The ZG Ford Fairlane: A Modern Day Classic 

The ZG Ford Fairlane hit the roads in October 1973 and stuck around until May 1976. It was an updated version of the previous ZF Fairlane, with safety improvements being a major focus by Ford. They beefed up the front-end structures to absorb more energy in case of an accident, making the car safer for everyone inside.

You could order the ZG Fairlane with three different engine options: a 250ci 4.1 Litre six, a 302ci 4.9 Litre V8, or a 351ci 5.8 Litre V8. The car also had some cool optional features like air-conditioning and a sunroof.

In September 1975, Ford upgraded the standard features on the ZG Fairlane because people thought it looked too much like the regular XB Falcon model. They added a vinyl roof, bumper overriders, more carpeting, and fancy interior trim. The price went up a bit, but the upgrades made the ZG Fairlane even more popular.

The ZG Fairlane had a distinctive look with its bold grille and matching tail-light surrounds. It was a facelift version of the ZF model, with some new badges and a sleek design. The car had a smooth ride with heavy-duty shock absorbers and a higher ride height for better handling.

The ZG Ford Fairlane was a hit with the buying public, selling 19,556 units during its run. It's still considered one of the most popular Fairlane models ever made. If you wanted a 1976 ZG Ford Fairlane 500 5.8 Litre 351 V8 automatic sedan back in the day, it would have cost you around $8,386.00. 
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WORKSHOP REPAIR MANUAL DETAILS

FORD FAIRLANE CUSTOM AND FAIRLANE 500 ZG 1973-1976 WORKSHOP REPAIR MANUAL | PDF DOWNLOAD

This manual is all about helping anyone who owns or works on a Ford Fairlane ZG. It's got everything you need to know about fixing big and small problems, making adjustments, and figuring out what's causing issues. With over 780 pages, it's super detailed but also really easy to understand. If you need help with your car, this manual has got your back!

Easy download to your Desktop PC (Mac or Windows), Laptop, Tablet, Smart Phone, iPhone, iPad.

This Workshop Manual is for the following 1973-1976 Ford models:

• Ford Fairlane Custom ZG
• Ford Fairlane 500 ZG
• This manual covers all XB and ZG models.

The following engines are included:

• 3.3 Litre (200 CID) 6 Cylinder
• 4.1 Litre (250 CID) 6 Cylinder
• 4.9 Litre (302 CID) V8
• 5.8 Litre (351 CID) V8

The following transmissions are included:

• Borg Warner Automatic Transmission
• C4 Automatic Transmission
• FMX Automatic Transmission
• Borg Warner 3 Speed Manual Transmission
• Borg Warner 4 Speed Manual Transmission

Below is a detailed list of topics included:

• BRAKES
  
• Diagnosis and Testing
• Preliminary Tests
• Road Test
• Common Adjustments and Repairs
• Parking Brake Linkage Adjustment
• Hydraulic System Bleeding
• Cleaning and Inspection
• Disc Brake Trouble Symptoms and Possible Causes
• Drum Brake Trouble Symptoms and Possible Causes
• In-Car Adjustments and Repairs
• Removal and Installation
• Major Repair Operations
• SUSPENSION
  
• Description & Operation
• Front Suspension
• Rear Suspension
• In-Car Adjustments &: Repairs
• Upper Ball Joint Replacement
• Upper Arm Shaft and/ or Bushing Replacement
• Stabilizer Replacement
• Lower Arm Strut and/or Bushing Replacement
• Removal & Installation-Front Spring
• Front Suspension Upper Arm
• Front Wheel Spindle Drum Brakes
• Front Wheel Spindle Disc Brakes
• Front Shock Absorber
• Rear Shock Absorber
• Rear Spring and/ or Bushing
• POWER STEERING
  
• Description & Operation
• Operation
• Power Steering Pump
• Flow Control Valve
• Pressure Relief Valve
• In-Car Adjustments & Repairs
• Pump Belt Tension Adjustment
• Power Steering Pump to Steering Box Hoses & Tubes
• Removal & Installation
• Power Steering Pump 6 Cylinder Engine, 8 Cylinder Engine
• Power Steering Pump Pulley
• Major Repair Operations
• Power Steering Gear - Disassembly
• Inspection & Overhaul of Component Assemblies
• Sector Shaft Assembly
• Piston Rack
• Worm Valve & Sleeve Assembly
• Reassembly
• Setting Preloads on Steering Gear
• Fitment of Steering Gear to Vehicle
• STEERING COLUMN AND LINKAGES
• Description
• In-car Adjustments
• Steering Column Removal & Replacement
• Major Repair Operations
• Ignition Lock Replacement
• Steering Linkage Repair
• Pitman Arm Replacement Manual and Power Steering
• STEERING GEAR
  
• Description
• In-Car Adjustments & Repairs
• Steering Gear Worm & Sector Adjustments
• Removal & Installation
• Major Repair Operations
• Steering Gear Disassembly
• Steering Gear Assembly
• WHEELS AND TYRES
  
• Description & Operation
• Front Wheel - Rear Wheel..
• In-Car Adjustments & Repairs
• Removal & Installation
• Major Repair Operations
• REAR AXLES
  
• Identification, Description and Operation
• Diagnosis and Testing
• In-Car Adjustment and Repair
• Rear Axle Overhaul - All models
• Removal and Installation of Rear Axle Housing-All
• Differential Assembly Overhaul - Integral Carrier Conventional
• Differential Assembly Overhaul Integral Carrier Limited Slip Differential
• Differential Assembly Overhaul-Removable Carrier Traction Lock Axle
• Specifications
• DRIVELINE
  
• Description and Operation
• Trouble Diagnosis
• Replacement
• Removal
• CLUTCH
  
• Diagnosis and Testing
• Diagnosis Guide-Clutch
• Flywheel Housing Alignment
• Inspection
• Correction
• Cleaning and Inspection
• Release Bearing
• Pressure Plate and Cover
• Clutch Disc
• Pilot Bushing
• In car Adjustments and Repairs
• Reservoir Topping-Up
• Bleeding the Clutch
• Removal and Installation
• Hydraulic System Repairs
• Clutch Operating Cylinder Disassembly
• Assembly
• MANUAL TRANSMISSION
  
• General Transmission Service
• Diagnosis and Testing
• Common Adjustments and Repairs
• Gear Shift Linkage Adjustment
• Rear Seal Replacement
• Rear Bushing and Seal Replacement
• Cleaning and Inspection
• 3 SPEED PARTIALLY SYNCHRONISED MANUAL SHIFT TRANSMISSION SERIES BW 199333
• Description and Operation
• In-Car Adjustments Gear Shift Linkage Adjustment
• Removal and Installation
• Major Repair Operations
• Disassembly
• Assembly
• 3 SPEED FULLY SYNCHRONISED MANUAL SHIFT TRANSMISSION SERIES BW 199332 & 199331
• Description and Operation
• In-Car Adjustments Gear Shift Linkage Adjustment
• Removal and Installation
• Major Repair Operations
• Disassembly
• Assembly
• 4-SPEED FULLY SYNCHRONIZED MANUAL TRANSMISSION
  
• Description and Operation
• In-Car Adjustments Gear Shift Linkage Adjustment
• Removal and Installation
• Major Repair Operations
• Disassembly
• Parts Repair or Replacement
• Gear Shift Lever
• Synchronizers
• Input Shaft Bearing
• Countershaft Gear Bearings
• Assembly
• Specifications
• AUTOMATIC TRANSMISSION
  
• BORG-WARNER AUTOMATIC TRANSMISSION
• Description and operation
• Torque converter
• Transmission
• Control system
• Hydraulic circuits and power flow
• Diagnosis and testing
• In car adjustments
• Table of shift speeds
• Cleaning and inspection
• Removal and installation
• Major repair operations
• C4 AUTOMATIC TRANSMISSION
• Description and operation
• Torque converter
• Transmission
• Control system
• Hydraulic circuits and power flow
• Diagnosis and testing
• In car adjustments
• Table of shift speeds
• Cleaning and inspection
• Removal and installation
• Major repair operations
• FMX AUTOMATIC TRANSMISSION
• Diagnosis and Testing
• Common Adjustments and Repairs
• Cleaning and Inspection Description
• In-Car Adjustment and Repairs
• Removal and Installation
• Major Repair Operations
• Specifications
  
• ENGINES
  
• GENERAL ENGINE SERVICE
• Diagnosis and Testing
• Diagnosis Guide
• Camshaft Lobe Lift
• Compression Test
• Manifold Vacuum Test
• Hydraulic Valve Lifters Tests
• Positive Crankcase Ventilation System Test
• Crankshaft End Play
• Flywheel Run out-Automatic Transmission
• Flywheel Ring Gear Run out
• Camshaft End Play
• Timing Chain Deflection
• Common Adjustments and Repairs
• Valve Clearance-Hydraulic Valve Lifters, Six cylinder engines
• Valve Clearance-Hydraulic Valve Lifters V8 engines
• Valve Rocker Arm· and / or Shaft Assembly
• Push Rods
• Valves
• Camshaft
• Crankshaft
• Pistons, Pins and Rings
• Cylinder Block
• Flywheel Ring Gear-Manual Shift
• Transmission
• Cleaning and Inspection
• Intake Manifold
• Exhaust Manifold
• Valve Rocker Arm and/or Shaft Assembly
• Push Rods
• Cylinder Heads
• Hydraulic Valve Lifters
• Timing Chain and Sprockets
• Camshaft
• Crankshaft Vibration Damper and Sleeve
• Crankshaft
• Flywheel-Manual Shift Transmission
• Flywheel-Automatic Transmission
• Connecting Rods
• Pistons, Pins and Rings
• Main and Connecting Rod Bearings
• Cylinder Block
• Oil Pan
• Oil Pump
• Positive Crankcase Ventilation System
• 200, 250 CID SIX CYLINDER ENGINES
• Description and Operation
• Manifolds
• Cylinder Head
• Cylinder Block
• Valve Train
• Lubrication System
• Crankcase Ventilation
• Cooling System
• In-Car Adjustments and Repairs
• Engine Supports
• Manifolds Remove and Replace 250 2 V
• Exhaust Manifold
• Valve Rocker Arm Shaft Assembly
• Cylinder Head
• Valve Spring Retainer and Stem Seal Replacement
• Cylinder Front Cover and Timing Chain
• Camshaft
• Camshaft Rear Bearing Bore Plug Replacement
• Hydraulic Valve Lifter
• Main and Connecting Rod Bearing Replacement
• Pistons and Connecting Rods
• Flywheel
• Clutch Pilot Bushing Replacement
• Oil Filter Replacement
• Oil Pan
• Oil Pump
• Engine Removal and Installation
• Major Repair Operations
• Crankshaft
• Camshaft Bearing Replacement
• Cylinder Assembly Replacement
• Cylinder Block Replacement
• Engine Disassembly
• Engine Assembly
• 302-351 CID V8 ENGINES
• Description
• In Vehicle Adjustments and Repairs
• Engine Front Supports
• Engine Rear Supports
• Valve Clearance Checking Procedure
• Valve Rocker Arm Cover and Rocker Arm
• Intake Manifold
• Exhaust Manifold
• Crankcase Ventilation System
• Cylinder Heads
• Valve Spring, Retainer and Stem Seal
• Water Pump
• Front Oil Seal
• Cylinder Front Cover and Timing Chain
• Camshaft
• Camshaft Rear Bearing Bore Plug
• Valve Lifter
• Valve Lifter Disassembly
• Crankshaft Rear Oil Seal Replacement
• Main Bearings
• Connecting Rod Bearings
• Pistons and Connecting Rods
• Flywheel
• Clutch Pilot Bushing
• Oil Filter
• Oil Pan
• Oil Pump
• Engine Removal and Installation
• Removal
• Installation
• Major Repair Operations
• Crankshaft
• Camshaft Bearings
• Cylinder Assembly Replacement
• Cylinder Block Replacement
• Engine Disassembly and Assembly
• SPECIFICATIONS
• IGNITION SYSTEM
  
• GENERAL IGNITION SYSTEM SERVICE
• Diagnosis and Testing
• General Information
• Ignition System Tests-Conventional
• Test Equipment
• Distributor Checks
• Distributor Tests-Dwell Tester
• Distributor Tests-Distributor Tester
• Common Adjustments and Repairs
• Breaker Points and Condenser
• Ignition Timing
• Spark Plug Wire Replacement
• Spark Plugs
• Resistance Wire Replacement
• 3 Cleaning and Inspection
• Spark Plugs
• Distributors
• Secondary Wiring
• Coil
• Distributor Cap
• Rotor
• Distributor Vacuum Advance Control Valve
• DUAL ADVANCE DISTRIBUTORS BOSCH 6 and 8 Cyl. Models
• Description and Operation
• 2 In-Car Adjustments and Repairs
• Breaker Point and Condenser Replacement
• Removal and Installation
• Removal
• Installation
• Major Repair Operations
• Bench Disassembly
• Bench Assembly
• DUAL ADVANCE DISTRIBUTORS MOTORCRAFT
• Description and Operation
• In-Car Adjustments and Repairs
• Vacuum Diaphragm Replacement
• Cam and Centrifugal Advance Mechanism
• Replacement
• 3 Removal and Installation
• Major Repair Operations
• Bench Disassembly
• Bench Assembly
• Specifications
  
• FUEL SYSTEM
  
• GENERAL FUEL SYSTEM SERVICE
• Diagnosis and Testing
• Diagnosis
• Fuel Tank and Lines Diagnosis Guide
• Carburetor Diagnosis Guide
• Tests
• Fuel Pump Tests
• Carburetor Tests
• Common Adjustments and Repairs
• Throttle Linkage Adjustments
• Accelerator Pedal Idle Height Adjustment
• Throttle Linkage Repair
• Cleaning and Inspection
• Carburetors
• Fuel Pump
• Air Cleaner
• STROMBERG CARBURETOR BV2- 200, 250 6 CYLINDER ENGINES
  
• DESCRIPTION AND OPERATION
• Description
• Operation
• IN VEHICLE ADJUSTMENTS AND REP AIRS
• Carburetor Adjustments
• Initial Idle Speed Adjustment
• Idle Limiter Cap Replacement
• Carburetor Repairs
• REMOVAL, MAJOR REPAIR OPERATIONS AND INSTALLATION
• Removal
• Disassembly
• Cleaning and Inspection
• Assembly
• STROMBERG CARBURETOR - WW SERIES 250 CID 2 V - 302 CID ENGINES
• Description and Operation
• Description
• Operation
• In vehicle Adjustments and Repairs
• Carburetor Adjustments
• Idle Speed and Mixture Adjustment
• Idle Limiter Cap Replacement
• Major Repair Operations
• Carburetor Repairs
• Disassembly
• Inspection
• Assembly
• Final Assembly
• MOTORCRAFT MODEL 2100 - D 2V CARBURETOR
• Description and Operation
• 2 Common Adjustments & Repairs
• Idle Speed Adjustment
• Idle Limiter Cap Replacement
• 3 Major Repairs Operations
• MOTOR CRAFT MODEL 4300 4-V CARBURETOR
• DESCRIPTION AND OPERATION
• Description
• Operations
• Fuel Inlet System
• Idle Fuel Supply System
• Primary Main Fuel Metering System
• Accelerating Pump System
• Power Fuel Supply System
• Secondary Main Fuel Metering System
• Automatic Choke System
• IN-CAR ADJUSTMENTS AND REPAIRS
• Idle Speed Adjustment
• Idle Limiter Cap Replacement
• MAJOR REPAIR OPERATIONS
• Removal
• Disassembly
• Air Horn
• Main Body
• Throttle Body
• Assembly
• Throttle Body
• Air Horn
• Air Horn to Main Body
• FUEL PUMP AND FUEL FILTER
• Description and Operation
• Removal and Installation
• Fuel Filter Replacement
• Fuel Pump Removal
• Fuel Pump Installation
• Major Repair Operations
• AC Fuel Pump - 6-Cylinder Engines
• Carter Permanently Sealed Fuel Pumps
• AIR CLEANERS
• Description and Operation
• Removal and Installation
• Air Cleaner Maintenance
• Removal
• Cleaning and Inspection
• Installation
• FUEL TANK AND LINES
• Description and Operation
• Removal and Installation
• Filler Pipe
• Fuel Tank
• Fuel Lines
• COOLING SYSTEM
  
• GENERAL COOLING SYSTEM SERVICE
• Diagnosis and Testing
• Trouble Diagnosis Guide
• Cooling System Pressure Test
• Thermostat Tests
• Maintenance
• Coolant-Cleaning Cooling System
• Draining and Filling the Cooling System
• Fan Drive Belts
• Common Adjustments and Repairs
• Drive Belts
• Fan Replacement
• Fan Drive Belt Replacement
• Radiator Hose Replacement
• Thermostat Replacement
• WATER PUMP
• Description and Operation
• Removal and Installation
• Six Cylinder Engines
• V8 Engines
• Major Repair Operations
• Six Cylinder Engines
• V8 Engines
• Fan Drive Clutch
• RADIATOR
• Description and Operation
• Removal and Installation
• EXHAUST SYSTEM
  
• GENERAL EXHAUST SYSTEM SERVICE
• Diagnosis and Testing
• Common Adjustment and Repairs
• Cleaning and Inspection
• EXHAUST PIPES, MUFFLERS
  
• Description
• Removal and Installation
• CHARGING SYSTEM
  
• GENERAL CHARGING SYSTEM SERVICE
• Diagnosis
• Battery Low in Charge, Headlights Dim at Idle
• Charge Indicator Light Stays On
• Lights and Fuses Fail Prematurely Short Battery Life
• Alternator Noisy
• Warning Light Flickers
• Testing
• Alternator Test
• Testing the Alternator System
• Battery Tests and Conclusions
• Common Adjustments and Repairs
• Belt Adjustment
• Cleaning and Inspection
• BOSCH ALTERNATOR
• Description and Operation
• Removal and Installation
• Major Repair Operations
• LUCAS ALTERNATOR
• Description and Operation
• Removal and Installation
• Major Repair Operations
• ALTERNATOR REGULATOR - BOSCH
• Description and Operation
• In-Car Adjustment and Tests
• LUCAS ALTERNATOR REGULATOR
• Description and Operation
• In-Car Adjustment and Tests
• STARTING SYSTEM
  
• FORD STARTING SYSTEM
• Description and Operation
• Diagnosis and Testing
• Removal and Installation
• Common Adjustments and Repairs
• Cleaning and Inspection
• Major Repair Operations
• BOSCH STARTING SYSTEM 250, 302, 351 2V
• Description and Operation
• Removal and Installation
• Major Repair Operations
• LUCAS STARTING SYSTEM
• Removal and Installation
• Major Repair Operations
• LIGHTING
  
• GENERAL LIGHTING SYSTEM, HORNS AND INSTRUMENT SERVICE
• Diagnosis and Testing
• Light Trouble Diagnosis Guide
• Instrument Trouble Diagnosis Guide
• Horn Trouble Diagnosis Guide
• Turn Indicator Trouble Diagnosis Guide
• Windshield Wiper Trouble Diagnosis Guide
• Headlight Switch and Beam Selector Switch
• Test
• Constant Voltage Regulator Test
• Fuel Gauge and Fuel Level Sending Unit Test
• Temperature Gauge Test
• Oil Pressure Indicator Light Test
• Charge Indicator Light Test
• Speedometer Tests
• Common Adjustments and Repairs
• Horn Adjustment
• Cleaning and Inspection
• Two Speed Wiper Motor
• LIGHTING SYSTEM AND HORNS
• Description and Operation
• Headlights
• Horns
• In-Car Adjustments and Repairs
• Headlight Alignment
• Headlight Adjustment
• Back-Up Light Adjustment
• Removal and Installation
• Headlights
• Parking Light
• Tail, Stop, and Back-Up Light Bulbs
• License Plate Light
• Dome Light
• Instrument Lights
• Horns
• Horn Switch
• Gear Selector Quadrant Light
• SWITCHES, CIRCUIT BREAKERS, AND FUSES
• Description and Operation
• Headlight Switch
• Fuse Panel
• Mechanical Stop Light Switch
• Reversing Light Switch
• Removal and Installation
• Headlight Switch
• Headlight Beam Selector Switch
• Stop Light Switch
• Dome Light Switch
• Ignition Switch and Lock Cylinder
• Windshield Wiper Switch
• Neutral Start Switch
• Back-Up Light Switch
• INSTRUMENTS
• Description and Operation
• Gauges
• Constant Voltage Regulator
• Fuel Gauge.
• Temperature Gauge
• Charge Indicator Light
• Oil Pressure Indicator Light
• Turn Indicator
• Speedometer
• Brake Warning Lamp
• In-Car Adjustments and Repairs
• Windshield Wiper Blade Adjustment
• Removal and Installation
• Instrument Cluster
• Fuel, Temperature Gauges
• Printed Instrument Circuit
• Fuel Sending Unit
• Temperature Sending Unit
• Oil Pressure Switch
• Turn Indicator Switch
• Turn Indicator Flasher
• Speedometer and Tachometer
• Speedometer Cable
• Windshield Wiper Motor
• Wiper Pivot Shaft and Link
• Major Repair Operations
• Disassembly-Permanent Magnet Type Two-Speed Electric Wiper Motor
• Inspecting and Testing Disassembled Motor
• Testing and Assembled Motor
• VENTILATING, HEATING, AIR COND AND ACCESSORIES
  
• Description and Operation
• Ventilating System
• Heating System
• Diagnosis and Testing
• Ventilating and Heating Trouble Diagnosis Guide
• Loose Motor Fan Test
• Blower Switch Test
• Plugged Heater Core Test
• Common Adjustments and Repairs
• Ventilating System
• Heating System
• Control Adjustments
• Blower Motor Electrical Circuit
• Heater Hose Routing
• Heater Hose Replacement
• Bleeding Air From Heater Core
• Removal and Installation
• Heater - Assembly Removal
• Heater - Assembly Installation
• AIR CONDITIONING
• Description and Operation
• Diagnosis and Testing
• Controls position and operation
• Sight glass
• Magnetic clutch test
• Receiver dryer test
• Compressor seal leak test
• Refrigerant leaks
• Compressor oil level check
• Safety Precautions
• Adjustments
• Discharging the system
• Evacuation
• Recharging
• Major Repairs
• Removal & installation
• Compressor
• Clutch bearing
• Specifications
• Operating instructions
• RADIO & RADIO TAPE PLAYER
• Description
• Diagnosis and Testing
• Common Adjustments and Repairs
• Removal and Installation
• Tape Player
• BODY, DOORS AND WINDOWS
  
• GENERAL BODY SERVICE
• Diagnosis and Testing
• Dust and Water Leaks
• Common Adjustments and Repairs
• Body Sealers and Application
• Body Alignment
• Paint Refinishing
• Cleaning and Inspection
• Hoisting
• Door Wind lace and Seals
• FRONT SHEET METAL, BUMPERS, EXTERIOR MOLDINGS
• In-Car Adjustments and Repairs
• Hood Adjustments .
• Hood Lock Adjustments
• Removal and Installation
• Hood Hinge
• Radiator Grille
• Front Bumper
• Rear Bumper
• Exterior Moldings
• Instrument Panel
• Sun Roof
• DOORS, WINDOWS, TAILGATE AND DECK LID
• In-Car Adjustments and Repairs
• Door Alignment
• Lock Striker Adjustment
• Vent Window Adjustment
• Front Door Glass Adjustment
• Rear Door Window Adjustment
• Single Action Tailgate Hinge Adjustment
• Deck Lock Adjustment
• Deck Lid Alignment
• Removal and installation
• Doors
• Front Door Lock
• Rear Door Lock
• Door Lock Cylinder
• Door Handle
• Door Lock Remote Control Handle
• Door Vent Window Frame
• Front Door Glass
• Front Door Window Regulator
• Rear Door Glass
• Rear Door Window Regulator
• Rear Quarter Window and /or Weatherstrip
• Station Wagon
• Windshield
• Back Window and/or Weatherstrip
• Tailgate Glass
• Tailgate Window Handle and Lock Cylinder
• Manual
• Tailgate Switch and Lock Cylinder - Power
• Deck Lid Lock
• Power Windows
• R/Vision Mirror
• Dual Action Tailgates
• TRIM & SEATS
  
• INTERIOR TRIM AND VINYL TOP COVER
• Door and Quarter Trim Panels
• Headlining
• Instrument Panel Safety Cover
• Roof Outside Cover
• SEATS
• Bench Seats - Removal and Installation
• Seat and Seat Track
• Front Seat Cushion and Back
• Rear Seat Cushion and Back
• Front Seat Cushion Cover
• Rear Seat Cushion Cover
• Front Seat Back Cover
• Rear Seat Back Cover
• Bucket Seats - Removal and Installation
• Front Seat and Seat Track
• Front Seat Cushion Cover
• Front Seat Back Cover
• Rear Seat Cushion Cover
• Seat Belts- General Information
• SCHEMATICS

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