DEMO - 1966 Ford Thunderbird Shop Manual

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This shop manual provides the Service Technician with complete information for the ... Figure 1 illustrates a Thunderbird Warranty plate. The warranty plate is ...
1966 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

1966 Ford Thunderbird Shop Manual EAN: 978-1-60371-016-9 ISBN: 1-60371-016-7 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 CHICLE IDENTIFICATION

Imrnf^k

m^ll

mI"**

pffllik

m^

liwik

DRIVE SHAFT AND CLUTCH

MANUAL SHIFT TRANSMISSION (Not Applicable) AUTOMATIC TRANSMISSION

ENGINE

mH .

\WL%\mjB/nKmKKMmmmmMm^

mm.

a

m^^simWimK^aBMkm^iwm^am^mm^mwm^Mmwm^m^mwKM

IGNITION SYSTEM

BB

FUEL SYSTEM 1^

ITS1 121 MM

COOLING SYSTEM EXHAUST SYSTEM

J^Mj

CHARGING SYSTEM STARTING SYSTEM UGHTJNG SYSTEM, HORNS AND INSTRUMENTS

VENTILATING, HEATING AND ACCESSORIES BODY, DOORS AND WINDOWS

TRIM, SEATS AND CONVERTIBLE TOP

fTTI

haWaaal

MAINTENANCE SCHEDULE MAINTENANCE OPERATIONS

20

LUBRICATION CHARTS AND SPECIFICATIONS

SCHEMATICS

^J5^)SERVICE FIRST

PUBLICATIONS

PRINTING

AUGUST,

1965 FORD MOTOR COMPANY.

Reproduced under

SPECIFICATIONS AND SPECIAL SERVICE TOOLS AT END OF EACH GROUP

1985

DEARBORN, MICHIGAN

License # 5008 from Ford Motor

Company May -

2000

FOREWORD

This shop

the Service Technician

manual provides

information for the

complete

proper

with

servicing of the

1966 Thunderbird

The information is work

being

frequently

grouped such

performed,

according to the type of as

diagnosis

performed adjustments and repairs,

adjustments,

etc.

overhaul,

mended special

Refer to the

tools

are

Specifications

testing,

and

in-vehicle recom

and

included.

opposite page

for important

vehicle

identi

fication data.

The descriptions

in

effect at

ing.

specifications

the time this

The Ford Motor

discontinue or

and

design,

models

at

manual were

manual was approved

Company

any time,

reserves

for

the

print

right

to

or change specifications

without notice and without

^d

in this

SERVICE

incurring obligation,

PUBLICATIONS

1-1

\/ri iif*i p

GROUP

IDENTIFICATION

1

EXTERIOR PAINT COLOR BODY STYLE

(2 DOOR HARDTOP)

AXLE RATIO CODE

(26TH DAY AUGUST)

\ \

(3.00:1 AXLE

INTERIOR TRIM SILVER MINK

TRIIVUJ

BODY// COLORJ

63A

DATE CODE

(WHITE)

RATIO)

dso/

U AXLE ILTRANS

'

M.'

21

N

33

26H

(C6 DUAL RANGE AUTOMATIC)

DETROIT DISTRICT

DATE//

TRANSMISSION CODE

N j

VEHICLE WARRANTY NUMBER

\\OT \pR

TITLE Q

>N PURPOSES

.

,

IEWS MANUFACTURED UNDER UNITED STATES D

CTOEI&N PATENTS AND PATENT APPLICATIONS

A P\\ODl\VT OF

y lt^^

MOTOR COMPANY

-\-

MODEL YEAR

(1966)

ASSEMBLY PLANT

(WIXOM) BODY SERIAL CODE (2-DOOR

CONSECUTIVE UNIT NUMBER

^ENGINE CODE (8 CYL. 390 CID ENGINE) HARDTOP)

M 1087-D

Fig. 1 -Thunderbird Warranty Plate Figure 1 illustrates a Thunderbird Warranty plate. The warranty plate is attach 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 war ranty plate for title or registration purposes. ed

letter. The next code gives the district in which the two numbers. The next to the last code is the Axle Ratio Code and is designated by a number for a conventional axle or a letter for an Equa-Lock axle. The last code in the vehicle data is the Transmis sion Code and consists of one number. The charts that follow, list in detail the various vehicle data codes. sists of

two numbers

and a

car was ordered and consists of

VEHICLE WARRANTY NUMBER The

vehicle

ing

on

warranty number is the second line of numbers and letters appear 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

The

next two numbers designate the Body Serial Code. Body Serial Code designates the Engine Code. The re maining numbers indicate the Consecutive Unit Number. Thecharts that follow, list the various Vehicle Warranty Number codes. car was manufactured.

M 1088-C

The letter

following

BODY

SERIAL AND STYLE CODES

the

The two-digit numeral which follows the assembly plant code identifies the body 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

series.

Fig. 2 -Vehicle Identification Number Location 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 of two or two letters identify the Exterior Paint Color. The next code consisting interior Trim. The Date Code numbers, or a letter and a number, identifies the conthe date the car was manufactured, follows the Trim Code and

showing

body

type.

Body Serial

Body Style

Code

Code

83 81 87 85

63A 63C 63D 76A

Body Type 2-Door Hardtop (Conventional Roof) 2-Door Hardtop (Blind Quarter Roof-Painted) 2-Door Landau (Blind Quarter Roof-Vinvh

Convertible

1}

GROUP

12

1-

VEHICLE IDENTIFICATION EXTERIOR PAINT COLOR CODES

INTERIOR TRIM CODES Code

Trim Schemes

M-32J Number

Code A B

12 16 21 22 23 24

25 26 27

28 42 46 51 52 53 54

55 56 57 58 62 65 66 ID 40 B2 B3 B4

B6 B7 B8

B9 Gl G2 G3 G4 G6 G7 G8 G9 K2 K3 K4

K6 K7

K8 K9 L2 L3 L4

L6 L7 L8 L9 PI P2

P3 P4

P6 P7 P8 P9

Dk. Blue Cloth and Dk. Blue Vinyl Black Cloth and Black Vinyl Silver Mink Vinyl Dk. Blue Vinyl Burgundy Vinyl Emberglo Vinyl Red Vinyl Black Vinyl Aqua Vinyl Ivy Gold Vinyl Dk. Blue Cloth and Dk. Blue Vinyl Black Cloth and Black Vinyl Silver Mink Vinyl Dk. Blue Vinyl

Burgundy Emberglo Red Vinyl

H

K L M N P

Black Vinyl Aqua Vinyl Ivy Gold Vinyl Dk. Blue Leather Red Leather Black Leather Parchment Cloth and Parchment Vinyl Parchment Cloth and Parchment Vinyl Blue and Parchment Vinyl

1624-A 1879-A 2008-A 1070-A 1921 A 1632-A 1915-A 1920-A 1907-A

R T U V X Z 1 2

letters for the month are preceded by a numeral to show the day of the Thunderbird was completed. The second year code letters to be used if model production exceeds 12 months.

The

code

the

month when

are

First Model Year

Emberglo and Parchment Vinyl Blackand Parchment Vinyl Turquoise and Parchment Vinyl Gold and Parchment Vinyl Palomino and Parchment Vinyl Silver Mink and White Pearl Vinyl Blue and White Pearl Vinyl

January February

Burgundy and White Pearl Vinyl

August

Emberglo and White Pearl Vinyl Black and White and White Pearl Vinyl Turquoise and White Pearl Vinyl Gold and White Pearl Vinyl Palomino and White Pearl Vinyl Blue and Parchment Vinyl Burgundy and Parchment Vinyl Emberglo and Parchment Vinyl Blackand Parchment Vinyl Turquoise and Parchment Vinyl Gold and Parchment Vinyl Palomino and Parchment Vinyl Blue and Parchment Leather Burgundy and Parchment Leather Emberglo and Parchment Leather Blackand Parchment Leather Turquoise and Parchment Leather Gold and Parchment Leather Palomino and Parchment Leather Silver Mink and White Pearl Vinyl Blue and White Pearl Vinyl Burgundy and White Pearl Vinyl Emberglo and White Pearl Vinyl Black and White and White Pearl Vinyl Turquoise and White Pearl Vinyl Gold and White Pearl Vinyl Palomino and White Pearl Vinyl

September

C6.

3 Speed Dual Range Automatic Cruise-O-Matic

Yellow

DATE CODES

Month

Type

Ivy

White Platinum Med. Palomino Met. Med. Blue Met. Dk. Green Met. Red Med. Turquoise Met. Emberglo Met. Maroon Met. Med. Sage Gold Met. Rose Met. Dk. Turquoise Met.

921-A

Burgundy and Parchment Vinyl

Code

Lt. Blue Brite Blue Met. Lt. Beige Dk. Blue Met.

1910-A

Q

Vinyl

TRANSMISSION CODE

4

E F G

Vinyl

Color Black Lt. Beige Met. Med. Silver Mink Met.

1724-A 1911 A 1446-A 1226-A 1905-A 1912-A 1903-A 1917-A 1619-A

Second Model Year N P

A B C D E F G H J K L M

March April

May June

July

October November December

Q R S T U V W X Y Z

DISTRICT CODES (DSO) Thunderbirds built to a Domestic Special Order, Foreign Special Order, or PreApproved 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 or dered the

unit.

If the

unit

is

regular

production, only the District code number

will appear.

Code 11 12 13 14 15 21

22 23 24

25 26 31 32 33 34 35 36 41 42 43 44

District Boston Buffalo New York

Pittsburgh Newark Atlanta

Charlotte Philadelphia Jacksonville Richmond Washington Cincinnati

Cleveland Detroit Indianapolis

Lansing Louisville Chicago Fargo Rockford Twin Cities

Code 45 51 52 53 54 55 61 62

63 64 65 71 72 73 74 81 83 84 85 89 90-99

District Davenport Denver Des Moines Kansas City Omaha St. Louis Dallas Houston Memphis New Orleans Oklahoma City Los Angeles San Jose Salt Lake City

Seattle Canada Government Home Office Reseive American Red Cioss Transportation Services Ford

of

Expoit

PART 1-VEHICLE IDENTIFICATION REAR AXLE RATIO CODE

ASSEMBLY PLANT CODES

Code

Ratio

1

3.00:1 3.20:1 2.80:1

3 6

ENGINE CODES Code Z

Q

1-3

Type 8 Cylinder 390 Cubic Inch (4 barrel) 8 Cylinder 428 Cubic Inch (4 barrel)

CONSECUTIVE UNIT NUMBER The assembly plant, with each model year, begins with ber 100001 and continues on for each unit built.

consecutive unit num

Code

Assembly

Code

Assembly

Letter

Plant

Letter

Plant

Atlanta

N p R S T U W Y

A B C D E G H J K L

Oakville Passenger Ontario Truck Dallas Mahwah

Chicago Lorain

Los Angeles Kansas City Michigan Truck

MODEL YEAR The number 6 designates 1966

Z

Norfolk

Twin Cities San Jose Pilot Plant Metuchen

Louisville Wayne Wixom

St. Louis

2-1

GROUP

PART 2-1

GENERAL BRAKE SERVICE

.

2-1

.

PAGE

PART 2-3

PAGE

SPECIFICATIONS

2.22

.

PART 2-2 2-7

BRAKE SYSTEM

PART 2-1

GENERAL BRAKE SERVICE

Section

Page

1 Diagnosis

Section

Preliminary Tests

2-1

Road Test

2-1

Disc Brake Trouble Symptoms and Possible Causes Drum Brake Trouble Symptoms and Possible Causes 2 Common Adjustments and Repairs

Page 2-4

Parking Brake Linkage Adjustment Power Brake Master Cylinder Push Rod

2-1

Testing

and

2-4

Adjustment

2-4

Hydraulic System Bleeding 3 Cleaning and Inspection Disc Brakes Drum Brakes Booster Unit

2-2

2-3 2-4

2-5 2-6 2-6 2-6

DIAGNOSIS AND TESTING

PRELIMINARY TESTING

brake. Depress the several

1. Check master

R103-A

level in the Rotunda

fluid

the

cylinder,

and

add

Super

Heavy Duty brake fluid (B7AZ-19542-A) if required. 2. Push the brake

far

it

as

running and

go

will or

while

vacuum

travels to a point

pedal

brake

adjustment

system

still.

If the

check

the

the automatic

and

adjusters.

To

tion,

brake

check rear check

components

installation

the

adjuster opera

shoes and

the adjuster

for binding or improper follow the procedure

and

Brake Shoe under described justments in Part 2-2, Section 2. Make

several reverse

brake

ensure uniform adjustment at

Ad

Then, depress

hold it in the

Start the

engine.

the

applied

If the

pedal

in

pedal

position.

is operating, the pedal will tend to fall under foot pressure and less pressure will be required to hold the pedal in the applied position. If no ac tion is felt, the vacuum booster system is not functioning.

stops

the

4. With the engine shut off, ex haust all vacuum in the system. Depress the brake pedal and hr'd it in the applied position. Ifthepc ually falls away under thi? the hydraulic system is lea!. all

tubing,

cylinders,

hoses,

to

rear

adjustment

is

brakes, a

the automatic

permanent

built-in

feature.

and connections

transmission

engine and

in neutral,

apply the parking

few drops

a

for leaks.

the

cause of

ROAD TEST The

car should

if the brakes

will

be

preliminary symptoms eliminate

tests.

For

the

causes

or

surge,

tirely

locked open

and

the car

the bleeder

must

screw

long enough

to

of

check

which

check

the and

are also

for brake

apply the brakes

air from the lines and See Hydraulic System Bleed ing, Section 2. Also, check for leaks or insufficient fluid.

brakes be be moved,

each

encountered,

or surge will

remove

car.

the

chatter

feels

tested only

brakes at a speed of 25-30 mph to check for the existence of the trouble symptoms listed in Table 1, with the exception of brake chatter and those symptoms resolved in the

Apply

Chatter

the

road

safely stop the

spongy, bleed the hydraulic system to

of

brake fluid.

the trouble.

lightly

pedal movement

one

of

bleeding operation will release brakes, but it will not correct the

at

5. Should

3. With the

out

listed in Table 1. To

calipers,

cylinder.

On front disc

let

This

vacuum system

away

If the brake

wheels.

stop the

system.

and

brake

all vacuum

less than 1

from the floor pan,

inch

as

the engine is

is in the

is standing

the car

down

pedal

the

service

times to exhaust

approximately 50 apply

mph.

almost en

to rear brakes only.

For booster

removal

and

installa

tion

procedures, refer to Part 2-2, Sec tion 3. No service repairs, other than adjustment of the push rod, are made

Replace the assembly booster is determined to be

onjhfcrfco-oster. Avlien the

defective.

GROUP 2

2-2

TABLE 1 Front (Disc) Brake Trouble Symptoms

and

-BRAKES

Possible Causes

CQ JL>

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