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 1962-63 Ford Galaxie and Mercury Monterey Shop Manual EAN: 978-1-60371-057-2 ISBN: 1-60371-057-4 Forel Publishing Company, LLC 3999 Peregrine Ridge Ct.
FOREWORD This manual provides information for the proper servicing of 1962 Ford Galaxie, Galaxie 500, and Station Wagons. The descriptions and specifications contained in this manual were in effect at the time the manual was approved for printing. The Ford Division of Ford Motor Company reserves the right to discontinue models at any time, or change specifications or design, without notice and without incurring obligation.
FORD GALAXIE IDENTIFICATION BODY COLOR TRIM DATE D.S.O. AXLE TRANS. SERIALNUMBER MADE IN U.S.A. BY REG. U.S. PAT. OFF. THIS VEHICLE IS CONSTRUCTED UNDER UNITED STATES LETTER PATENTS 2590719 2617681 2631694 2677572 2677574 2683578 2698012 2726894 2782722 2784363 2789621 2810447 OTHER PATENTS PENDING M1071-A Fig. 1— Ford Galaxie Patent Plate The Patent Plate is attached to the left door front pillar. Code A D E VEHICLE DATA Example (Fig. 1): 65A FM 12 65A FM 12 21H 1 3 21H 1 3 .
FORD CAR IDENTIFICATION SERIAL NUMBER TRIM (Continued) Trim Schemes Code 34. 35. 37. 39. 45. 54. 56. 62. 63. 72. 73. 74. 75. 77. 85. Example (Fig.
GROUP I ENGINES AND EXHAUST SYSTEMS PAGE P A RT 1 - 1 GENERAL ENGINE SERVICE 1-2 PART 1 - 2 MILEAGE MAKER SIX PART 1-3 292 V-8 1-42 PART 1 - 4 352 AND 390 V-8 1-65 PART 1 - 5 EXHAUST SYSTEMS 1-93 PART 1 - 6 SPECIFICATIONS 1-97 1-19
GENERAL ENGINE SERVICE Section Page 1 Engine Trouble Diagnosis.. 2 Engine Tests and Adjustments 3 Cleaning, Inspection, and Reconditioning Intake Manifold Exhaust Manifolds Valve Rocker Arm Shaft Assembly Push Rods 1-2 1-8 1-11 1-11 1-11 1-11 1-11 This part covers engine trouble diagnosis, tests, and adjustment procedures for all Ford Galaxie and Station Wagon engines. In addition, the Section 3 Cleaning, Inspection, and Reconditioning (Continued) Cylinder Heads Valves Hydraulic Valve Lifters..
P A R T 1-1-GENERAL ENGINE SERVICE 1-3 ENGINE TROUBLE DIAGNOSIS GUIDE (Continued) IF THERE IS A GOOD SPARK AT THE SPARK PLUGS ENGINE CRANKS NORMALLY, BUT WILL NOT START (Continued) Check the spark plugs. If the spark plugs are not at fault, check the following items: MANUAl CHOKE Check the choke linkage for binding or damage. Make certain the choke plate closes when the choke knob on the instrument panel is pulled out and that the plate opens when the knob is pushed in.
1-4 G R O U P 1-ENGINES AND EXHAUST SYSTEMS ENGINE TROUBLE DIAGNOSIS GUIDE ENGINE RUNS, BUT MISSES (Continued) (Continued) If a good spark occurs, check the spark plug. If the spark plug is not at fault, a mechanical component of the engine is probably at fault. ENGINE Perform a compression test to determine which mechanical component of the engine is at fault. reaching normal operating temperature. ENGINE Perform a compression test to determine which mechanical component of the engine is at fault.
P A R T 1-1-GENERAL ENGINE SERVICE 1-5 ENGINE TROUBLE DIAGNOSIS GUIDE (Continued) POOR ACCELERATION IGNITION SYSTEM Incorrect ignition timing. Fouled or improperly adjusted spark plugs. Improperly adjusted or defective breaker points. Distributor not advancing prop- Leaky power valve, gaskets, or accelerating pump diaphragm. D i r t o r c o r r o s i o n in accelerating s stem y Distributor vacuum passages in the carburet ° r blocked. Restricted fuel filter.
1-6 G R O U P 1-ENGINES AND EXHAUST SYSTEMS ENGINE TROUBLE DIAGNOSIS GUIDE (Continued) EXHAUST SYSTEM EXCESSIVE FUEL CONSUMPTION (Continued) Check the exhaust gas control valve operation. System restricted. ODOMETER Check calibration. IGNITION SYSTEM Check: Distributor breaker points. Ignition timing. ENGINE Crankcase ventilation regulator valve defective or restricted tubes (Positive Crankcase Ventilation System). FINAL CHECKS FUEL SYSTEM ENGINE Idle fuel mixture needle(s) for proper adjustment.
PART 1-1-GENERAL ENGINE SERVICE 1-7 ENGINE TROUBLE DIAGNOSIS GUIDE (Continued) ENGINE FAILS TO REACH NORMAL OPERATING TEMPERATURE NOISY HYDRAULIC VALVE LIFTER SILENT VALVE MECHANISM TEMPERATURE SENDING UNIT AND GAUGE Unit or gauge defective (not indicating correct temperature) or constant voltage regulator defective. COOLING SYSTEM Thermostat inoperative or of incorrect heat range.
G R O U P 1 - ENGINES AND EXHAUST SYSTEMS 1-8 E N G I N E TESTS A N D A D J U S T M E N T S PRELIMINARY (COLD) VALVE LASH—MECHANICAL VALVE LIFTERS If the valve rocker arm shaft assembly has been removed and installed, it will be necessary to make a preliminary (cold) valve lash adjustment before starting the engine. If the adjustment is made for an engine tune-up, follow the final adjustment procedure. The cylinders are numbered from front to rear—right bank, 1-2-3-4; left bank, 5-6-7-8.
P A R T 1-1-GENERAL ENGINE SERVICE stalled or severe wear has occurred at the push rod ends, rocker arm, or valve stem. In this case, it will be necessary to determine the area of discrepancy and the incorrect or defective part(s) should be replaced. If all the valve train components except the push rod are within limits, install a 0.060-inch longer push rod. 2. Rotate the crankshaft until No. 1 piston is on TDC at the end of the compression stroke. With No. 1 piston on TDC, check the following valves: No.
G R O U P 1-ENGINES AND EXHAUST SYSTEMS MO PLUNGER A1265-A FIG. 6-Correct Position of Eccentric Six, position the valve rocker arm. If an end valve rocker arm was removed, slide it into position on the shaft and install the washers and retaining pin. Perform a preliminary valve lash adjustment as necessary. Operate the engine until normal operating temperature has been reached. Check and adjust the valve lash or Silent Lash clearance.
P A R T 1-1-GENERAL ENGINE SERVICE However, the compression of all cylinders should be uniform within 10 pounds. A reading of more than the allowable tolerance above normal indicates excessive deposits in the cylinder. A reading of more than the allowable tolerance below normal indicates leakage at the cylinder head gasket, piston rings, or valves. A low even compression in two adjacent cylinders indicates a cylinder head gasket leak. This should be checked before condemning the rings or valves.
1-12 G R O U P 1-ENGINES AND EXHAUST SYSTEMS TO REMOVE STOCK FROM BOTTOM \ OF SEAT, \ USE 60° WHEEL Seat Width Scale TO REMOVE STOCK FROM TOP OF SEAT, USE 30° WHEEL 45 , v _ ^ CHECK DIAGONALLY 2) CHECK ACROSS CENTER A1207-A FIG. 11-Cylinder Head Flatness guide cleaning tool. Use cleaning solvent to remove dirt, grease, and other deposits. 'VALVE SEAT WIDTH: 0.060-0.080 A1211-B A1209-A FIG.
1-13 P A R T 1 - 1 -GENERAL ENGINE SERVICE A VS B = VERTICAL TAPER C VS D = HORIZONTAL TAPER A VS C AND B V S D z OUT-OF-ROUND CHECK FOR OUT-OF-ROUND AT EACH END OF JOURNAL Model TV-2 Runout Gauge Tool-67 LENGTH SCALE liiliPi A10M-A A1013-B FIG. 17-Valve Face Runout FIG. 19—Valve Spring Pressure Inspect the valve face and the edge of the valve head for pits, grooves, scores, or other defects. Inspect the stem for a bent condition and the end of the stem for grooves or scores.
1-14 G R O U P 1-ENGINES AND EXHAUST SYSTEMS Assemble the lifter assembly and check for freeness of operation by pressing down on the push rod cup. The lifters can also be checked with a hydraulic tester to test the leak-down rate. Follow the instructions of the test unit manufacturer. TIMING CHAIN Clean all parts in solvent and dry them with compressed air. Inspect the chain for broken links and the sprockets for cracks, and worn or damaged teeth.
P A R T 1-1-GENERAL ENGINE SERVICE Q GAUGE PULL IN POU 00 <<3 O I z ,-, \ \ V\ \ \ \ \ \ \ \ \ FIG. 23—Cleaning Ring Grooves INSPECTION Carefully inspect the pistons for fractures at the ring lands, skirts, and pin bosses, and for scuffed, rough, or scored skirts. If the lower inner portion of the ring grooves have high steps, replace the piston. The step will interfere with ring operation and cause excessive ring side clearance.
1-16 G R O U P 1-ENGINES AND EXHAUST SYSTEMS expand the reamer slightly and make another cut. Repeat the procedure until the proper fit is obtained. Check the piston pin for fit in the respective rod bushing. If necessary, ream or hone the bushing to fit the pin. 'A1020-A FIG. 27—Ring Side Clearance A1201-B FIG. 25-Checking Piston Fit Example 2. If a 0.003-inch feeler ribbon is used and it takes approximately 9-pounds pull to remove the ribbon, the resultant clearance is approximately 0.0015 inch.
P A R T 1-1-GENERAL ENGINE SERVICE in the threads may cause binding and result in a false torque reading. Use a tap to true-up threads and to remove any deposits. INSPECTION A1024-A FIG. 29-Flywheel Face Runout than 0.045 inch of stock from the original thickness, replace the flywheel. Inspect the ring gear for worn, chipped, or cracked teeth. If the teeth are damaged, replace the ring gear. With the flywheel installed on the crankshaft, check the flywheel face runout.
G R O U P 1-ENGINES AND EXHAUST SYSTEMS 1-18 OIL PUMPS Feeler Gauge A1026-A FIG. 3 1 — Outer Race to Housing Clearance piston fit, thoroughly wash the cylinder walls with solvent to remove all abrasive particles, then thoroughly dry the walls. Check the piston fit. Mark the pistons to correspond to the cylinders in which they are to be installed.
1-19 Section MILEAGE MAKER SIX Section Page 1 Description 2 Engine Removal and Installation 3 In-Chassis Repair Operations Engine Supports Manifolds Exhaust Gas Control Valve Replacement 1-19 1-22 1-24 1-24 1-24 1-25 Section Page 3 In-Chassis Repair Operations (Continued) Positive Crankcase Ventilation System Valve Rocker Arm Shaft Assembly Cylinder Head Valve Stem Seal Replacement Cylinder Front Cover and Timing Chain 1-26 1-26 1-27 1-29 1-29 Page In-Chassis Repair Operations (Continued) Camshaft
1-20 G R O U P 1 - ENGINES AND EXHAUST SYSTEMS VALVE TRAIN The intake and exhaust valve assemblies are the rotating-type. The tappets are the solid steel, mushroomtype. The camshaft is supported by four bearings pressed into the block. It is driven by a sprocket and timing chain in mesh with a sprocket on the crankshaft. Camshaft thrust is controlled by a thrust plate located between the timing chain snubber pad and the front journal of the camshaft.
1-21 P A R T 1-2-MILEAGE MAKER SIX A1553-A FIG. 5—Lubrication System the No. 4 valve rocker arm support. The oil from the shaft flows through drilled holes in each rocker arm to lubricate the eccentric, rocker arm shaft bore, the valve, and ball end of the rocker arm. Excess oil spirals down the rotating push rod and assists in lubricating the tappet and push rod seat. An oil outlet tube ex- hausts excess oil from the rocker shaft to lubricate the distributor lower bushing and distributor drive gear.
G R O U P 1-ENGINES AND EXHAUST SYSTEMS 1-22 HIGH SPEED OPERATION LOW INTAKE MANIFOLD VACUUM TO INTAKE MANIFOLD LOW SPEED OPERATION HIGH INTAKE MANIFOLD VACUUM FROM CRANKCASE OUTLET TO INTAKE MANIFOLD A1554-A A1192-A FIG. 8—Positive Crankcase Ventilation Regulator Valve In the vent tube-type system, the crankcase vapors are discharged to the atmosphere. In the positive system, the crankcase vapors are directed to the intake manifold.
P A R T 1-2-MILEAGE MAKER SIX 1-23 9. Remove the flywheel or converter housing to engine bolts. Support the transmission with a jack. Remove the remaining engine rear plate retaining bolts. 10. Remove the engine right and left support insulator to frame retaining nut. 11. Attach the engine lifting hook (Fig. 11). Raise the engine slightly, then carefully pull it from the transmission. Lift the engine out of the chassis, then install it on a work stand (Fig. 12). INSTALLATION A1T24-B FIG.
1-24 G R O U P 1-ENGINES AND EXHAUST SYSTEMS support insulator to engine retaining nuts (install the automatic transmission oil cooler lines bracket). 5. Install the remaining converter or flywheel housing retaining bolts. Install the engine rear plate lower retaining bolts. 6. Install the starter (and automatic transmission fluid filler tube bracket). On a car with an automatic transmission, install the transmission oil cooler lines in the bracket at the engine block. 7.
P A R T 1-2-MILEAGE MAKER SIX LOCKWASHER NUTS VALVE EXHAUST ^ % THERMOSTATIC SPRING BOLT BOLT 4 ^ BUSHING BUSHING \ \ \ STUD \ GASKET LOCKWASHER CLAMP WASHER INTAKE MANIFOLD COUNTERWEIGHT i AND SHAFT ASSEMBLY SLEEVE A1559-A FIG. 15—Manifold Assemblies bolts retain the radiator supply tank mounting bracket and one bolt retains the oil level dipstick tube bracket). Lift the manifold assemblies from the head. Remove the gaskets and sleeves. 6.
1-26 G R O U P I-ENGINES AND EXHAUST SYSTEMS When new bushings are installed, there should be a distance of 23/s inches from the inside edge of one bushing to the inside edge of the other bushing. The bushings should be equally spaced within the counterbores. 6. After installation, ream the bushings with a 5/16-inch reamer. 7. Lubricate the new shaft and bushings with FoMoCo Exhaust Control Valve Solvent (COAA-19A501A) or a penetrating oil and graphite mixture. 8.
P A R T 1-2-MILEAGE MAKER SIX 1-27 ADJUSTING SCREW OIL INLET TUBE PS - * OIL OUTLET TUBE COTTER PIN BRACKET SPRING WASHER A 1 5 6 0 . A FIG. 20-Valve Rocker Arm Shaft Assembly head. The cover is tightened in two steps. Torque the retaining bolts to specifications. Two minutes after the initial tightening, torque the bolts to the same specifications. Install the air cleaner. DISASSEMBLY 1. Remove the cotter pins from each end of the valve rocker arm shaft.
1-28 G R O U P 1 - ENGINES AND EXHAUST SYSTEMS A1065-A FIG. 24-Cylinder Head Bolt Tightening Sequence from the cylinder head. Brace the assembly so that the muffler inlet pipe will not be damaged. 12. Disconnect the radiator supply tank support at the water pump. Loosen the supply tank hose clamp at the coolant outlet housing and remove the supply tank. 13. Install the cylinder head holding fixtures for convenience in lifting the head and to protect the gasket surfaces (Fig. 22). 14.
P A R T 1-2-MILEAGE MAKER SIX thermostat and coolant outlet elbow. Torque the retaining bolts to specifications. UNDERSIDE OF SPRING RETAINER VALVE STEM SEAL REPLACEMENT SURFACE OF SPRING PAD A 1 0 4 7-A FIG. 27—Valve Spring Assembled Height 2. Install each valve (Fig. 26) in the valve guide from which it was removed or to which it wasfitted.Install a new stem seal on the valve. 3. Install the valve spring assembly over the valve. Install the spring retainer and sleeve. 4.
1-30 CAMSHAFT SPROCKET TIMING MARK G R O U P 1-ENGINES AND EXHAUST SYSTEMS 12 PINS BETWEEN MARKS 0.030-0.070 INCH WITH SLACK REMOVED SNUBBER PAD ToolT52L-6306-AEE A1064-A DRIVING CRANKSHAFT SPROCKET SIDE OF CHAIN TIMING MARK A 1 5 5 7 - A FIG. 33—Damper Installation FIG. 30— Aligning Timing Marks A1525-A out with the fingers. Measure the distance between the reference point and the chain. The deflection is the difference between the two measurements. 11.
