSMISSION CODE Code
Type
6
3-Speed Dual Range Automatic
MODEL The
the
day
year code
YEAR
number
ASSEMBLY
5 designates 1965
PLANT CODES
Code Letter
Assembly
A D E G H J K L
Atlanta Dallas Mahwah Chicago
Plant
Lorain Los Angeles
Kansas City Michigan Truck
Code Letter
Assembly Plant
N P R
Twin Cities San Jose
S
Pilot Plant
T U W Y Z
Metuchen
Norfolk
Louisville Wayne Wixom St. Louis
N
ENGINE CODES
P
....D
June
53 54 55 61 62 63 64 65 71 72 73
Second Model Year
A B C ....
Davenport Denver Des Moines
months.
First
January February
I istrict
45 51 52
3.00:1
show
second
Model Year
Month
to
Code
Boston Buffalo New York Pittsburgh Newark Atlanta
Code
CODES month are preceded
District
11 12 13 14 15 21 22 23 24 25 26 31 32 33
REAR
Burgundy (W Headrest) Leather Red Leather Red (W, Headrest) Leather Black Leather Black (W. Headrest) Leather Med. Palomino (Leather Print) Leather Med. Palommo(Leather Print)(W, Headrest) Leather
letters for the
Code
41 42 43 44
-
.
(DSO)
.
.
.
Q
Code
R S T U
Z 9
V W
X Y
Z
Type 8 Cylinder 390 Cubic Inch (4 barrel) 8 Cylinder 390 Cubic Inch (4 barrel Low
Compression)
CONSECUTIVE UNIT NUMBER The assembly plant, with each model year, begins number 100001 and continues on for each unit built.
with consecutive
unit
PART 2-1 GENERAL BRAKE SERVICE
PAGE .
PART 2-2 BRAKE SYSTEM
PAGE
PART 2-3 SPECIFICATIONS
.2-1
2-26
2-7
PART 2-1
GENERAL BRAKE SERVICE
Section
Page
Section
Page
Diagnosis and Testing 2 Common Adjustments and Repairs
3
2-1 2-4
1
Cleaning
and
Inspection,
.
.2-6
DIAGNOSIS AND TESTING
1. Check
in
level
fluid
the
SAE
add
cylinder, and
master
parking brake. Depress the brake pedal several times to
TESTING
PRELIMINARY
the
70R3re
quired.
as
it
running and
will
the
car
tween
the released check
the
To
eration,
check
the
tion
the
ad
press the
follow the
under
"Brake
in Part 2-2, Sec
several
reverse
uniform
brake
stops
front
the
adjustment
is
a
engine
Check
will
shut
pedal and
position.
hydraulic
off,
ex
De hold it in
system.
If the
pedal
auto
system
is leaking.
tubing, hoses, calipers, cylinders, and connections for all
permanent
cylinder.
pedal movement
bleed the hydraulic
feels
system
from the lines and See "Hydraulic System Section 2. Also, check for insufficient fluid.
remove
built-in feature.
tral,
the
stop the
transmission engine
and
in
apply
neu
the
leaks
operation
cause of
will
re
will
not
the trouble.
ROAD TEST The
car
should
be
road
tested
only if the brakes will safely stop the car. Apply the brakes at a speed of
25-30
to check for the exist
mph
trouble symptoms listed
in Table 1, with the exception of brake chatter and those symptoms resolved in the preliminary tests. For of
the symptoms encountered,
check and eliminate
the causes which
listed in Table 1. To check for brake chatter or surge, apply the brakes lightly at 50 are also
approximately
If the brake to
the
correct
each
air
Bleeding,"
3. With
bleeding
enough
brake fluid.
lease the brakes, but it
under this pres
leaks.
the
long
under
pressure
in the
gradually falls away sure, the
screw
to let out a few drops of
This
be moved,
the car must
ence of the
brake
applied
and
the bleeder
to
all vacuum
spongy, the
less
and
locked open
Chatter
mph.
adjustment at
disc brakes,
away
Guide."
the
and
to fall
hold the pedal in the applied position. If no action is felt, the vacuum booster system is not functioning. Follow the procedures in the "Booster Diagnosis haust
rear wheels.
matic
pressure
required
wheel
ensure
On
foot
be
op or
hold it in the
and
tend
will
adjuster
binding
Then, de
Start the engine. If system is operating, the
4. With the
2.
Make to
and
be
adjustment
for
described
Adjustments"
If the
halfway
shoes and
improper installation procedure
is
pedal
adjusters.
components
Shoe
engine
the system
position
brake
rear
as
still.
brake
the
automatic
check
juster
than
more
floor, and
is in
is standing
travels
pedal
the
while
go
vacuum
or
down
pedal
system.
applied position.
the vacuum
2. Push the brake far
the pedal
press
Wagner 21B(301) brake fluid if
in the
all vacuum
service exhaust
or
5. Should
one
of
the
brakes be
or
surge will apply entirely to rear brakes only. For booster removal and installa
almost
tion
procedures,
Section 3. For
refer
sembly procedures, Section 4. For tion refer to
to
Part 2-2,
disassembly refer
and
to Part
as
2-2,
cleaning and inspec Part 2-1, Section 3.
2-2
GROUP 2
TABLE 1 -Front
(Disc)
Brake Trouble Symptoms
and
-BRAKES
Possible Causes
CD c/>
ro CD
"So
CD
e CL
E
CC
CD
o
oo
CD
CL
ro Li_
a.
tr
~ro
o
-o
tr ro
CD
Q_
oo
CO
>-
~ro -j
GO
POSSIBLE CAUSES OF TROUBLE Shoe
Lining
and
Piston
Shoe
and
Air Leak
or
Knock-back
and
Violent
after
Lining Assembly
Insufficient Fluid
in
System
Loose Wheel
Bearing Adjustment
Damaged
Worn Caliper Piston Seal
or
not
or
Cornering
or
Rough Road Travel
Properly Seated
or
Positioned
Caliper
Rotor
Excessively
Frozen
or
and
or
CD
a.
o
CD :>
>
0
CD
oo in
0)
Jd
CD
oc
c_>
CO
O
r-
UJ
to
oc
X
m
a.
Rotor
Loose Caliper Attachment
Slightly Increase
Excessive Clearance Between Shoe
Shoe Hold Down Clips Missing Operator
Riding Brake
or
Up in
of
Parallel
ro
ro
a5
CO I
^
ro
X
Scores in the Cylinder Bore Corrosion Build
o
X
Parallel
Grease
CD
tx
CD
tr CD
X
Seized Pistons
Brake Fluid, Oil Shoe
out of
-a
CUJ
Q
~TO
X
Rotor
of
rj LU
tr -Z
CD
TO
o
-o
CQ
CD
a.
X
Improper Booster Push Rod Adjustment
Excessive Lateral Run-Out
tr
o
CD tr
Q_
ro
DO
O
C/5 CO
CD
?-
CD
Q
Rotor
X
PART 2-1 TABLE 2 -Rear
(Drum)
Brake
and
-GENERAL
2-3
BRAKE SERVICE
General System Trouble Symptoms
and
Possible Causes
(A
*
o
O
Li.
>
TS
>
C/0
oo ro
Ul
POSSIBLE CAUSES OF TROUBLE Mechanical Resistance
at
Pedal
or
Leaks
or
"ro
O
-o
o
00 CD
o
ro
Q_
co
o
e o
ro
a. cn
to
CD CD tr
X
ro
CD
CL
rr
X
X
X
X
Improperly Adjusted Brake Shoe
of
Round
Lining Glazed
or
Grease
on
Oil
or
oo
"=)
CD
a_
it CO
ro
O
tr
O
00
CD
a_
CD
o
CD
>
00
CD
o
_*:
CD
ro
O
CO
X UJ
X
X
X
X
X
X
X
X
X X
Worn
Lining
X
"ro r>
ro
CD
C
< -2d
o
oo
o
"ro
JC
-o
ro
CD
CD
o -tr
Dirty Brake Fluid
X
Faulty Master Cylinder
X
X
X
X
X
X
X
X
Operating
Insufficient Shoe-to-Carrier Plate Lubrication
Tire Tread Worn
Loose Front Suspension
Cracked Drum
o
a O
OO
CD OO
o
X
ro
CO
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X X X
X
X
X
X
X
X
X
X
X
X
to Drum Contact
Left by Drum
X
X
Air in Hydraulic System
"Threads"
z
X X
Lining
"o
ro
Z
CO
CL CL
=5
Scored Drum
on
CO
