FORD ZG Fairlane Custom and Fairlane 500 1973-1976 Factory Workshop Manual | PDF Download

FORD ZG Fairlane Custom and Fairlane 500 1973-1976 Factory Workshop Manual | PDF Download

This Ford Shop Manual is for the following Ford models manufactured between 1973 - 1976: 

• Ford Fairlane Custom ZG
• Ford Fairlane 500 ZG

This Factory manual covers all XB and ZG models.

The following engines are covered by this Ford Shop Manual:

• 4.1L 6 Cylinder
  
• 4.9L V8
• 5.8L V8

The following transmissions are covered by this Ford Shop Manual:

• Borg Warner Automatic Transmission
• C4 Automatic Transmission
• FMX Automatic Transmission
• 3 Speed Manual Transmission BW 199333
• 3 Speed Manual Transmission BW 199332 and 199331
• 4 Speed Manual Transmission RUG A.R. and RUG B.F.

Below is a detailed list of topics covered in this 700 plus page Ford Shop Manual: 

• 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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