Ford - Car - Workshop Manual - 1952 - 1962

I SHOP A U L Copyright © 2012, 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 1952, 1953 and 1954 Ford Passenger Car Shop Manual EAN: 978-1-60371-061-9 ISBN: 1-60371-061-2 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 Publisher 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. PREFACE This manual combines under one cover complete service information for the 1952 Ford Passenger Car. All aspects of the servicing of the parts, assemblies, or systems involved will be found here. Repair men will find step by step procedures plus disassembled views of all of the assemblies. The diagnostician will find that working procedures for each kind of trouble he will encounter are covered. Maintenance and lubrication data is provided for those interested in this aspect of service. Service Managers and salesmen will find hints of everyday care that they can pass on to their customers. Collision men will find construction detail well illustrated to assist them in collision work. Electrical men will find simply written principles, not only of operation, but of testing as well for each of the electrical units or systems. Upholstery men will find how-to-do-it procedures for their work. Step-by-step procedures for the disassembly, inspection, and repair are presented throughout this manual. In addition, each assembly has been illustrated disassembled, with each of the component parts arranged in the order of assembly or disassembly. In many cases, a glance at these illustrations will tell you all you need to know about how the parts go together. These illustrations carry basic part numbers for each of the parts. These basic numbers plus the model number of the car will permit you to order parts from any Ford dealer even though you may not have a "Parts Book." In recognition of the specialization that is currently practiced in many service establishments, this manual has been divided into five major divisions. These five parts are as follows: Part ONE-POWER PLANT -has to do with the Ford engines and the various systems that are necessary to their operation. These include fuel. system, ignition system, and the cooling system. Part TWO-CHASSIS-starting with the clutch, covers the entire power train (clutch, standard transmission, Overdrive, Fordomatic transmission, drive line, rear axles, etc.) and the running gear (wheels, tires, brakes, springs, suspension, frames, steering gear, and linkages, etc.). Part THREE - ELECTRICAL AND ACCESSORIES-covers all of the electrical systems and units (other than ignition which is covered in Part ONE) and all of the accessories, except the Overdrive and Fordomatic trans- missions which are covered in Part TWO, for Ford cars. Part FOUR-BODIES-contains complete information on the maintenance and repair of all body components, including adjustment and alignment not only of the body proper, but also of doors, deck lids, hoods, and fenders. In addition, convertible top maintenance and glass adjustments are given. Part FIVE-MAINTENANCE, TROUBLE SHOOTING, AND SPECIFICATIONS-has been arranged in the back of the book separately for the convenience of quick service men. In this part, all of the information ordinarily required for quick service men and service salesmen has been combined into three separate chapters. The Table of Contents on the next page shows not only the part break-down as described above, but also the chapters that have been established in each of the five parts. Each chapter has been divided into sections which also are listed in the Table of Contents. Regardless of the ,aspect of service in which you are interested or the unit of the vehicle in .which you may be specializing, a glance at the Table of Contents will quickly direct you to the portion of this manual in which you are interested. If you are interested in maintenance procedures, trouble shooting, or specifications, the information you desire will be found in Part FIVE. Otherwise, it will fall in one of the four other parts. A quick glance at the chapter and section listings under the part involved' will direct you to the page desired. Throughout this manual the top of each lefthand, even-numbered page gives the name of the chapter; and the top of each right-hand, oddnumbered page gives the name of the section involved. Thus, regardless of where you open the manual, a glance at the top of the two pages will tell you exactly what subject matter is discussed at that point. No one expects even the most experienced mechanic to remember all details of servicing these cars and you will find that you will have to occasionally refer to this manual. Keep your manual where it will be readily available for reference at all times. FORD DIVISION FORD MOTOR COMPANY SERVICE DEPARTMENT TABLE OF CONTENTS Preface ........ • . . .. .• . . . . . . .. . . .. . .. . .. . . . .. . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . .. . . . . . ... .. . Page 2 Part ONE-POWER PLANT CHAPTER I-EAA SERIES-6·CYLINDER ENGINE Page Page Section 1 2 3 4 5 Engine Removal and Installation. . . . . . Manifolds. . . . . . . . . . . . . . . . . . . . . . . . Cylinder Head . . . . . . . . ......... Valves, Valve Mechanism, and Valve Lash Adjustment. . . . . . 2 3 4 5 6 11 Oil Pan, Filtc:r. Oil Pump and Pressure Relief Valve .. . . . . . . . . Section 1 5 8 9 14 Section 6 Crankshaft Damper . . . . . . . . . . . . . . . . . . 7 Cylinder Front Cover and Oil Seal . . . . . . 8 Camshaft Sprocket, Camshaft, and ås .. ... .. . .... . .. ........ . 9 Flywheel, Crankshaft. and Bearings .... 10 11 Connecting Rods, Pistons, and Rings ... Exhaust System . . . . . . . . . . . . . . . . . . . .. CHAPTER II-EAB SERIES-8·CYLINDER ENGINE Engine Removal and Installation .. .. . . 34 Section 7 Valves, Springs, Guides, and Seats ..... Manifolds .... ... ............... 36 8 Camshaft Gear, Camshaft, and Cylinder Heads ......... . ..... . 37 Bearings ....... . .. . . .... .. .. . Oil Pan, Oil Pump, and Pressure Flywheel, Crankshaft, and Bearings .... 9 Relief Valve ........ . .. .......... 38 Connecting Rods, Pistons, and Rings ... 10 Crankshaft Pulley Replacement . ...... 40 Cylinder Front Cover .... . . . .. .. ..... 41 II Exhaust System ......... . CHAPTER III-IGNITION, FUEL, AND COOLING Section 6 g-Cylinder Carburetor Overhaul . ...... Section 1 Ignition ....... . ... ................. 57 7 Fuel Pumps and Vacuum Booster ...... 2 Distributor Minor Repair and Adjustment .................... . . . 60 8 Fuel Tanks and Lines . . .... ... . .. .... ...... ... 63 9 Fans and Belts ................... . . . 3 Distributor Overhaul . .. . 10 Water Pumps ....................... 4 Carburetor Operation and Adjustment .. 67 II Radiator, Hoses, and Thermostats ..... 5 6-Cylinder Carburetor Overhaul .. . .. 71 17 17 18 20 26 31 41 43 45 50 54 75 78 82 82 84 86 Part TWO-CHASSIS CHAPTER I-CLUTCH AND TRANSMISSION Section 1 Clutch .. ... ............ . .. . 2 Transmission Replacement .. 89 92 Section 3 4 Transmission Overhaul . . . . . . . • . . • . . .. Gear Shift Linkage . . . . . . . . . . . . . . . . . .. 92 97 CHAPTER II-OVERDRIVE Section 1 Operating Principles . . . . . . . . . . . . . . . 99 2 Removal... . . ....... 102 3 Disassembly and Inspection . .. ...... . . 103 Section 4 5 Assembly .. . Installation. 105 106 CHAPTER III-FORDOMATIC TRANSMISSION Section 1 Construction and Operation. .. . 107 2 Maintenance and Adjustment . . . . . . . .. 117 3 Replacement .. . .. ... . ............... 122 Section 4 5 Transmission Overhaul ...... . . Converter Overhaul. . . . .... ... ... . 128 149 CHAPTER IV-REAR AXLE AND DRIVE LINES Section 1 Passenger Car R ear Axle ..... 2 Station Wagon and Sedan Delivery Rear Axle . . .. . ............ . .. . 151 Section 3 Drive Lines. . . . . . . . . . . . . . . . . . . . . . . .. 163 159 CHAPTER V-RUNNING GEAR Section 1 2 3 4 Frames .... ........ .. . Front Suspension .. . Rear Springs . . ...... Shock Absorbers .. .. . . . ..... ...... 165 168 172 173 Section 5 6 7 8 Steering Gear ...... . .... . .. ... . ..... Steering Linkage .. . . ... .. .. . . . .. ... .. Wheels and Tires ...... . . . . ..... ... .. Hubs and Bearings .. . .. .... ..... ... .. 174 178 182 184 CHAPTER VI-BRAKES Page Section 1 Adjustments........................ 188 2 Hydraulic System .................... 189 3 Brake Assemblies. . . . . . . . . . . . . . . . . . .. 193 Page Section 4 5 Brake Drums. . . . . . . . . . . . . . . . . . . . . .. 194 Parking Brake ....................... 194 Part THREE-ELECTRICAL AND ACCESSORIES CHAPTER I-ELECTRICAL SYSTEMS Section 1 Generating System and Battery ....... 197 Section 4 Horns.............................. 22 6 2 Starting System. . . . . . . . . . . . . . . . . . . .. 213 5 Instruments. ~. . . . . . . . . . . . . . . . . . . . . .. 22 7 3 Lighting System ................... ,'. 219 CHAPTER II-ACCESSORIES Section 1 Radio.............................. 231 Section 3 Windshield Wiper .................... 240 2 Heater............................. 237 4 Miscellaneous Accessories. . . . . . . . . . . .. 241 Part FOUR-BODIES CHAPTER I-BODY CONSTRUCTION AND MAINTENANCE Construction Details and Sealer Section 5 Front Fender Alignment .............. Application ....................... 245 6 Body Alignment ..................... Door Alignment ..................... 251 7 Quarter Panel Repair. . . . . ........... Deck Lid Alignment ................. 254 8 General Body Maintenance ........... Hood Alignment ..................... 256 257 259 261 263 CHAPTER II-HARDWARE, GLASS, UPHOLSTERY, AND FLAT TRIM 6 Grille and Hood. . . . . . . . . . . . . . . . . . . .. Section 1 Door Locking Mechanism. . . . . . . . . . . .. 265 2 Window Regulators .................. 268 7 Deck Lid Locking Mechanism ....... " 3 Door Ventilator Assembly... . . . . . . . . .. 270 8 Door and Quarter Trim Panels. . . . . . .. 4 Door and Quarter Glass. . . . . . . . . . . . .. 271 9 Headlining Replacement. . . . . . . . . . . . .. 5 Windshield and Rear Window. . . . . . . .. 274 279 280 281 284 Section 1 2 3 4 CHAPTER III-CONVERTIBLE COUPE, VICTORIA, AND COUNTRY SQUIRE Section 3 Convertible and Victoria Window Section 1 Convertible Top Power System ...... ',' .287 Adjustments. . . . . . . . . . . . . . . . . . . . .. 291 2 Convertible Top Alignment. . . . . . . . . .. 289 4 Care of Country Squire Paneling. . . . .. 294 Part FIVE-MAINTENANCE, TROUBLE SHOOTING, AND SPECIFCIATIONS CHAPTER I-MAINTENANCE PROCEDURES Section 4 Lubrication......................... 305 Section 1 Engine Tune-up. . . . . . . . . . . . . . . . . . . .. 299 5 Preventive Maintenance. . . . . . . . . . . . .. 308 2 Wheel Alignment. . . . . . . . . . . . . . . . . . .. 301 3 Brake Adjustment. . . . . . . . . . . . . . . . . .. 305 CHAPTER II-TROUBLE SHOOTING Section 5 Accessories .......................... Section 1 Power Plant ......................... 311 2 Suspension, Steering Gear, and 6 Power Train ........................ Tire Wear ... ..................... 320 7 Overdrive ........................... 3 Brakes ............................. 322 Fordomatic Transmission ............. 8 323 Electrical and Instruments ............ 4 331 335 335 337 CHAPTER III-SPECIFICATIONS Section 9 Fuel System. . . . . . . . . . . . . . . . . . . . . . . .. Wheels and Tires. . . . . . . . . . . . . . . . . . .. 340 Brakes............................. 340 10 Generating System ................... Wheel Alignment and Steering. . . . . . .. 340 11 Starting System. " . . . . . . . . . . . . . . . . .. Rear Axle. . . . . . . . . . . . . . . . . . . . . . . . .. 341 12 Ignition............................ Frame and Springs. . . . . . . . . . . . . . . . . .. 342 13 Lights and Horns ................... '.' Engines............................ 342 14 Wiring Diagrams. . . . . . . . . . . . . . . . . . .. Clutch and Transmission. . . . . . . . . . . .. 344 15 Tools and Equipment ................ Cooling............................. 345 346 346 346 347 347 348 350 Section 1 2 3 4 5 6 7 8 ·P art ONE POWER PLANT Chapter EAA Series-6-Cylind~r Engine Section 1 2 3 4 5 6 7 8 9 10 11 Pa,e Engine Removal and Insta llation. . . . • . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . • . . . . . .. Manifolds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . • . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. Cylinder Head. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . • • . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. V alves, Valve Mechanism, and Valve Lash Adjustment. . . . .. .... .. ..... . . . .. . .... . . . . . . . . ... Oil Pan, Filter, Oil Pump, a nd Pressure Relief Valve ............ ... .. .. .... '. .. .. .... . .... ... Crankshaft Damper. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cylin der Front Cover and Oil Sea\. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Camshaft Sprocket, Camshaft, and Bearings. . . . . . . . • . . . • . . . . . . • • . . . . . . . . . . . . . . . . . . . . . . . . .. Flywheel, Crankshaft, and Bearings. . . . . . . . . . . . . . . . . . . • . . . . . . . . . . . . . . . . . . . . . . . . . . . • . . . . .. Connecting Rods, Pistons, and Rings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. Exha ust System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. '. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. The EAA series passenger car engine has 6-cylinders with a displacement of 21 5 c\lbic inches. The engine is rated at 101 horsepower with a 3!Y; Ii inch cylinder bore and a 3.6 inch stroke. The exterior features of the engine are illustrated in figs. 1 and 2. 5 8 9 11 14 17 17 18 20 26 31 Complete removal, repair, and installation information is included in this Chapter covering all the component parts of this engine as listed above. Always use new gaskets when maiP.t:lg repair or replacement procedures. A complete 1.' ~ngine overhaul gasket kit is available for service. 1. ENGINE REMOVAL AND INSTALLATION Engine removal and installation procedures include removal and installation without transmission, or removal and installation with transmission. a. Removal Without Transmission. 1f the vehicle is equipped with standard or overdrive transmission, follow If ( 1) Preliminary Steps-Standard EXHAUST MA.NII'O I.O CAP AND CRI'N':CA~E 1 218 BREATHER DIPSTICK Fig. I-EAA Series Engine (Left Side View) Fig. 2-EAA Series Engine (RighI Side View) 5 1219 6 Chapter I-EAA Series":"'6-Cylinder Erygine or Overdrive Transmission," then proceed with " ( 3) Engine Removal." If the vehicle is equipped with Fordom~tic, follow "(2) Preliminary Steps-Fordom~tic," then proceed with "(3) Engine R emoval." (1) PRELIMINARY STEPS-STANDARD OR OVERDRIVE TRANSMISSION. Disconnect the clutch pedal retracting spring a nd· the c1u.tch release rod. Remove the screws retainin g the clutch equalizer bar support to the flywheel housing, remove the support and bushing, and let the equa lizer bar and clutch release rod hang from the frame. Remove the transmission to flywheel housing screws. Place a jack under the transmission and raise the jack until it just touches the tra nsmission. (2) PRELIMINARY STEPS - FORDOMATIC. Fold back the front floor mat, remove the two rubber plugs, and remove the two top converter housi ng to engine bolts. Support the transmission with a jack and remove the remaining converter housing to engine bolts. Remove the engine rear plate to converter housing bolts. Remove the converter housing lower access cover, then remove the six converter to ft explate bolts. Disconnect the throttle linkage at th e cross sh aft and tie the linkage to the dash pa nel. Disconnect the acce lerator pedal shaft at the accelerator cross sha ft and remove the screws retaining the accelerato r cross shaft to the dash panel. Remove the st arte r motor. (3) ENGINE REMOVAL. Drain the coolant. R emove the hood and radiator. Disconnect the heater hose at the engine. R emove the heater blower motor. Disconnect the generator wires, engine temperature sending unit wire, oil pressue sending unit wire, a nd the ignition switch to coil wire at the various units on the engine. Remove the a ir cleaner and tape the ca rburetor opening closed. Disconnect the choke wire at the carburetor. Disconnect th e windshield wiper hose at the manifold. Disconnec t the accelerator linkage at the manifold bellcrank (except F ordomatic) . Disconnect the starter cable at the starter motor (except Fordomatic) . Disconnect the muffler inlet pipe at the exhaust manifold and pull the pipe away from tne manifold studs. Disconnect the fuel pump flexible line. Fig. 3-Engine lift Bracket Fig . 4-Mounting Engine on Work Stand Install the engine lift bracket (fig. 3) . Use the front notch in the bracket for proper engine balance, and take up the load with a hoist. Remove the engine front support bolts. Lift the engine slightly, adjust the jack supporting the transmission, a nd gently pull the engine away from the transmission. Raise the engine carefully, pull it forward over the crossmember, and lift it out of the compartment. Do not let the engine swing against the grille. Install the engi ne on a work stand using the adapter shown in fig. 4. Remove the lift bracket. h. Installation Without Transmission. If the vehicle is equipped with standard or overdrive transmission, follow steps (1) and (2) below. If the vehicle is equipped with Fordomatic, follow steps (1) and (3). (1) ENGINE INSTALLATION. Install the engine lift bracket. Using the front notch for proper engine balance, take up the load with a hoist. Remove the engine from the work stand. Lower the engine carefully into the compartment. Center the clutch release bearing on the clutch a nd start the transmission main drive gear through the bearing a nd into the clutch disc (except Fordo matic) . On Fordomatic units, start the converter pilot into the crankshaft. NOTE: On standard or overdrive units, it may be n ecessary to adjust tile position 01 the transmiuion witli relation to th e engine il the main drive gear will not enter til e clutclt disc. 'I the e ngine "hangs up" Section 1- Engine Removal and Installation alter the gear enlers, turn the crankshaft slowly (wilh the transmiuion in gear) unlil tile drive gear splines mesh wilh Ihe clutch disc. Lower the engine (and transmission) until it rests on the front supports. Install the front support bolts. Remove the engine lift bracket, install the two cylinder head bolts, and tighten them to 65-70 foot-pounds. Connect the muffler inlet pipe to the exhaust manifold. Connect the starter cable (except Fordomatic). Connect the accelerator linkage (except Fordomatic). Connect the choke wire and the windshield wiper hose. Connect the fuel pump flexible line. Connect the generator wires, the engine temperature sending unit wire, the oil pressure sending unit wire, and the ignition 'switch to coil wire. Remove the tape seal from the carburetor and install the air cleaner. Install the heater blower motor. Install the heater hose. Install the radiator and connect the radiator hose. Install the hood. Fill the cooling system and the crankcase. (2) CONNECT STANDARD OR OVERDRIVE TRANSMISSION. Install the transmission to flywheel housing bolts a-nd lock washers, then tighten them to 4050 foot-pounds. Install Jhe equalizer rod bushing on the rod and slide the support over the bushing. Install the screws .and lock washers which attach the support to the flywheel housing and tighten the screws to 37-42 footpounds. Connect the clutch release rod and spring. Remove the jack supporting the transmission. Check the clutch pedal free play (V8-IV8 inch). Adjust the free play if necessary. (3) CONNECT FORDOMATIC TRANSMISSION. Install and connect the starter motor. Install the four lower converter housing to engine bolts and tighten them to 40-45 foot-pounds. Install the engine rear plate to converter housing bolts. Install the six converter to flexplate bolts. Install the converter housing lower access cover. Install the upper converter housing to engine bolts and tighten them to 40-45 foot-pounds. Install the rubber plugs and replace the floor mat. Secure the accelerator cross shaft bracket to the dash panel and connect the accelerator pedal shaft to the accelerator cross shaft. Connect the transmission throttle linkage to the cross shaft. Remove the jack supporting the transmission. (4) CHECK ENGINE FOR LEAKAGE. Warm up the engine and check for coolant leaks at all hose connections. c. Removal With Transmission. If the vehicle is equipped with standard or overdrive transmission follow "( I) Preliminary Steps-Standard 7 or Overdrive Transmission," then proceed with "(3) Engine Removal." If the vehicle is equipped with Fordomatic, follow "(2) Preliminary Steps-Fordomatic," then proceed with "(3) Engine Removal." (I) PRELIMINARY STEPS-STANDARD OR OVERDRIVE TRANSMISSION. Disconnect the driveshaft at the rear axle and pull the shaft out of the transmission extension. Remove the engine rear support to transmission extension bolts. Disconnect the gearshift rods at the transmission. Disconnect the clutch pedal retracting spring and the clutch release rod. Remove the equalizer bar support to flywheel housing screws, remove the support and bushing, and let the equalizer bar and rod hang from the frame. Disconnect the speedometer cable. NOTE: On Ihe overdrive transmission, disconnect Ille manual control rallie al Ihe overdrive lever, remove Ihe screw relaining Ihe callie housing clip to Ihe transmission, and pull the callie away from the transmission. Disconnect the two wires at the solenoid and the wire to Ihe governor. (2) PRELIMINARY STEPS - FORDOMATIC. Disconnect the manual control linkage at the transmission. Disconnect the driveshaft at the rear axle and pull it out of the transmission extension. Remove the two screws retaining the transmission to the rear support. Disconnect the accelerator pedal shaft at the accelerator cross shaft and remove the screws retaining the cross shaft to the dash panel. (3) ENGINE REMOVAL. Drain the coolant. ·Remove the hood and radiator. Remove the heater blower motor. Disconnect the heater hose at the engine. Disconnect the generator wires, engine temperature sending unit wire, oil pressure sending unit wire, and the ignition switch to coil primary wire. Remove the air cleaner and tape the carburetor opening closed. Disconnect the choke wire at the carburetor. Disconnect the windshield wiper hose at the intake manifold. Disconnect the starter cable at the starter motor. Disconnect the accelerator linkage at the manifold bellcrank (except Fordomatic). Disconnect the fuel pump flexible line. Disconnect the muffler inlet pipe at the exhaust manifold and pull the pipe away from the manifold studs. Remove the engine front support bolts and washers. Install the engine lift bracket (fig. 3). Use the rear notch in the bracket for proper engine balance and take up the load with a hoist. Lift the engine and at the same time move it forward over the crossmember. Carefully raise the engine to remove it from the compartment. Do not let the engine swing against the grille or the compartment. Install the engine on a stand using the adapter shown in fig. 4. Remove the lift bracket. 8 Chapter 1- EAA Series-6-Cylinder Engine d. Installation With Transmission. If the vehicle is equipped with standard or overdrive transmission, follow steps (1) and (2). If the vehicle is equipped with Fordomatic, follow steps (1) and (3). (1) ENGINE INSTALLATION. Install the engine lift bracket. Use the rear notch for proper engine balance and take up the load with a hoist. Remove the engine from the work stand. Lower the engine carefully into the compartment. Be sure that the transmission extension goes over the frame crossmember and is centered on "the rear support. Lower the engine into position on the front supports. Install the front support bolts. Install the engine rear support to transmission bolts and lock washers. Tighten the bolts to 40-50 foot-pounds. R emove the engine lift bracket, install the two cylinder head bolts and tighten them to 65-70 foot-pounds. Connect the muffler inlet pipe to the exhaust mani· fold. Connect the starter cable. Connect the acce lerator linkage (except Fordomatic) . Connect the choke wire and the windshield wiper hose. Remove the tape seal from the carburetor opening and install the air cleaner. Connect the generator wires, the engine temperature sending unit wire, the oil pressure sending unit wire, and the ignition switch to coil wire. Install the heater blower motor. Inst all the heater hose. Install the radiator and connect the radiator hose. Install the hood. Fill the crankcase with the proper grade and amount of engine oil. Fill the cooling system. (2) CONNECT STANDARD OR OVERDRIVE TRANSMISSION. Insta ll the gearshift rods at the trans-. mission. Install the equalizer rod bushing on the rod and slide the support over the bushing. Install the screws retaining the support to the flywheel housing and tighten the screws to 37-42 foot-pounds. Connect the clutch release rod and retracting spring. Check the clutch pedal free play (%-1 V. inch) . Adjust the free play if necessary. Install the speedometer cable. NOTE: On the over(l~ive transmission, conned the manual control cable at th e overdrive lever and secure th e housing clip to the transmission. Connect the two solenoid wires and th e governor wire. Check th e operation of th e manual control. (3) CONNECT FORDOMATIC TRANSMISSION. Install the bracket retaining the accelerator cross shaft to the dash panel. Connect the accelerator pedal rod to the cross shaft. Install the drives haft. Connect the manual control linkage to the transmission. M ake an operational check of the transmission to be sure the control linkage is in adj ustment. 2. MANIFOLDS A chamber is built into the intake manifold center section where the carburetor and exhaust man ifold are attached. An exhaust control valve, located in the exhaust manifoid, directs exhaust gases into this chamber when the engine is cold to provide for faster intake manifold warm-up. NOTE: Do not re move manifolds when hot. They may warp anrI make reassembly difficult. a. Removal. Lift up the hood, then remove the air cleaner and the carburetor. D isconnect the throttle linkage and remove the bell crank from the manifold. Disconnect the windshield wiper vacuum line. Disconnect the muffler inlet pipe from the exhaust manifold and pull the pipe away from the fl ange. Remove the manifold to head hold down bolts and lift the manifold assembly off the head. Remove the intake port ring inserts· and gaskets. R emove the nuts and the bolt holding the m anifolds together and separate the manifolds. A disassembled v iew' of the manifolds in shown in fig. 5. h. Cleaning. Clean the gasket surfaces on the manifolds and the cylinder head. Clean the outside of the manifolds with solvent. c. Exhaust Thermostat Valve Replacement. The exhaust thermostat valve does not require replacement unless it becomes inoperative. NUT-339n lOCKWASHER_34827_8~ . GASKET-9447-:::::--r..:.;r; ·u- NUT -33814-8 LOCKWASHER- 34847·8 STUD-88620· 8 "'-=- INSERT INTAKE MANIFOLD 9471 HOSE COI