1968 Cougar Fairlane Falcon Montego Mustang Shop Manual
1968 Cougar, Fairlane, Montego and Mustang Shop Manual is the original shop and service manual used by the Ford mechanics to service and/or repair these vehicles. This is an easy to read, step-by-step manual on how to make minor and major repairs.
Manual chapters:
1 - Vehicle Identification
2 - Brakes
3 - Suspension, Steering, Wheels and Tires
4 - Rear Axle
5 - Drive Shaft and Clutch
6 - Manual Shift Transmissions
7 - Automatic Transmission
8 - Engine
9 - Ignition System
10 - Fuel System
11 - Cooling System
12 - Exhaust System
13 - Charging System
14 - Starting System
15 - Lighting System, Horns and Instruments
16 - Ventilating, Heating and Accessories
17 - Body, Doors and Windows
18 - Trim, Seats and Convertible Top
19 - Schematics
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Full list of manual chapters:
1968 Shop Manual
Group 1 - Vehicle Identification
Typical Warranty Plate
Vehicle Warranty Number
Vehicle Data
Official Vehicle Indentification Numbers
Model Year Code
Body Serial and Style Codes
Montego
Fairlane
Cougar
Mustang
Falcon
Consecutive Unit Number
Engine Codes
Transmission Codes
Rear Axle Codes
Date Codes
Assembly Plant Codes
District Codes (DSO)
Ford
Mercury
Ford of Canada
Exterior Paint Color Codes
Interior Trim Codes
Group 2 - Brakes
Part 2-1 General Brake Service
1. Diagnosis and Testing
2. Common Adjustments and Repairs
3. Cleaning and Inspection
Part 2-2 Brake System
1. Description and Operation
2. In-Vehicle Adjustments and Repairs
3. Removal and Installation
4. Major Repair Operations
Part 2-3 Specifications
Group 3 - Suspension, Steering, Wheels and Tires
Part 3-1 Suspension, Steering, Wheels and Tires General Service
1. Diagnosis and Testing
2. Common Adjustments and Repairs
3. Cleaning and Inspections
Part 3-2 Suspension
1. Description and Operation
2. In-Vehicle Adjustments and Repairs
3. Removal and Installation
Part 3-3 Manual Steering
1. Description
2. In-Vehicle Adjustments and Repairs
3. Removal and Installation
4. Major Repair Operations
5. Steering Linkage Repair
Part 3-4 Power Steering
1. Description and Operation
2. In-Vehicle Adjustments and Repairs
3. Removal and Installation
4. Major Repair Operations
Part 3-5 Wheels and Tires
1. Description and Operation
2. In-Vehicle Adjustment and Repairs
3. Removal and Installation
4. Major Repair Operations
Part 3-6 Specifications
Group 4 - Rear Axle
Part 4-1 General Axle Service
1. Diagnosis and Testing
2. Common Adjustments and Repair
3. Cleaning and Inspection
Part 4-2 Rear Axles Integral Carrier Types
1. Description and Operation
2. In-Vehicle Adjustments
3. Removal and Installation
4. Major Repair Operations
Part 4-3 Removable Carrier Type Rear Axle and Limited Slip Rear Axle
1. Description and Operation
2. In-vehicle Adjustment and Repair
3. Removal and Installation
4. Major Repair Operations
Part 4-4 Specifications
Group 5 - Drive Shaft and Clutch
Part 5-1 Drive Shaft
1. Diagnosis and Testing
2. Description
3. Removal and Installation
4. In-vehicle Repair
5. Major Repair Operations
Part 5-2 General Clutch Service
1. Diagnosis and Testing
2. Flywheel Housing Alignment
3. Cleaning and Inspection
Part 5-3 Clutch
1. Description and Operation
2. In-Vehicle Adjustments and Repairs
3. Clutch Removal and Installation
Part 5-4 Specifications
Group 6 - Manual Shift Transmissions
Part 6-1 General Transmission Service
1. Diagnosis and Testing
2. Common Adjustments and Reparis
3. Cleaning and Inspection
Part 6-2 Model 3.03 Three-speed Transmission
1. Description and Operation
2. In-Vehicle Adjustments and Repairs
3. Removal and Installation
4. Major Repair Operations
Part 6-3 Ford Design Four-speed Transmission
1. Description and Operation
2. In-Vehicle Adjustment and Repairs
3. Removal and Installation
4. Major Repair Operations
Part 6-4 (Omitted)
Part 6-5 Specifications
Group 7 - Automatic Transmission
Part 7-1 General Transmission Service
1. Diagnosis and Testing
2. Common Adjustments and Repairs
3. Cleaning and Inspection
Part 7-2 C4 Automatic Transmission
1. Description and Operation
2. In-Vehicle Adjustments and Repairs
3. Removal and Installation
4. Major Repair Operations
Part 7-3 C6 Automatic Transmission
1. Description and Operation
2. In-Vehicle Adjustments and Repairs
3. Removal and Installation
4. Major Repair Operations
Part 7-4 Specifications
Group 8 - Engine
Part 8-1 General Engine Service
1. Diagnosis and Testing
2. Common Adjustments and Repairs
3. Cleaning and Inspection
Part 8-2 170 and 200 Six
1. Description and Operation
2. In-Vehicle Adjustments and Repairs
3. Engine Removal and Installation
4. Major Repair Operations
Part 8-3 289 V-8 and 302 V-8
1. Description and Operation
2. In-Vehicle Adjustments and Repairs
3. Engine Removal and Installation
4. Major Repair Operations
Part 8-4 390 and 427 V-8
1. Description and Operation
2. In-Vehicle Adjustments and Repairs
3. Engine Removal and Installation
4. Major Repair Operations
Part 8-5 Specifications
Group 9 - Ignition System
Part 9-1 General Ignition Service
1. Diagnosis and Testing
2. Common Adjustments and Repairs
3. Cleaning and Inspection
Part 9-2 Autolite Dual Advance Distributors
1. Description and Operation
2. In-Vehicle Adjustments and Repairs
3. Removal and Installation
4. Major Repair Operations
Part 9-3 Specifications
Group 10 - Fuel System
Part 10-1 General Fuel System Service
1. Diagnosis and Testing
2. Common Adjustments and Repairs
3. Cleaning and Inspection
Part 10-2 Autolite Model 1100 1-v Carburetors
1. Description and Operation
2. Removal and Installation
3. Major Repair Operations
Part 10-3 Carter Model YF 1-v Carburetors
1. Description and Operation
2. Removal and Installation
3. Major Repair Operations
Part 10-4 Autolite Model 2100 2-v Carburetors
1. Description and Operation
2. Removal and Installation
3. Major Repair Operations
Part 10-5 Autolite Model 4300 4-v Caruretor
1. Description and Operation
2. Removal and Installation
3. Major Repair Operations
Part 10-6 Holley Model 4150C 4-v Carburetor
1. Description and Operation
2. Removal and Installation
3. Major Repair Operations
Part 10-7 Air Cleaner
1. Description and Operation
2. Removal and Installation
Part 10-8 Fuel Pump and Fuel Filter
1. Description and Operation
2. Removal and Installation
3. Major Repair Operations
Part 10-9 Fuel Tank and Lines
1. Description and Operation
2. Removal and Installation
Part 10-10 Specifications
Group 11 - Cooling System
Part 11-1 General Cooling System Service
1. Diagnosis and Testing
2. Common Adjustments and Repairs
3. Cleaning and Inspection
Part 11-2 Radiator and Thermostat
1. Description and Operation
2. Removal and Installation
Part 11-3 Fan Drive Clutch
1. Description and Operation
2. Removal and Installation
Part 11-4 Ford Flex Blade Fan
Part 11-5 Specifications
Group 12 - Exhaust System
Part 12-1 General Exhaust Systems
1. Diagnosis and Testing
2. Common Adjustments and Repairs
3. Cleaning and Inspection
Part 12-2 Exhaust Pipes, Mufflers and Control Valve
1. Description
2. Removal and Installation
Part 12-3 Specifications
Group 13 - Charging System
Part 13-1 Charging System Diagnosis
1. Diagnosis Procedures
Part 13-2 Charging System Testing
1. Autolite Charging System
Part 13-3 Autolite Alternator
1. Description and Operation
2. Common Adjustments and Repairs
3. Removal and Installation
4. Major Repair Operations - Except 65-Amper Alternator
Part 13-4 Autolite Alternator Regulators
1. Description and Operation
2. Removal and Installation
Part 13-5 Specifications
Group 14 - Starting System
Part 14-1 General Starting System Service
1. Diagnosis and Testing
Part 14-2 Starter
1. Description and Operation
2. Removal and Installation
3. Common Adjustments and Repairs
4. Major Repair Operations
Part 14-3 Specifications
Group 15 - Lighting System, Horns and Instruments
Part 15-1 Lighting Systems
1. Description and Operation
2. Diagnosis and Testing
3. In-Vehicle Adjustments
4. Removal and Installation
5. Specifications
Part 15-2 Turn Signals, Emergency Warning Flasher and Horns
1. Description and Operation
2. Diagnosis and Testing
3. In-Vehicle Adjustment
4. Removal and Installation
Part 15-3 Instrument Cluster, Gauges and Controls
1. Description and Operation
2. Diagnosis and Testing
3. In-Vehicle Adjustment and Repair
4. Removal and Installation
5. Specifications
Part 15-4 Windshield Wipers and Washer
1. Description and Operation
2. Diagnosis and Testing
3. In-Vehicle Adjustment
4. Removal and Installation
5. Major Repairs and Cleaning and Inspection
Part 15-5 General Wiring, Fuses and Circuit Breakers
1. Description and Operation
2. Removal and Installation
3. Specifications
Group 16 - Ventilating, Heating and Accessories
Part 16-1 Ventilating System and Heater
1. Description and Operation
2. Diagnosis and Testing
3. Common Adjustment and Repairs
4. Removal and Installation
Part 16-2 Air Conditioning
1. Description and Operation
2. Diagnosis and Testing
3. Common Adjustments and Repairs
4. Removal and Installation
Part 16-3 Speed Control
1. Description and Operations
2. Diagnosis and Testing
3. Removal and Installation
Part 16-4 Radio
1. Description and Operation
2. Diagnosis and Testing
3. Common Adjustments and Repairs
4. Removal and Installation
Part 16-5 Specifications
Group 17 - Body, Doors and Windows
Part 17-1 General Body Service
1. Diagnosis and Testing
2. Common Adjustments and Repairs
3. Cleaning and Inspection
4. Hoisting Vehicle
Part 17-2 Paint
1. Paint and Surface Defects
2. Repair Procedures
3. Materials and Tools
Part 17-3 Doors, Windows, Tailgate and Deck lid
1. In-Vehicle Adjustments and Repairs
2. Removal and Installation
Part 17-4 Windshield, Window Glass, and Window Mechanisms
1. Diagnosis and Testing
2. In-Vehicle Adjustments and Repairs
3. Removal and Installation
Part 17-5 Door and Tailgate
1. Diagnosis and Testing
2. In-Vehicle Adjustments and Repairs
3. Removal and Installation
Group 18 - Trim, Seats and Convertible Top
Part 18-1 Interior Trim and Roof Outside Cover
1. Door and Quarter Trim Panels
2. Headlining
3. Instrument Panel Pad
4. Console
5. Roof Outside Cover
6. Interior Cleaning
Part 18-2 Seats
1. Standard Seats
2. Bucket Seats - Manual
3. Power Seats
4. Seat Belts
5. Front Seat Headrest
Part 18-3 Convertible Top
1. Care of Top Fabric
2. Diagnosis and Testing - Power Top
3. Adjustments and Light Repairs
4. Removal and Installation
Group 19 - Schematics
