15-1

PART 15-1 PAGE PART 15-3

GENERALLIGHTING SYSTEM, SWITCHES,CIRCUIT
BREAKERS
HORNS AND INSTRUMENTS PART 15-4 AND FUSES

SERVICE .. .15-1
PART 15-5 15-12

INSTRUMENTS
PART 15-2
LIGHTING SYSTEM AND HORNS . .15-6 SPECIFICATIONS . . . . 15-24

GENERAL LIGHTING SYSTEM, HORNS AND

INSTRUMENT SERVICE
Section Page
TemperatureGaugeTest. . . . . . . . . . . . . . . . . .15-4
Oil PressureIndicator Light Test. . . . . . . . . . . .15-4
Oil PressureIndicator GaugeTest-
Comet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15-4
ChargeIndicator Light Test. . . . . . . . . . . . . . . . 15-4
Ammeter Test-Comet, Falcon, Mustang 15-4
SpeedometerTests 15-4
2 Common Adjustments and Repairs. . . .. . . . . .15-4
Horn Adjustment 15-4
3 Cleaningand Inspection 15-4
SingleSpeedWiper Motor. . . . . . . . . . . . . . . . .15-4
Two SpeedWiper Motor 15-5

D DIAGNOSIS AND TESTING

LIGHT TROUBLE DIAGNOSIS GUIDE

1. Loose battery cable. S. Loose or broken wire to the

2. Loosequick disconnector bro- bulbs.
ken wire from the battery to the 6. Defectivebeam selectorswitch.
ALL HEADLIGHTS DO headlightswitch. 7. All headlightbulbs burned out.
NOT LIGHT 3. Defective headlight switch. This may be causedby a defective
4. Disconnectedor broken wire or improperly adjusted alternator
from the headlight switch to the voltage regulator (Group 13).
beamselectorswitch.
1. Burned out bulb. 3. Poor ground.
INDIVIDUAL LIGHTS 2. Loose or broken wires to the
DO NOT LIGHT bulb.
1. Loose or corroded electrical 3. Improperly adjusted or defec-
LIGHTS BURN OUT connections. tive alternator voltage regulator
REPEATEDLY 2. Excessivevibration. (Group 13).
CONTINUED ON NEXT PAGE
15-2 GROUP 1 5 -LIGHTING SYSTEM,HORNSAND INSTRUMENTS

INSTRUMENT TROUBLE DIAGNOSIS GUIDE

1. Indicator bulb burned out. 3. Defective oil pressure sender

OIL PRESSURE INDICATOR
2. Looseor broken wire from the unit (in this part).
LIGHT INOPERATIVE
light to the indicator switch.

CHARGE INDICATOR 1. Burned out bulb. 2. Loose or broken wires.

LIGHT INOPERATIVE

CHARGE INDICATOR 1. Idle speedtoo low. 3. Loose fan belt.

LIGHT STAYS ON AT 2. Parallel resistancewire burned
IDLE out.

1. Loose or broken wire from the the engineoil pressuresendingunit.

OIL PRESSURE INDICATOR constantvoltage regulator to the oil 3. Defective gauge.
GAUGE INOPERATIVE-
pressuregauge. 4. Defective oil pressure sending
COMET 2. Groundedor broken wire from unit.

AMMETER GAUGE 1. Defective gauge (in this part). 3. Charging systemmalfunction.

INOPERA JIVE-COMET 2. Loose or broken wires.

1. Looseor broken wire from the 4. Defective constantvoltage reg-

constantvoltageregulator to the fuel ulator.
FUEL GAUGE ERRATIC gauge. 5. Defective fuel tank sending
OR INOPERATIVE
2. Defective fuel gauge. unit.
3. Loose, broken, or shorted wire 6. Poor ground betweenfuel tank
from fuel gauge to the fuel tank and body.
sending unit.

1. Looseor brokenwire from con- perature gauge.

stant voltage regulator to the tem-
TEMPERATURE GAUGE perature gauge.
ERRATIC OR INOPERATIVE 2. Defective temperaturegauge.
3. Loose or broken wire from the
temperaturesendingunit to the tem-
4. Defective temperature sending
unit.
5. Defective constantvoltage reg-
ulator.

1. Loose or corroded constant 3. Broken or loose wire from or

FUEL, TEMPERATURE, AND
voltage regulator ground. to the constantvoltageregulator.
OIL PRESSURE GAUGES 2. Defective constantvoltage reg- 4. Defective ignition switch.
ERRATIC
ulator.

HORN TROUBLE DIAGNOSIS GUIDE

CONTINUED ON NEXT PAGE

 TURN INDICATOR TROUBLE DIAGNOSIS
WINDSHIELD WIPER TROUBLE DIAGNOSIS GUIDE
TESTING
Refer to Wiring Diagram Manual
Form 7795P-66 for schematics and
locations of wiring harnesses.
HORN TEST
The only test necessary on the
horn is for current draw.
Current Draw Test
Connect a voltmeter and ammeter
to the horn and to a voltage supply
as shown in Fig. 1. The normal cur-
rent draw for the horns at 12 volts is
3.5-5.5 amperes.
GUIDE
switch or a beam selector switch is
defective:
Turn on the headlights, and oper-
ate the beam selector switch. If none
of the headlights turn on when the
beam selector switch is operated, yet
the instrument panel lights operate,
the headlight switch or the red-yel-
low stripe wire from the headlight
switch to the beam control switch is
probably defective. Substitute a
known good switch for the suspected
switch to determine whether the
switch or the wiring is at fault.
If the headlights operate only with
the beam selector switch in one posi-
tion, the selector switch or the wir-
ing from the switch to the headlight
is defective. Substitute a known good
selector switch for the suspected
switch to determine whether the
switch or the wiring is at fault.
CONSTANT VOLTAGE
REGULATOR TEST
Turn the ignition switch on,
check for voltage at the gauge feed
wire (black with green stripe) at one
of the gauges. The voltage should
oscillate between zero and about 10
volts. If it does not, the constant
voltage regulator is defective, or
there is a short to ground between
the voltage regulator and the gauges.
If a gauge unit is inaccurate or
does not indicate, replace it with a
new unit. If the gauge unit still is
erratic in its operation, the sending
unit or wiring to the sending unit is
faulty.
If both the fuel gauge and the
temperature gauge indicate improp-
erly and in the same direction, the
constant voltage regulator could be
defective, as it supplies both gauges.
FUEL GAUGE AND FUEL
LEVEL SENDING UNIT TEST
Disconnect the wire from the fuel
level sending unit and connect it to
a known good sending unit. Using a
jumper for a ground, connect it to
the sending unit mounting plate and
car frame. Raise the float arm to
the upper stop, the instrument panel
gauge should read full. Lower the
float arm to the bottom stop, the
gauge should read empty.
If the gauge reads properly, the
sending unit in the gas tank is defec-
tive.
If the gauge unit still indicates im-
properly or is erratic in its operation,
the gauge unit or the wiring to the
15-4 GROUP 15
gaugeunit is faulty. Repair the wire
or replacethe gaugeunit.
TEMPERATURE GAUGE TEST
Start the engine and allow it to
run at 1200 rpm for 30 minutes.
Place a thermometerin the coolant
at the radiator filler cap. The tem-
perature should read a minimum of
180oP.,and the gaugein the instru-
ment panel should indicate within
the normal band.
If the gauge does not indicate,
short the temperature sender unit
terminal wire to ground (ignition
switch on). Do not leave the sender
wire groundedlonger than necessary
to make the test, as the gaugemay
be damaged.If the gaugenow indi-
cates,the senderunit is defectiveor
not properly sealedto the engine.Be
sure to use an electricallyconductive
sealer C3AZ-19554-B. If the gauge
does not indicate, the gauge, the
wires leading to the gauge, or the
constant voltage regulator are at
fault.
OIL PRESSUREINDICATOR
LIGHT TEST
To test the indicator light, turn on
the ignition switch. Do not start the
engine. The light should come on.
Start the engine.The light shouldgo
out, indicating that the oil pressure
has built up a safevalue.
To test the oil pressureswitch on
the engine, turn the ignition switch
on, enginenot running, the indicator
light should come on. If the indica-
tor light doesnot come on, short the
terminal of the oil pressureswitch
unit to ground. If the light now
comeson, the oil pressureswitch is
defective or not properly sealed to
the engine.Be sure to use electrical-
ly conductivesealerC3AZ-19554-B.
If the light still does not come on,
the bulb is burned out or the wires
from the bulb to the ignition switch
COMMON ADJUSTMENTS AND REPAIRS
HORN ADJUSTMENT
Horn current can be adjusted by
changing the contact tension. Con-
CLEANING AND INSPECTION
SINGLE-SPEED WIPER MOTOR
1. Clean the gear housing of all
old grease. Do not allow any clean-
LIGHTINGSYSTEM,HORNSAND INSTRUMENTS
a?d oil pressure switch are defective.
OIL PRESSURE INDICATOR
GAUGE TEST-COMET
Remove the oil pressure sender
unit and temporarily attach an oil
pressure gauge in its place. Operate
the engine to determine the oil pres-
sure. If the oil pressure is normal,
the gauge should indicate within the
normal band.
If the gauge did not indicate, mo-
mentarily short the oil pressure
sender wire to ground. Do not leave
the sender wire grounded longer
than necessary to make the test, as
the gauge may be damaged. If the
gauge now indicates, the sender unit
is defective or not properly sealed to
the engine. Be sure to use electri-
cally conductive sealer C3AZ-
19554-B. If the gauge does not in-
dicate, the gauge, the wires leading
to the gauge or the constant voltage
regulator are at fault.
CHARGE INDICATOR LIGHT
TEST
To test the charge indicator light,
turn the ignition switch on with the
engine stopped. The light should
come on. If it does not, the bulb is
burned out, or the wiring to the light
is defective.
An open resistor wire in the Ford
alternator charging system wiring
harness will usually cause the charge
indicator light to stay on until the
engine speed is increased to several
thousand rpm. This effect will be no-
ticed each time the engine is started.
In some cases the light will not go
out at all.
The charge indicator light may be
tested with the use of a test light
containing a trade number 67 or
1155 bulb.
Disconnect the regulator plug
from the regulator. Turn the ignition
switch to ACC position. Touch one
test probe from test light to the igni-
nect the horn as shown in Fig. 1.
Turn the self-locking adjusting nut
ing fluid to contact the armature
shaft and output shaft bearings.
tion terminal and the other to the
regulator base. The test light will
come on if the circuit is in proper
working order. If the 15 ohm resis-
tor or circuit is open, the indicator
light will operate at full brightness
and the test light will be out.
AMMETER TEST-COMET,
FALCON, MUSTANG
To test the ammeter, turn the
headlights on with the engine
stopped. The meter pointer should
move toward the D or discharge
scale. If no movement of the needle
is observed, check the rear of the
meter housing to see if the battery
to circuit breaker wire connections
are loose. If the connections are
tight, and the meter does not indi-
cate a discharge, the meter is inop-
erative. If the meter pointer moves
toward the C or charge scale when
the headlights are turned ON, the
wire connections at the meter are re-
versed. When the headlights are
turned on, the battery is reversed, or
the wire passes through the loop in
the wrong direction. Feed the wire
through in the opposite direction to
correct this condition, after checking
first to make sure that the battery is
not reversed.
SPEEDOMETER TESTS
To test the odometer accuracy,
drive the car over a measured mile.
Speedometer accuracy can be
checked by comparing the speedom-
eter in question against one known
to be accurate, while two cars are
moving at the same speed, or by
timing the car on a measured mile.
The Ford Car Master Parts Cata-
log or the Lincoln-Mercury Parts
and Accessories Catalog show the
proper combination of gears to use
for various rear axle and tire size
combinations.
until the current is within the limits
for the horn being adjusted.
2. Wipe all other parts with a
clean cloth.
3. Cover the motor housingbear-
 PART 15-1 -
jng, and blowout any dust from the
housingwith compressedair.
4. Inspectthe armaturefor burned
commutator bars and loose connec-
tions. Checkall shafts,bushings,and
gearsfor scoredsurfaces.Check the
thrust ball for pitting or discoloration
due to heat. Make sure that the out-
put gear is not loose on the output
shaft, and that the cam surface is
not worn. Replace any defective
parts.
5. Check the armature for
groundswith a test light. Replacethe
armatureif it is grounded.
6. Inspect the brush plate assem-
GENERAL
LIGHTINGSYSTEM,HORNSAND INSTRUMENT
SERVICE
bly for cracks or distortion. The
brush holdersshouldbe securelyfas-
tened to the brush plate. Inspect the
contact points for burned or pitted
surfaces.Replacedefectiveparts.
7. Inspect the motor housing and
magnet assembly. Replace the as-
semblyif it has a crackedmagnet,or
if the thrust button is hollowed out
to a diametergreater than 1/32inch.
8. Replacethe brushesif they are
worn to 5/16inch. Replacedistorted
or burned brush springs.
9. Add new greaseto the hous-
ing and gears.
15-5
TWO-SPEED WIPER MOTOR
1. Clean the gear housing of all
old grease.Do not allow any clean-
ing fluid to contact the armature
shaft and output shaft bearings.
2. Wipe all other parts with a
clean cloth.
3. Inspect the gear housing for
cracks or distortion. Replace a
cracked or distorted housing.
4. Check all shafts, bushings,and
gears for scored surfaces. Replace
defective parts and add new grease
to the housingand gears.
 15-6

LIGHTING SYSTEM AND HORNS

Section Page Section Page

Headlights. . . . . . . . . . . . . . . . . . . . . . . . . . . . .15-6 Headlights. . . . . . . . . . . . . . . . . . . . . . . .15-8
1
Description
and
Operation
. . .15-6 Parking Light. . . . . . . . . . . . . . . . . . . . .15-8
Horns. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15-6 Tail, Stop, and Back-Up Light Bulbs . .15-8
2 In-Car Adjustments and Repairs. . . . . . . . . .15-6 TachometerLight Bulbs. . . . . . . . . . . . .15-8
No.1 Headlight High Beam Adjustment- . . .15-6 Dome Light. . . . . . . . . . . . . . . . . . . . .
License Plate Light
. .15-8
Headlight
Alignment
. .15-8
Lower Lights. . . . . . . . . . . . . . . . . . . . . . . .15-7 Horns. . . . . . . . . . . . . . . . . . . . . . . . . .
Instrument Lights
. .15-8
No.2 Headlight Low Beam Adjustment- . .15-8
3 Removal and Installation. . . . . . . . . . . . . .
Upper Lights . .15-7 Horn Button. . . . . . . . . . . . . . . . . . . . . .15-8
. .15-8

DESCRIPTION AND OPERATION

Refer to Wiring Diagram Manual
Form 7795P-66for locationsof wir-
ing harnesses.Schematicsare shown
in Group 22 of this manual.
HEADLIGHTS
The Falcon and Mustang use two
No.2
Each light has low-beam and high-
beam filaments.
The Comet and Pairlane use four terminals are color coded. Like
sealed-beam headlights. The No.1 colored terminals are connectedto-
light is in the lower position and the
gether.
No.2 light is in the upper position.
A conventional beam selector HORNS
A pair of tuned horns are used.
switch is located on the floorboard
at the left of the driver. The horn button closesthe circuit to
type sealed-beam headlights. Quick disconnect terminals are al- the horns. One of the horns has a
so provided at the left and right of high-pitched tone; the other has a
the radiator support assembly. The low-pitchedtone.

IN-CAR ADJUSTMENTS AND REPAIRS

HEADLIGHT ALIGNMENT
ESTABLISHVERTICALCENTERLINEON WALL
ESTABLISH 20"
All headlight adjustmentsshould ,POINTS. ARRIVED AT BY SIGHTING OVER 20"

- --
HORIZONTAL
LINE ON UPRIGHTS.REPRESENT THE 20" HEIGHT
be made with a half-full fuel tank WALL REGARDLESSOF ACTUAL
DISTANCE FROM FLOOR
--
plus or minus one gallon, with a per-
~
" CENTERLINE OF FRONT
SURFACE OF HEADLIGHT BULB
son seatedin the driver's seat and a ---

personin the passengerseat,the car

unloaded and the trunk empty ex-
25 FEET
cept for the spare tire and jacking
equipment, and recommendedpres-
--
~~
sure in all tires. Before each adjust- PLACE WHERE CENTERLINEOF FRONT AXLE

ment, bouncethe car by pushingon

WOULD BE, WITH VEHICLEIN
PLACE WHERE CENTERLINEOF REAR AXLE
--
the centerof both the front and rear WOULD BE,.WITH VEHICLEIN POSITION Kl086-C
bumpers,to level the car. FIG. 1-Floor and Wall Layout
To align the No.1 headlightsby portion of the shop floor. Layout Establish the headlight horizontal
meansof a wall screen,selecta level the floor and wall as shownin Fig. 1. centerline by subtracting 20 inches
~
 I. DIMENSION
"A"
from the actual measured height of
the headlight lens center from the
floor and adding this difference to the
20-inch reference line obtained by
sighting over the uprights to obtain
dimension B (upper diagram Fig.
2). Draw a horizontal line 2 inches
below, and parallel to the headlight
horizontal centerline. Then draw the
HEADLIGHTS 25 FEET
NO.1 LIGHT HIGH BEAM DIAGRAM
headlight vertical centerlines on the
FROM WALL I. DIMENSION"A" ~I
screen as measured on the car (di-
mension A, upper diagram Fig. 2).

NO.1 HEADLIGHT HIGH BEAM

ADJUSTMENT-LOWER LIGHTS

Adjust eachNo.1 headlightbeam

as shown in Fig. 2 upper diagram.
Cover the No.2 lights when making
this adjustment.
NO.2 LIGHT LOW BEAM DIAGRAM
K1192-C Some statesmay not approve of
2-Headlight Wall Screens the 2-inch dimensionfor the No.1
headlights.Checkthe applicablestate
law, as a 3-inch dimensionmay be
required.
NO.2 HEADLIGHT LOW BEAM
ADJUSTMENT-UPPER LIGHTS

To align the No.2 headlights(up-

per lights), a new wall chart is used.
DimensionB for the No.2 lights will
be different than B for the No.1
lights, but dil)1ensionA which is
measuredon the car will be the same
as for the No.1 lights. Note that the
line of adjustmentof the No.2 lights
is the horizontalcenterlineof the No.
2 lights. Turn the headlightsto low
beam and adjust eachNo.2 light as
shown in Fig. 2.
Each headlightcan be adjustedby
meansof two screwslocated under
the headlighttrim ring. Always bring
eachbeaminto final positionby turn-
ing the adjustingscrewsclockwiseso
that the headlights will be held
1628-A againstthe tension springswhen the
operation is completed (Fig. 3).
3-Headlight Adjustment-Comet
 REMOVAL AND INSTAllATION
HEADLIGHTS
1. Remove the screws and remove
the headlight trim ring (Fig. 3).
2. Place a hand over the head-
light assembly and unhook the spring
from the retaining ring.
3. Remove the retaining ring by
unhooking the ring from the clip lo-
cated directly across the bulb from
the spring hook.
4. Pull the headlight bulb forward
and disconnect the wiring assembly
plug.
5. Plug in the new bulb and place
it in position, locating the bulb glass
tabs in the positioning slots.
6. Hook the retaining ring over
the clip, then over the bulb and se-
cure it with the existing ball-ring
spring.
7. Align the bulb with the wall
screen.
8. Install the trim ring in posi-
tion and install the retaining screws.
PARKING LIGHT
The parking light is shown in Fig.
4. To replace the bulb, remove the
lens retaining screws and the lens.
TAIL, STOP, AND BACK-UP
LIGHT BULBS
To replace the tail, stop, and/ or
the back-up lights, remove the re-
taining screws and remove the lens,
FIG. 4-Parking Light-Typical
then remove the bulb.
TACHOMETER LIGHT BULBS
To replace the light bulb in either
the Sun, or the Sprint tachometer, it
is necessary to remove the tachome-
ter from its mounting. In the case of
the Sprint tachometer it is also nec-
essary to remove the tachometer
from its outside housing. The snap-
in bulb socket is then pulled out for
replacement of the bulb.
On the Rotunda tachometer the
bulb is not serviceable.
LICENSE PLATE LIGHT
To replace the bulb, remove the
bezel retaining screw, bezel, and lens.
DOME LIGHT
Remove the two screws retaining
the dome light lens. Remove the lens
and then replace the bulb.
INSTRUMENT LIGHTS
The instrument panel light bulbs
can be replaced by pulling out the
individual light sockets from the rear
of the instrument panel.
HORNS
Disconnectthe horn wire from the
terminal. Removethe horn mounting
bracket to horn retaining screwsand
removethe horn.
To install, mount the horn in posi-
tion, then connect the horn wire to
the horn terminal.
HORN BUTTON
1. Disconnectthe horn wire con-
nector, that has a yellow and a yel-
low-green wire in it, under the in-
strument panel, to the left of the
steeringcolumn.
2. Pressdown evenly on the horn
button and turn counter-clockwise
until it lifts out from the steering
wheel.
3. Remove the horn button and
spring.
4. The horn button contactsarein-
tegral with the turn signalswitch and
are removedwith the switch.
5. Install the horn button spring
and button.
6. Connectthe horn wire connec-
tor under the instrumentpanel.

Section
1 Description and Operation. . . .
Mechanical
Headlight
Fuse Panel Switch
2 Removal and Installation.
Headlight Beam Selector Switch
Headlight Switch
DESCRIPTION AND OPERATION
Refer to Wiring Diagram Manual
Form 7795P-66for locationsof wir-
ing harnesses.Schematicsare shown
in Group 22 of this manual.
HEADLIGHT SWITCH
A combination headlight switch
and two circuit breakers is used (Fig.
1). The headlight circuit is protected
by an 18 ampere circuit breaker
for the Comet and Fairlane, a 12
ampere circuit breaker for the Fal-
con and the Mustang. The tail,
parking, license plate light and horn
circuits are protected by a 15 am-
pere circuit breaker.
1 -Headlight Switch
FUSE PANEL
The fuse panel is mounted on the
15-9
SWITCHES, CIRCUIT BREAKERS, AND
FUSES
Page Section Page
.15-9 Ignition Switch and Lock Cylinder 15-10
Stop
Dome
Light
Light
Switch
Switch
Stop Light Switch. .15-9 15-10
.15-9 15-10
.15-9 WindshieldWiper Switch. . . . . . . . 15-11
.... 15-10 Neutral Start Switch. . . . . . . . . . . . 15-11
15-10 Back-UpLight Switch. . . . . . . . . . . 15-11
15-10
left side cowl panel except that on MECHANICAL STOP LIGHT
Fairlane cars it is mounted on the SWITCH
brake pedal support. Fig. 2 shows The mechanical stoplight switch
the fuses,their valuesand locations.
differs from the hydraulic switch for-
merly used. The switch assembly is
installed on the pin of the brake ped-
al arm so that it straddles the master
cylinder push rod. The switch assem-
bly is a slip fit on the pedal arm pin
and thus the switch assembly moves
with the pedal arm whenever the
bra~e pedal is depressed.
The brake pedal arm pin has a de-
signed-in clearance with the eye of
the master cylinder push rod (Fig.
3). Because of this clearance, when-
ever the brake pedal is pushed for-
ward, the stop light switch contacts,
moving with the pedal arm, are ac-
tually pushed against the end of the
master cylinder push rod, through the
switch actuating pin. It is this move-
ment of the switch with respect to
the actuating pin and master cylin-
der push rod that closes the switch
contacts completing the circuit to the
K1451-A stoplights.
When the brake pedal is released,
the spring in the stop light switch re-
turns the actuating pin to its normal
position and the circuit to the stop
lights opens.
1 5-10 GROUP
FIG. 3-Mechanical StoplightSwitchOperation
HEADLIGHT SWITCH
1. Disconnect the battery ground
cable.
2. Remove the control knob and
shaft by pressing the knob release
button on the switch housing (Fig. 1),
with the knob in the full ON posi-
tion. Pull the knob out of the switch.
3. Unscrew the mounting nut, re-
move the switch, then remove the
junction block from the switch.
4. To install the switch, connect
the junction block to the headlight
switch, position the switch in the in-
strument panel, and install the
mounting nut.
5. Install the knob and shaft as-
sembly by inserting it all the way in-
to the switch until a distinct click is
heard. In some instances it may be
necessary to rotate the shaft slightly
until it engages the switch-contact
carrier.
6. Connect the battery ground ca-
ble.
HEADLIGHT BEAM
SELECTOR SWITCH
Lay the floor mat back from the
area of the switch. and remove the
1 5 -LIGHTING SYSTEM,HORNS AND INSTRUMENTS
mounting screws (Fig. 4). Discon-
nect the wire terminal block from the
switch.
FIG. 4-Headlight Beam
Selector Switch
To install the switch, connect the
terminal block to the switch and in-
stall the switch to the floor. Replace
the floor mat.
STOP LIGHT SWITCH
1. Disconnect the wires at the con-
nector.
1. Remove the hairpin retainer,
slide the stOD lieht switch. the Dush
rod and the nylon washersand bush-
ing awayfrom the pedal,and remove
the switch (Fig. 5).
3. Position the switch, push rod,
and bushing and washers on the
brake pedal pin, in the order shown
in Fig. 5, and install the hairpin re-
tainer.
4. Connect the wires at the con-
nector, and install the wires in the
retaining clip (Fig. 5).
DOME LIGHT SWITCH
The dome light switch is part of
the headlight switch. It is actuated
by rotating the switch control knob
to the maximum counterclockwise
position. The dome light and head-
light switch is replacedasa unit (Fig.
1).
IGNITION SWITCH AND
LOCK CYLINDER
1. Disconnect the negative cable
from the battery.
2. Turn the ignition key to the ac-
cessoryposition. Slightly depressthe
pin shown in Fig. 6, turn the key
counterclockwise,and pull the key
and lock cylinder out of the switch
assembly.If only the lock cylinder is
 PART 15-3 - SWITCHES,
CIRCUITBREAKERS,
AND FUSES 1 5-11

RELEASE-PIN HOLE Kl176-A

FIG. 6-Typical Ignition Switch

Removal

9. If a new lock cylinder is to be

4,
4",...,..., 2B129NYLON WASHER
installed,insert the key in the cylin-
der and turn the key to the accessory
position. Place the lock and key in
the ignition switch, depressthe pin
slightly (Fig. 6) and turn the key
counterclockwise.Push the lock cyl-
inder into the switch. Turn the key
to checkthe lock cylinder operation.
10. Connectthe battery cableand
_13480STOP LIGHT checkthe ignition switch.
I SWITCHASSEMBLY
I
WINDSHIELD WIPER SWITCH
-
~ASt~
puSH ROD THRU
DA~PANEL TO
CYLINOER 1. Disconnectthe battery cable.
2. Removethe wiper switch knob,
rr
.--, HA)RPIN
RETAINER
"
bezel nut, and bezel.
'1'~
3. Pull out the switch from under
the instrumentpanel. Disconnectthe
plug connectorfrom the switch and
BUSHING removethe switch.
4. Position the switch and con-
nect the plug connector.
5. Position the switch in the in-
strumentpanel and install the bezel,
BRAKEPEDAL-- ,r 28129 NYLON WASHER
K1157.B bezel nut, and knob.
6. Connect the battery cable and
FIG. 5-MechanicalStoplight Switch Assembly checkthe operationof the switch.

to be replaced, proceed to Step 9.
3. Press in on the rear of the
switch and rotate the switch 1/8 turn
counterclockwise (as viewed from the
terminal end). Remove the bezel,
switch, and spacer.
4. Remove the nut from the back
of the ignition switch. Remove the
accessory and gauge feed wires from
the accessory terminal of the switch.
Pull the insulated plug from the rear
of the switch.
5. If a new ignition switch is to
be installed, insert a screwdriver into
the lock opening of the ignition
switch and turn the slot in the switch
to a full counterclockwise position.
6. Connect the insulated plug
with wires to the back of the ignition
switch. Position the accessory and
gauge wires on the ignition switch
stud and install the retaining nut.
7. Position the spacer on the
switch with the open face away from
the switch.
8. Place the bezel, switch, and
spacer in the switch opening, press
the switch toward the instrument
panel and rotate it 1/8 turn to lock
it in position.
NEUTRAL START SWITCH
See Part 7-2 for replacement of
the neutral start switch on cars
equipped with automatic transmis-
sions.
BACK-UP LIGHT SWITCH
On cars equipped with the steering
column standard shift, the switch is
located on the lower end of the steer-
ing column.
On cars equipped with a shift le-
ver directly over either the standard
or automatic transmissions, the back-
up light switch is located on the
transmission.
 15-12

INSTRUMENTS

Section Page Section Page

1 Description and Operation. . . . . . . . . . . . . . 15-12 Electric
Charge Clock-Fairlane
Indicator Gauge-Comet .""""",." 15-18
Constant Voltage Regulator. ............ 15-12 15-18
Gauges
15-12 Turn Indicator Flasher. . . . . . . . . . . . . . . . . 15-18

Turn
Indicator
Switch
Fuel Gauge. . . . . . . . . . . . . . . . . . . . . . . . . . 15-13 15-18
Charge Indicator Light-Except 15-13 Emergency Warning Flasher. . . . . . . . . . . . 15-18
Temperature
Gauge
Speedometer-Fairlane .. . . . . . . . . . . . . . . . 15-18
Comet. ........................... 15-13 Speedometer-Falcon, Mustang. . . . . . . . . . 15-18
.........

Speedometer-Comet
Charge Indicator Gauge-Comet 15-13 15-19
Oil Pressure Indicator Light-Except Comet 15-13 Speedometer Cable """""""""" 15-19
Turn Indicator. ....................... 15-13 Windshield Wiper Motor-Except Fairlane 15-19
Oil
Pressure
Indicator
Gauge-Comet
Windshield Wiper Switch-Fairlane

15-13 15-19
Emergency Warning Flasher. . . . . . . . . . . . 15-13 Wiper Pivot Shaft and Link. ............ 15-19

Windshield
Wiper
Motor-Fairlane
Speedometer. ........................ 15-13 15-20
Windshield Wiper-Comet .............. 15-13 4 Major Repair Operations. . . . . . . . . . . . . . . 15-20
2 In-Car Adjustments and Repairs. . . . . . . . . 15-15 Disassembly-Permanent Magnet Type
Windshield Wiper Blade Adjustment. ..... 15-15 Single or Two-Speed Electric Wiper
3 Removal and Installation. .............. 15-15 Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-20
Instrument Panel Control Identification 15-15 Parts Repair or Replacement. . . . . . . . . . . . 15-21
Instrument
Cluster-Except
Fairlane
Assembly-Permanent Magnet Type
Auxiliary
Lens-Fairlane Instrument
, Cluster- 15-15 Single or Two-Speed Electric Wiper
Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-21
Temperature Gauge-Except Comet. . . . . . 15-16 Windshield Wiper Motor Park Switch
Constant
Constant
Fuel
Fuel
Fuel
Fuel
Mustang
Sending
Gauge-Comet
Gauge-Falcon,
Gauge-Fairlane
Voltage
Voltage
Rally
Unit
Pac
Regulator-Fairlane
Regulator-Comet
Mustang
15-16 Test and Adjustment-Single and
15-16 Two-Speed Permanent Magnet Type. . . . 15-21
15-16 Disassembly-Oscillating Type Two-
15-16 Speed Electric Wiper Motor. . . . . . . . . . 15-21
15-17 Parts Repair or Replacement. . . . . . . . . . . . 15-22
15-17 Assembly-Oscillating Type Two-
15-17 Speed Electric Wiper Motor. . . . . . . . . . 15-22
Temperature Sending Unit. ............. 15-17 Electro-Pneumatic Governor
Temperature
Gauge-Comet
15-17 and Control Selector Switch-Comet ... 15-23
Oil Pressure Sending Unit or Oil 15-17 Speedometer Diagnostic Procedures. . . . . . 15-23
Oil
Pressure
Indicator
Gauge-Comet
Speedometer Repair Procedures 15-23
Pressure Switch 15-18

DESCRIPTION AND OPERATION

Refer to Wiring Diagram Manual Comet includes the same components
Form 7795P-66 for locations of wir- except that an oil pressure indicator
ing harnesses.Schematics are shown gauge and a charge indicator gauge
in Group 22 of this manual. are used instead of indicator lights.
All of the instruments are electri- There are also separate left-and-
cally operated except the speedome- right-hand turn signal indicator
ter. Brightness of the instrument pan- lights in the instrument panel.
el lights is controlled by a rheostat
on the lighting switch. CONSTANT VOLTAGE
REGULATOR
GAUGES The constant voltage regulator
The instrument cluster for the Fal- (Fig. 1) used with the fuel, tempera-
con, Fairlane and Mustang includes ture, and oil gauges maintains an
a fuel gauge, temperature gauge, average value of 5.0 volts at the
charge indicator light, oil pressure gauge terminals.
indicator light, speedometer, high- The regulator operates by means
beam indicator light, and a left and of a bimetallic arm and a heating
right-hand turn signal indicator light. coil. When the ignition switch is
The instrument cluster for the turned on, the heating coil (Fig. 1)
heats the bimetallic arm causing it
to bend and break the contacts,dis-
connectingthe voltage supply from
the heating coil. The bimetallic arm
then cools and brings the contacts
together again. The making and
breaking of the contacts, causesa
pulsating voltage, with an effective
averagevalue of 5.0 volts to be sup-
plied to the gauges.Although these
pulsations are quite rapid, there is
in eachgaugea bimetallic arm which
changes temperature quite slowly,
and this assuressteadyaverageread-
ings.
As the pulsating voltage would
normally causeradio interference,a
radio interferencesuppressionchoke
is connectedin serieswith the con-
stant voltage regulator supply wire.
FUEL GAUGE
The fuel gaugeconsistsof a send-
ing unit, located on the gas tank,
and a remote register unit (fuel
gauge) mounted in the instrument
cluster. The remote register unit
pointer is controlled by a bimetallic
arm and heating coil. The sending
unit is a rheostat that varies its re-
sistancedependingon the amount of
fuel in the tank. The rheostatis op-
eratedby a float control. As the fuel
level rises or falls the float control
arm moved by the float, varies the
resistance.
TEMPERATURE GAUGE
The temperature gauge consists of
a sending unit mounted in the cylin-
der head at the top front on the
V-8 (Fig. 2 or 3), left rear on the
six, and a remote register unit, (tem-
perature gauge) mounted in the in-
strument cluster.
Changes of engine temperature
vary the resistance of the sending
unit which in turn operates the tem-
perature gauge.
CHARGE INDICATOR
LIGHT-EXCEPT COMET
A red alternator charge indicator
light is used. This light flashes on if
the battery is discharging and the al-
ternator is not supplying current.
When the ignition switch is closed,
battery current flows through the
charge indicator light and 15-ohm
parallel resistor, and through the reg-
ulator voltage limiter contacts to the
field.
When the alternator builds up
enough voltage to close the field re-
lay contacts, full voltage is applied
to the field, and the charge indicator
light goes out.
TEMPERATURE SENDING UNIT
~rlfc
-, " """J""'*'*"'.~-""""""c-
OIL PRESSURE SWITCH
FIG. 2-Temperature Sender
and Oil PressureSwitch-Falcon
and Comet V-8
TEMPERATURE SENDER
OIL PRESSURESWITCH-
FIG. 3-Temperature and Oil
Pressure Sender-Fair lane 6
CHARGE INDICATOR
GAUGE-COMET
The charge indicator gauge is an
ammeter, which indicates whether
the ,battery is being charged or dis-
charged. The ammeter is non-adjust-
able and should be replaced if proved
to be defective.
OIL PRESSURE INDICATOR
LIGHT-EXCEPT COMET
A red indicator light flashes on
when the oil pressure is below a safe
value. The light should come on when
the ignition switch is first turned on,
and it should go out when the engine
comes up to speed. The light is con-
nected between the oil pressure
switch unit mounted on the engine at
the left rear on the six, above the oil
filter on the V -8 (Fig. 2), and the coil
terminal of the ignition switch.
OIL PRESSURE INDICATOR
GAUGE-COMET
The meter-type oil pressure gauge
consists of a sending unit on the en-
gine above the oil filter on the V-8
(Fig. 3), at the left rear on the six,
and a remote register unit in the in-
strument cluster.
The sending unit operates by vary-
ing resistance according to actual
oil pressure against it, which in turn
operates the oil pressure gauge.
TURN INDICATOR
The turn indicator uses the dual
filament parking lights as indicator
K1525-A
lights.
The turn indicator flasher is lo-
cated in the back of the instrument
panel, On the steering column brace.
On the Mustang the flasher is
mounted on the front side of the air
duct.
EMERGENCYWARNING
FLASHER
The emergency flasher warning
system is controlled by a combination
switch and flasher assembly. All turn
signal lights can be made to flash
at the same time by closing the
switch of the switch-flasher assembly.
SPEEDOMETER
The speedometer is connected to
the output shaft of the transmission
by means of a flexible shaft, and a
drive gear located inside the trans-
mission. The flexible shaft drives the
K 1627-A
speedometer which registers speed in
miles per hour and also drives an
odometer which records distance
traveled in miles and tenths of a
mile.
WINDSHIELD WIPER-COMET
The Comet wiper provides high
speed(65 to 75 cycles per minute)
constantwiping action, and also in-
termittent low speed(5-30 cyclesper
minute), intermittent wiping action.
This low speed operation is based
not on a low speedwiping strokebut
on an adjustabledwell period in the
park position.
The intermittent wiper is operated
through the use of a dual knob. The
outer or large knob, whenin the cen-
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ter position, turns the system off.
When turned fully clockwise, the
wiper is in the constant high speed
setting. When turned fully counter-
clockwise, the wiper goes on the in-
termittent lower speed range. The
intermittent wiper action is controlled
by the inner, or small knob.
The intermittent wiper control is
an electro-pneumatic system, a gov-
ernor located in the engine compart-
ment, that allows selection of either
varying dwell between wipe cycles or
continuous wiper action thru applica-
tion of variable opposing vacuum and
pressure within the system.
With the control selector in the in-
strument panel turned to intermittent
wiper control, engine manifold vacu-
um is applied to the upper chamber
of the governor (Sketch I, Fig. 4).
Atmospheric pressure in the lower
chamber then moves the diaphragm
upward. Simultaneous rotation of the
governor valve cam thru the spiral
action of the follower applies mani-
fold vacuum to the diaphragm of the
normally closed electrical switch. The
switch diaphragm is moved down-
IN-CAR ADJUSTMENTS AND REPAIRS
WINDSHIELD WIPER
BLADE ADJUSTMENT
Turn the ignition switch to the ac-
REMOVAL AND INSTAllATION
INSTRUMENT CLUSTER-
EXCEPTFAIRLANE
1. Disconnectthe battery cable.
2. Disconnectthe speedometer ca-
ble from the speedometerhead.
3. Removethe six screwsretain-
ing the instrument cluster assembly
to the instrument panel and tilt the
cluster forward.
4. Disconnectthe wiring and the
bulb socketsand remove the cluster
assembly.
5. Positionthe clusterand connect
the wiring and the bulb sockets.
6. Install the instrumentclusteras-
semblyto the instrumentpanel with
the six retaining screws.
7. Connectthe speedometercable
and the battery cable.
8. Check the operation of all
gauges,lights, and signals.
To replace the fuel gauge, tem-
perature gauge, oil pressuregauge,
PART 15-4 INSTRUMENTS
ward compressing the diaphragm
spring and moving the switch into the
park position. The wiper blades then
move to the park position and re-
main there. (Sketch II, Fig. 4).
Rotation of the governor valve
cam that applied vacuum to the gov-
ernor switch also opened the upper
governor chamber to atmosphere.
The compressed diaphragm spring
applies downward pressure to the dia-
phragm creating super atmosphere in
the lower chamber. This is allowed
to bleed off thru a variable orifice
in the control selector. The size of
this orifice is determined by the posi-
tion of the intermittent selector (in-
ner knob) and establishes the length
of wiper cycle dwell (Sketch II, Fig.
4).
As the diaphragm moves down-
ward, the governor valve cam is ro-
tated thru the spiral action of the
cam follower, opening the lower
chamber of the electrical switch dia-
phragm to atmosphere. The com-
pressed diaphragm spring moves the
switch into the closed position, actu-
ating the wiper motor. Simultane-
cessory position momentarily, with
the wiper switch off. After bringing
the pivot shafts to their park posi-
charge indicator gauge, and speed-
ometer,it is necessaryto removethe
instrument cluster assembly.
INSTRUMENT PANEL CONTROL
IDENTIFICATION LENS-
FAIRLANE
1. Disconnectthe battery ground
cable.
2. Remove the radio, knobs and
nuts.
3. Disconnectthe speedometer ca-
ble.
4. Remove the screws from the
cluster assemblyand position it out-
ward.
5. Disconnect the bulbs, constant
voltage regulator and ground wire,
clock and the fuel gauge.Move the
cluster assemblyto a bench.
6. Removethe clock knob and the
screwsretaining the rear clustercov-
er which retains the speedometer,
15-15
ously, the rotational movement of
the valve cam applies manifold vac-
uum to the upper chamber of the
governor, thus beginning a new cycle.
If the engine is subjected to sudden
acceleration as in passing, the avail-
able manifold vacuum will be great-
ly reduced. When the vacuum loss
becomes sufficient to allow the elec-
trical switch diaphragm spring to
overcome the vacuum, the switch
will be moved to the closed position
providing continuous wiper opera-
tion. This will continue until the en-
gine has returned to an operating
condition that will provide normal
manifold vacuum. The wipers will
then return to whatever wiper cycle
dwell had been previously selected.
In the same manner as above, un-
der engine acceleration, if any loss
of vacuum or pressure in the inter-
mittent control system occurs due to
a mechanical failure or malfunction,
the wipers will automatically shift to
continuous operation, thereby render-
ing the system fail safe (Sketch III,
Fig. 4).
tions, install the wiper blades so
that they lie flat against the lower
edge of the windshield.
clock, fuel gauge, and bulbs for the
alternator, oil pressure, and hot and
cold water temperature.
7. Remove the screws from the
right side front of the cluster. Re-
move the mask and the lens.
8. Insert and position the new lens
and retaining screws.
9. Position the rear cover assem-
bly to the front of the cluster and
install the retaining screws. Install
the clock knob and screw.
10. Position the cluster assembly
and connect all leads and bulbs.
11. Position the cluster assembly
to the instrument panel and install
the retaining screws.
12. Position the radio to the clus-
ter and install the nuts and bulbs.
13. Connect the speedometer ca-
ble.
14. Connect the battery and check
the operation of all disconnected
parts.
1 5-16 GROUP 15 LIGHTINGSYSTEM,HORNSAND INSTRUMENTS

AUXILIARY INSTRUMENT 6. Install the constant voltage reg- FUEL GAUGE-FALCON,

CLUSTER-MUSTANG
RALLY PAC
REMOVAL
1. Disconnectthe battery ground
cable.
2. Disconnectthe wiring. Note the
color code relationships(for correct
assemblylater).
3. Remove the mounting clamp
assemblyscrews below the steering
column and removethe clamp.
4. Removethe RALLY PAC clus-
ter assemblyfrom the steering col-
umn.
INSTALLA nON
1. Positionthe RALLY PAC clus-
ter assemblyto the steeringcolumn.
2. Position the mounting clamp
and install the retaining screws.
3. Connect the wiring (Fig. 5).
4. Connectthe battery ground ca-
ble.
..
~::::;:::::::;::::
ulator in place with the ground wire MUSTANG
and retaining screw and connect the 1. Removethe instrument cluster
electrical leads to the regulator. assembly.
7. Install the instrument cluster as- 2. Remove the six screwsretain-
sembly to the instrument panel and ing the instrumentclusterback plate
secure it with screws. assembly,and removethe back plate
8. Connect the speedometer cable.
assembly.
9. Check the operation of all dis- 3. Removethe two screwsretain-
connected parts. ing the fuel gaugeto the back plate
and removethe gauge.
CONSTANT VOLTAGE
4. Position the fuel gaugeand in-
REGULATOR-FAIRLANE stall the two retaining screws.
1. Disconnect the battery ground 5. Position the back plate assem-
cable. bly and install the six retaining
2. Remove the radio knobs, screws.
mounting nuts and radio. 6. Install the instrument cluster as-
3. Disconnect the speedometer ca- sembly in the instrument panel.
ble.
4. Remove the screws retaining FUEL GAUGE-COMET
the cluster assembly to the instru- 1. Disconnect the battery.
ment panel. Position the cluster out- 2. Disconnectthe speedometerca-
ward. ble.
5. Disconnect the wire leads and 3. Remove the screws retaining
remove the mounting screw from the the cluster assemblyto the instru-
TO TACHOMETER (Red) TO IGNITION SWITCH
-,,-cc "'f"" ;;
-:::;- :::=::::-~(Red-GreenStr;pe)
~~~~:I~TOR (,"k)W!RE

\ -\:::::::5~;;;;======:--
Pin"
~
c: \
~ ~~
\C { I,f'
;;:~;;~;~~
""':;-'
~
l!}, ~ ,/ \ "

~j
l~~~y
.""--
'y1
Red Stripe
:HOMETER LlGtlT 'Cc...
~ -17
:'i:r:
/1
/I'
-;;f;
PAC

Slue ':~';"c"
. TO IGNITION SWITCH Block. Green Stripe
/
AND~ES.I~T,QR(, '.~t~
W)) GROUND
Block
'---
'TOCLOCKlIGHT
Slue-ReJ Stripe
.,
~~~
CLOCK POWER
Slue -Slack Stripe
PAC

III U VIEW THROUGH INSTRUMENT PANEL K 1573-A

FIG. 5-Rally PacWiring Connections

CONSTANT VOLTAGE
REGULATOR-COMET
1. Disconnectthe battery ground
cable.
2. Disconnectthe speedometer ca-
ble.
3. Removethe instrument cluster
assemblyfrom the instrument panel
and tilt the cluster outward.
4. Disconnectthe wires from the
constantvoltage regulator.
5. Remove the constant voltage
regulatorretaining screwand remove
the regulator and ground wire from
under the samescrew.
constant voltage regulator and re- ment panel and position it outward.
move the regulator. 4. Disconnect the bulbs, tempera-
6. Position the new constantvolt- ture gauge, fuel gauge, constant volt-
age regulator, install the mounting age regulator, and charge indicator
screw and connectthe wire leads. and remove the assembly to a
7. Positionthe clusterassemblyto bench.
the instrument panel and install the 5. Remove the screws retaining
retaining screws. the back cover of the cluster to the
front of the cluster. There is no clock
8. Position the radio to the clus- in this cluster. The light for the oil
ter and install the nuts and knobs.
pressure indicator is in the charge in-
9. Connectthe speedometer cable. dicator gauge.
10. Connectthe battery and check 6. Remove the nuts retaining the
the operation of all disconnected fuel gauge.
parts. 7. Position the new fuel gauge and

install the retaining nuts.
8. Position the rear cover to the
front of the cluster with retaining
screws. The rear cover retains all
gauges and the speedometer head.
9. Position the cluster assembly
and connect all leads and bulbs.
10. Install the cluster assembly to
the instrument panel and secure it
with screws.
11. Connect the speedometer ca-
ble.
12. Connect the battery and check
the operation of all disconnected
parts.
FUEL GAUGE-FAIRLANE
1. Disconnectthe battery ground
cable.
2. Remove the radio knobs,
mountingnuts and radio..
3. Disconnectthe speedometer ca-
ble.
4. Removethe screwsretainingthe
cluster assemblyto the instrument
panel. Position the cluster assembly
outward.
5. Disconnectthe bulbs, constant
voltageregulator, the clock and fuel
gauge.Removethe cluster assembly
to a bench.
6. Removethe clock knob and the
screws retaining the rear cluster
cover.
The cover retainsthe speedometer,
clock and fuel gauge,also the bulbs
for the alternator charge indicator,
oil pressuregaugeand the hot-cold
enginetemperatureindicator.
7. Remove the screws retaining
the speedometerhead to the cover
and four rubber insulators.Remove
the head.
8. Removethe nuts retaining the
fuel gauge,and remove the gauge.
9. Install the new fuel gaugewith
mounting nuts.
10. Position the speedometerand
install the retaining screws at the
rear. Install the four rubber insula-
tors in the front.
11. Positionthe rear cover assem-
bly to the front of the cluster and
install the retaining screws. Install
the clock knob and screw.
12. Position the cluster assembly.
Connect all of the wire leads and
bulbs.
13. Position the cluster assembly
to the instrument panel and install
the retaining screws.
14. Position the radio to the clus-
ter and install the mountingnuts and
knobs.
15. Connect the speedometerca-
ble.
PART 15-4 INSTRUMENTS
16. Connectthe battery and check
the operation of all disconnected
parts.
FUEL SENDINGUNIT
1. Removethe fuel from the fuel
tank.
2. Disconnect the fuel gauge send-
ing unit wire from the sending unit.
3. Loosenthe hoseclamp and dis-
connectthe tank line at the sending
unit.
4. Remove any dirt that has ac-
cumulated around the sending unit
so that it will not enter the tank.
S. Turn the sendingunit retaining
ring counterclockwiseand remove
the unit, retaining ring, and mount-
ing gasket.
6. Clean the fuel gauge sending
unit mounting surface at the fuel
tank.
7. Position the sending unit and
mountinggasketon the fuel tank and
securewith the retaining ring.
8. Connect the sendingunit wire
and the fuel tank line.
9. Fill the tank with the fuel re-
moved.
10. Check the fuel gauge opera-
tion and check for leaks.
TEMPERATURE GAUGE
1. Remove the instrument cluster
assembly.
2. Remove the six screws retain-
ing the instrument cluster back plate
assembly and remove the back plate
assembly.
3. Remove the two screws retain-
ing the temperature gauge to the
back plate and remove the gauge.
4. Position the temperature gauge
and install the two retaining screws.
5. Position the back plate assem-
bly and install the six retaining
screws.
6. Install the instrument cluster as-
sembly in the instrument panel.
TEMPERATURE GAUGE
-COMET
1. Disconnect the battery.
2. Disconnect the speedometer ca-
ble.
3. Remove the screws retaining
the cluster assemblyto the instrument
panel and position it outward.
4. Disconnect the bulbs, tempera-
ture gauge, fuel gauge, constant volt-
age regulator, and ammeter and re-
move the assembly to a bench.
5. Remove the screws retaining
the back cover of the cluster to the
front of the cluster. There is no clock
15-17
in this cluster. The light for the oil
pressure indicator is in the ammeter.
6. Remove the nuts retaining the
temperature gauge.
7. Position the new gauge and in-
stall the retaining nuts.
8. Position the rear cover to the
front of the cluster with retaining
screws. The rear cover retains all
gauges and the speedometer head.
9. Position the cluster assembly
and connect all leads and bulbs.
10. Install the cluster assembly to
the instrument panel and secure it
with screws.
11. Connect the speedometer ca-
ble.
12. Connect the battery and check
the operation of all disconnected
parts.
TEMPERATURE SENDING UNIT
1. Disconnect the temperature
sending unit wire from the sending
unit.
2. Prepare the new temperature
sending unit for installation by apply-
ing a small amount of conductive
water resistant sealer C3AZ-19554-
B, to the threads.
3. Remove the temperature send-
ing unit from the cylinder head and
immediately install the new tempera-
ture sending unit.
4. Connect the wire to the tem-
perature sending unit.
5. Start the engine and check the
sending unit operation.
OIL PRESSURE INDICATOR
GAUGE-COMET
1. Remove the instrument cluster
assembly.
2. Remove the six screws retain-
ing the instrument cluster back plate
assembly and remove the back plate
assembly.
3. Remove the two screws retain-
ing the speedometer, the two screws
retaining the speedometer dial to the
back plate, and remove the speedom-
eter assembly.
4. Remove the two nuts retaining
the oil pressure gauge and remove
the gauge.
5. Position the oil pressure gauge
and install the two retaining nuts.
6. Position the speedometer as-
sembly and install the "two speedom-
eter dial retaining screws and the
two speedometer retaining screws.
7. Position the back plate assem-
bly and install the six retaining
screws.
8. Install the instrument cluster
assembly to the instrument panel.
1 5-18 GROUP 15
OIL PRESSURE SENDING UNIT
OR OIL PRESSURE SWITCH
To replace the unit, disconnect the
wire from the terminal. Remove the
unit from the engine. Apply conduc-
tive sealer C3AZ-19554-B to the
threads of the new unit and install
the unit. Connect the wire to the ter-
minal and check the operation of the
unit.
CHARGE INDICATOR
GAUGE-COMET
1. Disconnect the battery.
2.. Disconnect the speedometer ca-
ble.
3. Remove the screws retaining
the cluster assembly to the instru-
ment panel and position it outward.
4. Disconnect the bulbs, tempera-
ture gauge, fuel gauge, constant volt-
age regulator, and charge indicator
and remove the assembly to a bench.
S. Remove the screws retaining
the back cover of the cluster to the
front of the cluster. There is no clock
in this cluster. The light for the oil
pressure indicator is in the charge in-
dicator gauge.
6. Remove the nuts retaining the
charge indicator gauge.
7. Position the new gauge and in-
stall the retaining nuts.
8. Position the rear cover to the
front of the cluster and install the re-
taining screws. The rear cover re-
tains all the gauges and the speedom-
eter head.
9. Position the cluster assembly
and connect all leads and bulbs.
10. Install the cluster assembly
to the instrument panel and secure it
with screws.
11. Connect the speedometer ca-
ble.
12.. Connect the battery and check
the operation of all disconnected
parts.
ELECTRIC CLOCK-FAIRLANE
1. Disconnect the battery ground
cable.
2.. Remove the clock setting knob.
3. Remove the clock push-on con-
nector.
4. Remove the clock screws and
the clock from under the instrument
panel. Handle the clock with care, as
the clock hands are not protected.
s. Position the clock from the un-
derside of the instrument panel and
install the retaining screws.
6. Push on the clock wire connec-
tor.
7. Install the clock setting knob.
8. Connect the battery ~round ca-
LIGHTINGSYSTEM,HORNSAND INSTRUMENTS
ble and set the clock hands to the
exact time.
TURN INDICATOR SWITCH
REMOVAL
1. Disconnect the negative
(ground) cable from the battery.
2. Removethe steeringwheel hub
and steeringwheel retaining nut.
3. Remove the steering wheel
from the shaft.
4. Disconnect the two wire-con-
nector blocksat the dashpanelabove
the steeringcolumn.
5. Removethe wires and terminals
from the connectorblocks. This can
be doneby depressingthe tab on the
wire terminal with an awl, or by in-
serting a ball point pen (refill plas-
tic type) over the bullet pin and pull
the wire and terminal from the con-
nector block. Record the color code
and location of eachwire before re-
moving it from the connectorblock.
Tape the wires together and attach
a pieceof heavycord to the wires to
help pull the wires through the steer-
ing column during installation.
6. Remove the turn indicator
handle from the side of the steering
column.
7. Remove 3 bearing retainer at-
taching screwsand removethe bear-
ing retainerand turn indicator switch
and wires from the steeringcolumn.
Disconnectthe heavy cord from the
switchwires.
INSTALLATION
1. Tape the ends of the switch
wires together and attach the cord
to the wires.
2. Pull the wires down through
the steering column with the cord,
and position the switch to the steer-
ing column hub.
3. Install the bearingretainer and
attachingscrews.
4. Install the turn indicator switch
lever.
5. Pressthe switch wires into the
connectorblocks in their correct lo-
cation recordedduring removal.Plug
the connector blocks together with
the mating connector blocks at the
dashpanel.
6. Install the steeringwheelon the
shaft.
7. Install the steering wheel re-
taining nut and hub.
8. Connect the battery ground
cableand checkthe operationof the
turn signal switch and horns.
TURN INDICATOR FLASHER
Disconnect the wires from the
flasher unit terminals and pull the
flasher from its retaining clip. Ob-
serve the color code and number on
the cover of the flasher. Be certain
to replace it with a new flasher with
the same color code and number on
the cover.
EMERGENCY
WARNING
FLASHER
Pull the flasherfrom the retaining
clip, and disconnectthe wires (Fig.
6).
SPEEDOMETER-FAIRLANE
1. Disconnectthe battery ground
cable.
2. Remove the radio knobs,
mountingnuts, and radio.
3. Disconnectthe speedometer ca-
ble.
4. Remove the screws retaining
the cluster assemblyto the instru-
ment panel. Position the cluster as-
semblyoutward.
5. Disconnectthe bulbs, constant
voltage regulator and its ground
wire, the clock and the fuel gauge.
6. Removethe cluster assemblyto
a bench.
7. Removethe clock knob and the
screwsretaining the rear cluster cov-
er. The cover retains the speedome-
ter, clock, fuel gauge,the bulbs for
the alternator charge indicator, oil
pressure,and the hot and cold en-
gine temperature indicators.
8. Remove the screws retaining
the speedometerhead to the cover
and the four rubber insulators. Re-
move the speedometerhead.
9. Position the speedometerand
install the retaining screws at the
rear. Install the four rubber insula-
tors.
10. Position the rear cover assem-
bly to the front of the cluster. In-
stall the retaining screws.Install the
clock knob.
11. Position the cluster assembly.
Connectall leadsand bulbs.
12. Position the cluster assembly
to the instrument panel. Install the
retaining screws.
13. Position the radio to the clus-
ter and install the mountingnuts and
knobs.
14. Connect the speedometerca-
ble.
15. Connectthe batterygroundca-
ble and check the operation of the
disconnectedparts.
SPEEDOMETER-COMET
1. Disconnectthe battery ground
cable.
2. Disconnectthe speedometerca-

~
, ,
, ,
I 1. Disconnect the battery ground
I 2. Remove both control knobs
I
~ ,
.../ ~~~-ij"'--:.~-
, /Q,;~~~.:;;o---, ---,
\
'
STEERING COLUMN
TO FRONT OF
V"Hlrl"
15583- EMERGENCYWARNING-WIRING,
SWITCHAND FLASHER ASSEMBLY
FIG. 6-EmergencyWarningFlasher
ble.
3. Remove the screws retaining
the cluster assemblyto the instru-
ment panel. Position the cluster as-
semblyoutward.
4. Disconnectthe bulbs, and wir-
ing from the temperature gauge,
fuel gauge,constantvoltage regula-
tor and chargeindicator. Removethe
assemblyto a bench.
5. Remove the screws from the
cover retaining the back portion of
the cluster assemblyand separateit
from the front portion.
6. Remove the screws retaining
the speedometerand remove the
speedom~t~r head.
7. Position the new speedometer
headand.i?stall the retaining screws.
8. Position
cluster to thethe back cover
forward portionof and
the
install the retaining screws.The back
cover housesall of the gaugesand
the speedometer head.
9. Connect all wire leads and
bulbs in the cluster assembly.
10. Position the cluster assembly
to the instrument panel and install
the retaining screws.
11. Connect the speedometerca-
ble.
12. Connectthe battery groundca-
ble and check the operation of all
disconnectedparts.
SPEEDOMETER-FALCON,
MUSTANG
1. Disconnectthe battery ground
cable.
2. Disconnect the speedometer
cable.
3. Removethe instrument cluster
assembly.
4. Remove the six screws retain-
ing the instrument cluster back plate
~
PART 1 5 -4 -INSTRUMENTS 15-19
the retainer clip through the gear
SWITCHAND FLASHER slots.
I
LOCATION AND MOUNTING
(TYPICAL)
.:-:::::::::=:::::::::::::::::::::::::::::::::::::. WINDSHIELD WIPER SWITCH
"
-FAIRLANE
cable.
and disconnect the washer.
l
I
~:::E:::::::::::::::::~~~~~~~~~~~~~~~.
?-
3. From the lower edge of the
cluster remove the retaining screws
from the switches. Disconnect the
electrical leads and remove the switch
assembly from the instrument panel.
4. Remove a screw and separate
/ the wiper and washer switches from
~ ~ each other including the plastic bar
between the switches.
K1578.B
~
5. Assemble the wiper and wash-
er switches to each other including
the plastic bar so that when the
assemblyand removethe back plate washer switch is turned on the wip-
assembly. ers will start.
5. Removethe two screwsretain- 6. Connect the electrical leads to
ing the speedometer,the two screws the assembly and install it to the in-
retaining the speedometer dial to the strument panel.
back plate, and removethe speedom- 7. Install the control knobs and
eter assembly. connect the wiper washer.
6. Position the speedometerand 8. Connect the battery ground ca-
install the two speedometerdial re- ble.
taining screwsand the two speedom-
eter retaining screws. WINDSHIELD WIPER MOTOR
7. Position the back plate assem- -EXCEPT FAIRLANE
bly and install the six retaining 1. Disconnectthe harnessconnec-
screws. tor from the wiper motor.
8. Install the instrumentclusteras- 2. Remove the three bolts retain-
semblyto the instrumentpanel. ing the wiper motor and mounting
9. Connect the speedometer cable, bracket assembly to the dash panel.
avoiding sharp bends. Lower the assembly and disconnect
10. Connect the battery ground the wiper links at the motor. Remove
cable. the motor and bracket assembly.
3. Transfer the mounting bracket
SPEEDOMETER CABLE with grommets to the new motor.
To replace the speedometer drive 4. Position the motor and bracket
cable, disconnect the cable housing assembly and connect the wiper links
from the speedometer, and pull the to the motor.
cable out of the housing. Wipe off S. Position the motor and bracket
all of the old lubricant. Lubricate assembly to the dash panel and in-
the new cable with cable lubricant stall the three retaining bolts.
B5A-19581-A (do not over lubri-
6. Connect the harness connector
to the wiper motor.
cate), insert it all the way into the
7. Connect the battery and check
housing, and twist it slightly to make
the operation of the wiper motor and
sure that the squared drive is
the park position of the wiper blades.
engaged in the speedometer driven
gear. If a speedometer cable is bro- WINDSHIELD WIPER MOTOR
ken, it wiD be necessaryto disconnect -FAIRLANE
both ends of the cable housing in
1. Disconnect the wiper links drive
order to remove the broken sections. arm from the wiper motor drive shaft
Tighten the mounting bolt to 3-41/2 (under the instrument panel).
foot-pounds torque (Fig. 7). 2. Disconnect the wiring leads
The speedometer driven gear is from the motor.
held on to the speedometer cable 3. Remove the wiper motor
housing by a retainer clip. When re- mounting bolts and remove the mo-
placing the driven gear, make cer- tor.
tain that the gear is secure by placing 4. Apply sealer around the edge of
the gear in position before inserting the new motor mounting bracket and
 1 5-20 GROUP lS LIGHTINGSYSTEM,HORNSAND INSTRUMENTS

7. Checkthe operationof the wip-

FIG. 7-SpeedometerDriven Gear Retainer and Mounting
around each bracket bolt hole. Posi-
tion the motor to the dashand install
the mounting bolts.
5. Attach the wiring leads to the
'-- er and adjust the park position if
necessary.
) \ WIPER PIVOT SHAFT AND
LINK
1. Remove the windshield wiper
/ blade and arm assembly.
2. Removethe pivot shaft retain-
ing nut, bezeland gasket.
3. Disconnectthe wiper link from
the motor and remove the link and
pivot shaft assembly.
4. Positionthe link and pivot shaft
assemblyon the cowl and wiper mo-
tor. Connectthe link to the motor.
K 1629-A 5. Install the pivot shaft to the
cowl and install the gasket, bezel,
and retaining nut.
motor. 6. Install the wiper blade and arm
6. Position the wiper links drive assembly.
arm on the motor driveshafi and in- 7. Check the pivot shaft and link
stall the mounting nut. operation.

MAJOR REPAIR OPERATIONS

DISASSEMBLY-PERMANENT 1. Remove the gear cover retain- tainer.
MAGNET TYPE SINGLE OR ing screws, ground terminal and cov- 3. Removethe idler gear and pin-
TWO-SPEED ELECTRIC er (Fig. 8). ion and thrust washer.
WIPER MOTOR 1. Remove the geai"and pinion re- 4. Remove the motor through

SPRING WASHER
/ OUTPUT ARM SPACER WASHER
0 RING

GEAR HOUSING
""~::o ..,.,. -
(
ARMATURE SHAFT
END PLAY SPRING
PARK SWITCH TO
~tf.~~~~g;=:::~i:!:::
1> , ~""..'~ --' ~" , PARKING SWITCHLEVER
PARK SWITCH '-
SCREW(y/,,~
ADJUSTING OUTPUT GEAR AND SHAFT

\ """, :::~:::::_~'(3) BRUSH PLATE

AND SWITCH ,
,'t» ' GEAR
COVER
~ ASSEMBLY
e,
"",""
PARKING SWITCH
FOR TWOSPEED LEVER WASHER
MOTOR
,'
'{ ltJ IDLER GEAR -::i::;
'\J ANDPINION i' ",."~

,.
r'

.
(2) BRUSH PLATE
AND SWITCH
GEAR AND PINION RETAINER
ASSEMBLY
ARMATURE FOR SINGLE SPEED
MOTOR
GROUND
TERMINAL

MOTOR HOUSING AND

MAGNET ASSEMBLY

K 1632- A

FIG. 8-DisassembledSingleor Two-Speed

Wiper Motor-PermanentMagnet
Type
~
 PART 15-4 INSTRUMENTS 15-21

bolts, motor housing, switch terminal 7. Apply Sun Prestige grease to justment (Figs. 8 and 10).
insulator sleeve, and armature. Do the ball bearing in the end of the Remove the motor thru bolts and
not pound the motor housing magnet armature shaft. Position the arma- remove the motor cup and armature.
assembly as the ceramic magnets ture shaft in the gear housing and Rotate the output shaft until the
may be damaged. remove the brush retracting wires. park switch lower contacts are firm-
5. Mark the position of the output 8. Holding the armature in posi- ly closed as shown.
arm with respect to the output shaft, tion, install the terminal insulating Rotate the adjusting screw clock-
for assembly. Remove the output sleeve, motor housing and magnet wise until the park switch lower con-
arm retaining nut, output arm, spring assembly, and through bolts. Seal the tacts just open.
washer, flat washer, output gear- area where the terminal insulator
Rotate the adjusting screw coun-
shaft assembly, thrust washer, and sleeve seats against the motor and
terclockwise one full turn.
parking switch lever and parking gear housings.
switch lever washer. Check the bridge to assure that
9. Apply Sun Prestige grease to
the legs are contacting the brush
6. Remove the brushes and brush the worm gear and idler gear, and
install the idler gear, thrust washer plate when the lower contacts are
springs. closed.
7. Remove the brush plate and and retainer.
10. Apply a generous amount of Install the armature, motor cup
switch assembly, and remove the
switch contact to parking lever pin Sun Prestige grease to the area and thru bolts.
from the gear housing. around the end of the armature DISASSEMBLY-OSCILLATING
shaft. Install the gear housing cover TYPE TWO-SPEED ELECTRIC
PARTS REPAIR OR and ground terminal.
REPLACEMENT WIPER MOTOR
All parts on both the single-speed WINDSHIELD WIPER MOTOR The two-speed electric motor may
and two-speed wiper are replaced PARK SWITCH TEST AND be disassembled for service of the
and not repaired. ADJUSTMENT-SINGLE AND drive mechanism parts.
TWO-SPEED PERMANENT 1. Remove the gear housing cover
ASSEMBLY-PERMANENT MAGNET TYPE plate and gasket (Fig. 11).
MAGNET TYPE SINGLE 2. Remove the output shaft re-
OR TWO-SPEED ELECTRIC With jumper wires connected as
shown in Fig 9, the motor should tainer and spacer washer.
WIPER MOTOR
move to the park position. If it does, 3. Remove the crankpin bearing
1. Install the parking switch lever
the motor is all right and the fault retainer and remove the spacer wash-
washer.
lies in the panel switch or wiring. If er and cam return spring assembly.
2. Install the parking switch lever
the motor does not park, proceed 4. Remove the arm and link as-
on the gear aQd pinion shaft with the
with the following park switch ad- sembly.
cam rider pointing toward the gear
housing output shaft hole. Make cer-
tain that the lever bottoms against
the casting.
3. Apply a film of Sun Prestige
grease to the output gear teeth and
shaft bearing surface. Insert the shaft
in the bearing. Make certain that
the parking switch lever is clear of
the cam and gear assembly.
4. Place the spacer washer and
spring washer on the shaft, position
the output arm on the shaft in the
marked position from which it was
removed, and install the mounting
nut.
5. Position the brush springs and
brushes in the holders and wrap wire
around them to hold them in the
fully retracted position. Push the in-
sulated brush connector onto the
switch terminal.
6. Place the switch-contact to
parking-lever pin in the gear hous-
ing. Position the brush plate assem-
bly to the housing and install the
mounting screws.
Make the park switch contact
points adjustment covered under
Windshield Wiper Motor Park Switch K 1630 A
Test and Adjustment-Single and
Two-Speed Permanent Magnet Type FIG. 9-Windshield Wiper Motor Park SwitchTest-
in this section. Single-Speed
 PARTS REPAIR OR
REPLACEMENT
~ All parts on both the single-speed
and the two-speed electric wipers
are replaced and not repaired.

ASSEMBLY-OSCILLATING
"':;'l' TYPE TWO-SPEED ELECTRIC
WIPER MOTOR
1. Tighten the motor cover. Ad-
just the motor shaft end play to
BRIDGE
LEGS 0.000-0.005 inch by turning the shaft
stop screw. Measure with a feeler
~.. 'f:- ~. gauge between the stop screw and
the motor shaft.
LOWER. / i~!, 2. Install the input gear shim on
CONTACTS : the input gear shaft and install the
gear in the housing. Adjust the end
play to 0.005 to 0.010 inch by add-
ing or removing shims under the in-
put gear retainer. Install the retain-
7, er.
3. Install the output gear on the
output shaft. Make surethat the gear
"~- OUTPUT
SHAFT is bottomed on the shaft.
4. Install the output shaft and gear
assemblyinto the housing with the
~ gear teeth facing the motor. Install
K1631-A one spacerwasherto the outsideend
of the output shaft and assemblethe
FIG. 1 a-Windshield Wiper Motor Park Switch Adjustment wiper arm lever to the output shaft,
with the linkage studs facing away
from and abovethe shaft. Securethe
RET~INER , I
01, ITPI'JT
. GFAR lever with a lock washerand nut.
~V. --
-~PACER WASHER GEAR H~~""""'~-.. 5. Place the bearing cam on the
OUTPUT SHAFT j \, l GEAR crankpin with the small diameter
", HOUSING
.. COVER
portion of the cam facing outward.
I... 6. Install the arm and link assem-
SHIMS\ ,~
19 GASKET bly to the bearing cam. As the arm
is placedon the shaft, the gearsmust
"
-- c
\
be meshedand the link which is riv-
J
RING GEAR ~ '0 eted to the arm must be installed to
\
,.." the output shaft at the same time.
RETAINER ~\ B
MOTOR SHAFT
Proper gear indexing is obtained
STOP SCREW --.,: RING "" '_~6 when the bottom tooth of the arm
WORM --~., GEARSHIM 'J --
INPUT GEAR I
Y@~
r
and gear segmentwill be in mesh
with the bottom valley of the output
TESTING CONNECTIONS
CRANKPIN ~,i RETAINER! shaft gear.
TO PARK
B TERMINALTO VOLTAGE SOURCE BEARING CAM
CAM RETURN
J ""
-
""'~ 7. Install the output shaft spacer
C TERMINALTO Blue AND Red
Yellow TO White Black TO GRnIINr"J SPRING ASSEMBLY. washerand retainer. Check the end
TO OPERATE AT HIGH SPEED TO OPERATE AT LOW SPEED
"'.I play of the output shaft (0.005-0.010
Yellow TO VOLTAGE SOURCE Red AND Yellow TO VOLTAGE SOURCE inch). Remove or install spacer
Blue TO White Black TO GROUNr-
,..J Blue TO White Block TO GROUND washersunder the shaft retainer to
BAND C TERMINALS
AND Red NO CONNECTION
-
R At-in r TFRMlt-IAI'<:t-In rnt-it-lFrTlnN J
K1090-D adjust the end play.
8. Install the cam return spring
FIG. 11-Two-SpeedWiper Motor-OscillatingType assembly.
9. Install the bearing spacer and
S. Remove the crankpin bearing and spacer,and remove the output retainer.If the retainer cannotbe in-
cam. shaft and gear assemblyfrom the stalled, one or more coils of the
6. Removethe input gear retainer housing. spring clutch are probably out of
and outer spacershim, and remove 9. The output gear may be re- place. If the bearing has excessive
the input gear and inner spacer movedfrom its shaft by tappingwith end play on the crankpin, the pro-
shim. a fiber hammer. Be careful not to jection of the bearing may ride out
7. Remove the wiper arm lever damagethe end of the shaft. of the semi-circularslot in the end
nut and lock washer. The worm drive gearand armature plate. Add spacerwashersunder the
8. Remove the wiper arm lever assemblyis not serviced. retainerif necessary.
~
 10. Apply generous amounts of
Sun Prestige grease to all moving
parts. Install the gear housing cover
plate.
When operating the unit on the
bench, do not place hands or fingers
between the wiper lever and the case,
or inside the gear housing, as con-
siderable power is developed by the
gear reduction.
ELECTRO-PNEUMA TIC
GOVERNOR AND CONTROL
SELECTORSWITCH-COMET
The electro-pneumatic governor
and the control selector switch are
servicedas assembliesonly. Should
any internal componentbecomede-
fective the complete assemblymust
bereplaced.
In the event of suspectedpartial
or total blockage of internal pas-
sages,light air pressuremay be ap-
plied in an attempt to remove the
causeof blockage.
Although the vacuumhosesare an
integral part of the wiring harness
assembly,individual hosesmay be re-
placed if required.
SPEEDOMETER DIAGNOSTIC
PROCEDURES
Speedometersystem complaints are
generally the result of a visible or
audible defect in the system. It is im-
perative that the specific defect be
determined prior to attempting any
physical repairs to preclude unnec-
essarily disassembling system compo-
nents. The following suggestions are
intended to aid in quick and accurate
system problem diagnosis.
VISmLE DEFECTS
Slight Needle Waver or
Severe Needle Fluctuation
(No Noise)
1. Loosecable nut.
2. Defective speedometerhead.
3. Bent cable core at attaching
nut.
4. Kinked or pinched cable hous-
ing.
5. Excessivegreasein speedome-
ter head.
6. Defective speedcontrol regula-
tor.
Inoperative
1. Broken cable core.
2. Defective drive and/or driven
gear.
3. Defectivespeedometer head.
AUDmLE DEFECTS
Clicking or Ticking (With
Needle Waver), Grinding
or Ringing
1. Loosecablenut.
2. Defective drive and/or driven
gear.
3. Defective speedometerhead.
4. No lube on cable.
SPEEDOMETER
REPAIR
PROCEDURES
LOOSE CABLE ATTACHING
NUTS
1. Cable nuts should be tightened
with pliers to approximately18 to 25
in-lbs.
2. Cablenuts shouldstart and run
up freely by hand for at least three
to four turns.
3. A loose cable nut can causea
bent cable core. Tightening will not
alwayscorrect the problem.
DEFECtIVE SPEEDOMETER
HEAD
Before removing a speedometer
head, disconnect the cable at the
headand inserta short sectionof ca-
ble core in the head.Rotate the sec-
tion of core to check for any drag-
ging or noise.The speedometer shaft
should turn freely and evenly.
DEFECTIVE CABLE CORE
AND HOUSING
1. To check for a kinked cable
core remove and wipe dry. Lay the
core out straight on a flat surface
and roll it back and forth. Any kinks
or damagewill be seen.Then take
an end in each hand, allowing core
to hang in approximately a 9-inch
loop. Rotate both ends to be sure
core turns evenly.
2. Routing of the cablehousingis
particularly important where the ca-
ble leavesthe speedometer head.The
optimum routing would provide that
the cable and housing take virtually
no change of direction for at least
a length of 8 inchesfrom the speed-
ometerhead.
3. When installing a new cable
and housing it is necessarythat the
new assemblybe guided and routed
properly to eliminate any kinks.
4. Proper lubrication of the cable
core is accomplishedby a light ap-
plication of B5A-19581-A lubricant
after the cablehas beenwiped clean.
A light film is all that is required.
DEFECTIVE DRIVE AND
DRIVEN GEARS
1. A scorenicked or gougeddriv-
en gear is usually indicative of a de-
fective drive gear on those vehicles
that have the drive gear integral
with the transmissionoutput shaft.
The output shaft should be carefully
inspectedfor imperfectionsand re-
placedif necessary.
2. A driven gear with two or
three adjoining teeth badly scored is
indicative of improper assemblypro-
cedure.The gear should be inserted
in the transmissionwhile simultane-
ously turning the drive shaft. This
will insure initial gear engagement
and prevent gear damage. Force
should never be used.
3. Whenever a drive gear is re-
placed,a new driven gear should al-
so be installed, regardlessof its ap-
parent condition.
15-24

SPECIFICAliONS

BULB CHART

Fog-Light (Mustang)
Front Turn Signal/Parkin"
, RearTurn Signal and StoP/Tail

I EngineCompartment(Comet)
I DomeLipht

J Illumination

<DCandela
is the new internationalterm for candlepower
 PART 15-5 SPECIFICATIONS 1 5-25

CIRCUIT PROTECTION

Falcon
Comet Fairlane Mustang
FUNCTION LOCATION RATING TYPE RATINGTYPE I RATINGTYPE
I,
I Tail-Park
Lice~se.Cargo
DomeCourtesy-Map - -Fuse P"aiieI 7112SFE 71/2SFE I 7112SFE
LightSwitch 15 C.B. I 15-C:B: I 15C.B.
I Stop
~ Clock
light
~
! Light Switch 15 C.B. 15 C.B. I 15 C.B.
FusePanel 7¥2 SFE 71/2 SFE 7112 SFE
I Back-up FusePanel T4""SFE 14 SFE 14 SFE
I Turn Signals(act asa circuit breaker)
I Radio Fuse Panel (Acc. Socket) ~ 14SFE T4""SFE
FusePanel T4""SFE T4"""SFE T4""SFE
FusePanelHeaterSocket T4""SFE
FusePanel 14 SFE 14 SFE mFE
20 SFE 20 SFE I 20SFE
\ Tachometer FusePanel-{DomeSocket! 7¥2 SFE 7¥2SFE I 71f2
SFE
I Convertible
Top Betweenstarter relay & Safety ~ link SafetY"
JunctionBlock link Link
I PowerWindow-Power
s-e"it OnStarter Relay 20 C.B. 20 C.B. I 20C.B.
I Overdrive Clipsto overdriverelay 20m 20 SFE I 20SFE
I Seat Belt Warning Fuse 14 SFE T4""SFE T4"""SFE
WindshieldWasher Panel 14 SFE 14 SFE
(Twospeedwiper) Acc.
WindshieldWasher Socket 14SFE 14SFE I 14 SFE
(SinRlespeedwiper)
WindshieldWasher WiperSwitch 12 C.B.
(Twospeedwiper)
WindshieldWiper WiperSwitch 6 (S. Sp,) C.B. 6 (S. Sp.) C.B. 5 (S.Sp.JC.B. ,
7 (2 Sp,) C.B. 7 (2 Sp.J C.B. 12 (2 Sp.JC.B.
(Falcon)
7 Intermittent
Light-InstrumentPanel FusePanel 21fz AGA 21f2 AGA 2¥2 AGA
Light-InstrumentCluster Instrument 21fz AGA 21f2 AGA 2¥2 AGA
Light-Clock LPSocket 21fz AGA 21f2 AGA 21/2 AGA
Light-Tachometer Connectedinto 21fz AGA 21/2 AGA 21/2 AGA
Light-AshReceptacle 15 C.B. 21fz AGA 21f2 AGA 2¥2 AGA
Light-PRNDL Dial LightSwitch 21fz AGA 21f2AGA
I Uf1ht-PRNDl Dial (ConsoleOnly) FusePanelAcc.Socket 14SFE
~~ ,s~~- I
~Luggage Compartment FusePanel 7¥2 SFE 71/2 SFE -7TJ;m
I Light-Door
OpenWarning FusePanel 71/2 SFE
FusePanel. 7112 SFE 7¥-;;;t~ 7¥2 SFE
In Line 71/2 SFE 7¥2 SFE I 7¥2SFr-
light-Headlights LightSwitch 18 CometC:B:r
12 FalconC.B!
I EmergencyWarningFlasher FusePanel 14SFE I 14SFE 14Sff
~Horns li~ht Switch 15 C.B. I 15 C.B. 15c:B:""
Air Conditioner(Integrated) OnIgn.Switch 25 C.B. 25c:B:- 25-c:B:-
BackLight Control At StarterRelay 20 C.B. 2Off
I EconomyAir Conditioner In line 15AGC 15AGC 15 AGC
MotorWindshieldWiper Circuit C.B. C.B. C.B.
Motor ConvertibleTop Breaker C.B. C.B. C.B.
Motor PowerWindow
Integral C.B. C.B.
With C.B.
I Motor PowerSeat Motor C.B. C.B. C.B.

SPEEDOMETER CABLE

Mounting Clip bolt Torque 3-41/2 ft. Ibs.