Mercury Cyclone & Cyclone CJ 1969 Shop Manual | PDF Download

Whether you’re sorting out a Cyclone’s brakes or rebuilding its engine, this 1969 Mercury Cyclone Shop Manual has the answers. More than 1,400 pages of detailed steps, measurements and torque settings, written for DIY owners and professional technicians alike.

Carburetor overhauls, 4-speed gearbox repairs, disc brake service, rear axle setup and emissions system tests are all here, along with the specifications to go with them.

Models covered

• Mercury Cyclone
• Mercury Cyclone CJ

Engines

• 351 V8
• 390 V8
• 428 V8 (including the Cobra Jet)

Transmissions

• 3-speed manual
• 4-speed manual
• Automatic

What’s included

Engine

• Engine removal and installation
• Cylinder head removal, overhaul and installation
• Valves, valve springs, push rods and hydraulic lifters
• Valve clearance adjustment
• Camshaft removal and installation
• Timing chain and front cover, front oil seal replacement
• Crankshaft, main bearings and connecting rod bearings
• Pistons, piston pins and rings
• Cylinder block cleaning and inspection
• Oil pump, oil pan and oil filter
• Intake and exhaust manifolds
• Engine mounts
• Flywheel and clutch pilot bushing
• Compression test, vacuum test, camshaft end play
• Crankcase ventilation system
• Thermactor emission control system tests (428)
• Engine specifications and torque figures

Ignition and tune-up

• Points and condenser replacement and adjustment
• Distributor, cap, rotor and coil testing and overhaul
• Ignition timing and timing mark locations
• Spark plugs and spark plug wires

Fuel system

• Carburetor overhaul and adjustment (2-barrel and 4-barrel, including Holley and Autolite)
• Fuel pump testing
• Fuel tank and fuel lines
• Air cleaner service
• Accelerator pump and throttle linkage

Cooling and exhaust

• Radiator and radiator hoses
• Thermostat testing and replacement
• Fan, fan belt and fan drive
• Cooling system pressure test and cleaning
• Exhaust pipes, mufflers and mounting brackets

Clutch, manual and automatic transmissions

• Clutch adjustment, removal and installation
• 3-speed and 4-speed manual transmission overhaul
• Gear shift linkage adjustment
• Automatic transmission overhaul, fluid checks, drain and refill
• Band and linkage adjustments
• Engine idle speed check
• Fluid leak diagnosis

Driveshaft and rear axle

• Driveshaft balance and angle checks
• Universal joint overhaul
• Rear axle removal, overhaul and installation
• Pinion bearing preload and ring gear backlash
• Gear tooth contact patterns
• Differential and axle shaft service
• Limited-slip differential testing
• Rear axle ratio codes

Brakes

• Disc brake service
• Drum brake service
• Brake adjustment
• Master cylinder and wheel cylinder overhaul
• Power brake booster
• Hydraulic system bleeding
• Brake pedal height and travel checks
• Parking brake adjustment

Suspension, steering and wheels

• Front end inspection and lubrication
• Caster, camber and toe-in adjustment
• Ball joints and front springs
• Shock absorber checks
• Power steering pump and steering gear service
• Steering columns and linkage
• Steering wheel spoke position adjustment
• Wheel balancing, tire service and wheel bearings

Electrical

• Starter motor testing and overhaul
• Alternator and regulator testing
• Battery service
• Headlight system and alignment
• Instrument panel, gauges and clusters
• Turn signals, emergency flasher and horns
• Windshield wipers and washers
• Wiring diagrams, fuses and circuit protection

Heating and ventilation

• Heater core, hoses and blower motor
• Control cables and vacuum actuators
• Defroster nozzles and vents

Body and interior

• Door removal, trim panels and window regulators
• Door lock and handle service
• Side window mechanisms
• Windshield and back window replacement
• Grille, bumpers and exterior mouldings
• Seats, interior trim and headlining
• Roof outside cover

Servicing and identification

• Lubrication chart and service intervals
• Maintenance schedule
• Pre-delivery checks
• Body, paint, trim, engine, transmission and rear axle codes
• Specifications, torque figures and special service tools

Please Note: This manual covers all 1969 Ford, Mercury and Lincoln range of passenger cars.