group 15 Lighting, Horns and Instruments.pdf

15-1 

PART 15.1 

PAGE 

General Lighting System, Horns 

and Instruments Service 15-1 

PART 15-2 

Lighting System and Horns 15.9 


Switches, Circuit Breakers 

and Fuses 15-17 


PAGE 

Instruments 15-26 


Specifications 15-44 

Section 

Page 

1 Diagnosis and Testing 15-1 

Light Trouble Diagnosis Guide 15-4 

Instrument Trouble Diagnosis Guide 15-5 

Horn Trouble Diagnosis Guide 15-5 

Turn Indicator Trouble Diagnosis Guide 15-6 

Seq uential Turn Signal Trouble 

Diagnosis Guide 15-6 

Windshield Wiper Trouble Diagnosis Guide 15-7 

Windshield Washer Trouble Diagnosis Guide... 15-8 

Horn Test 15-1 

Headlight Switch and Beam Selector 

Switch Test , 15-1 

Instrument Voltage Regulator Test 15-2 

Section 

Page 

Fuel Gauge and Fuel-Level Sending 

Unit Test 15-2 

Temperature Gauge Test 15-2 

Oil Pressure Indicator Light Test 15-2 

Oil Pressure Indicator Gauge Test 15-2 

Charge Indicator Light Test 15-2 

Ammeter Test 15-3 

Speedometer Tests 15-3 

Temperature Indicating Light Test 15-3 

2 Common Adjustments and Repairs 15-3 

Horn Adjustment 15-3 

3 Cleaning and Inspection 15-4 

Two Speed Wiper Motor 15-4 

DIAGNOSIS AND TESTING 

DIAGNOSIS 

Refer to Figs. 4 through 12 for 

lighting system horns and- instruments 

trouble diagnosis. 

TESTING 

Refer to Wiring Diagram Manual 

Form 7795P-67 for locations of wiring 

harnesses. Schematics are shown in 

Group 19 of this manual. 

HORN TEST 

The only test necessary on the 

horn is for current draw. 

Current Draw Test 

Connect a voltmeter and ammeter 

to the horn and to a voltage supply 

as shown in Fig. 1. The normal current 

draw for the horns at 12 volts is 

3.5-5.5 amperes. 

HEADLIGHT SWITCH AND 

BEAM SELECTOR SWITCH 

TESTS 

The following tests may be made 

to determine whether a headlight 

switch or a beam selector switch is 

defective: 

Turn on the headlights, and operate 

the beam selector switch. If none 

of the headlights turn on when the' 

beam selector switch is operated, yet 

the instrument panel lights operate, 

the headlight switch or the red-yellow 

stripe wire from the headlight 

switch to the beam control switch is 

HORN 

FIG. l-Horn 

POSITIVE 

LEAD 

NEGATIVE LEAD 

(,~ LEAD -II~II 

.J -- pas. 

LEAD 

JUMPER WIRE 

,-- ~.u-- 


probably defective. Substitute a 

known good switch for the suspected 

switch to determine whether the 

switch or the wiring is at fault. 

If the headlights operate only with 

the beam selector switch in one position. 

the selector switch or the wiring 

from the switch to the headlight 

is defective. Substitute a known good 

selector switch for the suspected


GROUP 15-Lighting System, Horn~ And Instruments 

switch to determine whether the 

switch or the wiring is at fault. 

INSTRUMENT VOLTAGE 

REGULATOR TEST 

Turn the ignition switch on, 

check for voltage at the gauge feed 

wire (black with green stripe) at one 

of the gauges. The voltage should 

oscillate between zero and about 10 

volts. If it does not, the constant 

voltage regulator is defective, or 

there is a short to ground between 

the voltage regulator and the gauges. 

If a gauge unit is inaccurate or 

does not indicate, replace it with a 

new unit. If the gauge unit still is 

erratic in its operation, the sending 

unit or wiring to the sending unit is 

faulty. 

If both the fuel gauge and the 

te mperature gauge indicate improperly 

and in the same direction, the 

constant ~oltage regulator could be 

defecti~e, as it supplies both gauges. 

FUEL GAUGE AND FUEL 

LEVEL SENDING UNIT 

TEST 

Disconnect the wire from the fuel 

level sending unit and connect it to 

a known good sending unit. Using a 

jumper for a ground, connect it to 

the sending unit mounting plate and 

car frame. Raise the float arm to 

the upper stop, the instrument panel 

gauge should read full. Lower the 

float arm to the bottom stop, the 

gauge should read empty. 

If the gauge reads properly, the 

sending unit in the gas tank is defective. 

If the gauge unit still indicates improperly 

or is erratic in its operation, 

the gauge unit or the wiring to the 

gauge unit is faulty. Repair the wire 

or replace the gauge unit. 

TEMPERATURE 

GAUGE TEST 

Start the engine and allow it to 

run at 1200 rpm for 30 minutes. 

Place a thermometer in the coolant 

at the radiator filler cap. The temperature 

should read a minimum of 

1800 F., and the gauge in the instrument 

panel should indicate within 

the normal band. 

If the gauge does not indicate, 

short the temperature sender unit 

terminal wire to ground (ignition 

switch on). Do not leave the sender 

wire grounded longer than necessary 

to make the test, as the gauge may 

be damaged. If the gauge now indicates, 

the sender unit is defective or 

not properly sealed to the engine. Be 

sure to ~e an electrically conductive 

sealer C3AZ-19554-B. If the gauge 

does not indicate, the gauge, the 

wires leading to the gauge, or the 

constant voltage regulator are at 

fault. 

OIL PRESSURE INDICATOR 

LIGHT TEST 

To test the indicator light, turn on 

the ignition switch. Do not start the 

engine. The light should come on. 

Start the engine. Th~ light should go 

out, indicating that the oil pressure 

has built up a safe value. 

To test the oil pressure switch on 

the engine, turn the ignition switch 

on, engine not running, the indicator 

light should come on. If the indicator 

light does not come on, short the 

terminal of the oil pressure switch 

unit to ground. If the light now 

comes on, the oil pressure switch is 

defective or not properly sealed to 

the engine. Be sure to use electrically 

conductive sealer C3AZ-19S54-B. 

If the light still does not come on, 

the bulb is burned out or the wires 

from the bulb to the ignition switch 

and oil pressure switch are defective. 


GAUGE TEST 

Remove the oil pressure sender 

unit and temporarily attach an oil 

pressure gauge in its place. Operate 

the engine to determine the oil pressure. 

If the oil pressure is normal, 

the gauge should indicate within the 

normal band. 

If the gauge did not indicate, momentarily 

short the oil pressure 

sender wire to ground. Do not leave 

the sender wire grounded longer 

than necessary to make the test, as 

the gauge may be damaged. If the 

gauge now indicates, the sender unit 

is defective or not properly sealed to 

the engine. Be sure to use electrically 

conductive sealer C3AZ- 

I 9554-B. If the gauge does not indicate, 

the jauge. the wires leading 

to the gauge or the constant voltage 

regulator are at fault. 

The sending unit used with the 

warning indicator light system is not 

interchangeable with the sending unit 

used with the gauge system. Refer 

to the Ford Car Master Parts Catalog 

for proper parts usage. 

Misuse of the sending units will 

result in inoperative oil pressure 

warning systems and damaged sending 

units or gauges. 

CHARGE INDICATOR 

TEST 

LIGHT 

To test the charge indicator light, 

turn the ignition switch on with the 

engine stopped. The light should 

come on. If it does not, the bulb is 

burned out, or the wiring to the light 

is defective. 

An open resistor wire in the Ford 

alternator charging system wiring 

harness will usually cause the charge 

indicator light to stay on until the 

engine speed is increased to several 

thousand rpm. This effect will be noticed 

each time the engine is started. 

In some cases the light will not go 

out at all. 

The charge indicator light may be 

tested with the use of a test light 

containing a trade number 67 or 

1155 bulb. 

Disconnect the regulator plug 

from the regulator. Turn the ignition 

switch to ACC position. Touch one 

test probe from test light to the ignition 

terminal and the other to the 

regulator base. The test light will 

come on if the circuit is in proper 

working order. If the 15 ohm resistor 

or circuit is open, the indicator 

light will operate at full brightness 

and the test light will be out. 

Block - Red 

~Stri~e ". 

p"", 

;HT 

'//0 

r;:- 

w Strip e I 

"-- "'V ~,. 

RED LIGHT PROVE OUT 

SWITCH CONTACTS 

CLOSE IN START POSITI~ 

~ I 

IGNITION SWITCH 

TERMINAL 

K1581.~ 

FIG. 2- Temperature Indicator Light 

System

PART 15-1-General Lighting System, Horns And Instruments Service 


AMMETER TEST 

To test the ammeter, turn the 

headlights on with the engine 

stopped. The meter pointer should 

move toward the D or discharge 

scale. If no movement of the needle 

is observed, check the rear of the 

meter housing to see if the battery 

to circuit breaker wire connections 

are loose. If the connections are 

tight, and the meter does not indicate 

a discharge, the meter is inoperative. 

If the meter pointer moves 

toward the C or charge scale when 

the headlights are turned ON, the 

wi re connections at the meter are reversed. 

When the headlights are 

turned on, the battery is reversed, or 

the wire passes through the loop in 

the wrong direction. Feed the wire 

through in the opposite direction to 

correct this condition, after checking 

first to make sure that the battery is 

not reversed. 

SPEEDOMETER TESTS 

To test the odometer accuracy, 

drive the car over a measured mile. 

Speedometer accuracy can be 

checked by comparing the speedometer 

in question against one known 

to be accurate, while two cars are 

moving at the same speed, or by 

timing the car on a measured mile. 

The Ford Car Master Parts

15-4 GROUP 1 S-Lighti ng System, Horns And Instruments 

CLEANING AND INSPECTION 

TWO-SPEED WIPER MOTOR 

I. Clean the gear housing of all 

old grease. Do not allow any cleaning 

fluid to contact the armature 

shaft and output shaft bearings. 

2. Wipe all other parts with a 

clean cloth. 

3. Inspect the gear housing for 

cracks or distortion. Replace a 

cracked or distorted housing. 

4. Check all shafts, bushings, and 

gears for scored surfaces. Replace 

defective parts and add new grease 

to the housing and gears. 

ALL HEADLIGHTS DO 

NOT LIGHT 

1. Loose battery cable. 

2. Loose quick disconnect or broken 

wire from the battery to the 

headlight switch. 

3. Defective headlight switch. 

4. Disconnected or broken wire 

from the headlight switch to the 

beam selector switch. 

S. Loose or broken wire to the 

bulbs. 

6. Defective beam selector switch. 

7. All headlight bulbs burned out. 

This may be caused by a defective 

or improperly adjusted alternator 

voltage regulator (Group 13). 

INDIVIDUAL LIGHTS 

DO NOT LIGHT 

LIGHTS BURN OUT 

REPEATEDLY 

FIG. 4-Light Trouble Diagnosis Guide 

1. Burned out bulb. 

2. Loose or broken wires to the 

bulb. 

I. Loose or corroded electrical 

connections. 

2. Excessive vibration. 

3. Poor ground 

3. Improperly adjusted or defective 

alternator voltage regulator 

(Group 13).

PART 1S-1-General Lighting System, Horns And Instruments Service 



LIGHT INOPERATIVE 

1. Indicator bulb burned out. 

2. Loose or broken wire from the 

light to the indicator switch. 

3. Defective oil pressure sender 

unit (in this part). 


LIGHT INOPERATIVE 

CHARGE INDICA TOR 

LIGHT STAYS ON AT 

IDLE 


GAUGE INOPERATIVE 

AMMETER GAUGE 

INOPERA TIVE 

FUEL GAUGE ERRATIC 

OR INOPERATIVE 

1. Burned out bulb. 

2. Loose or broken wires. 

1. Loose or broken drive belt. 

2. Parallel resistance wire (15 

-ohm) burned out. 

3. Loose connections or broken 

wires. 


constant voltage regulator to the oil 

pressure gauge. 

2. Grounqed or broken wire from 

1. Defective gauge (in this part). 

2. Loose or broken wires. 


constant voltage regulator to the fuel 

gauge. 

2. Defective fuel gauge. 

3. Loose, broken, or shorted wire 

from fuel gauge to the fuel tank 

sending unit. 

3. Defective alternator regulator. 

4. Regulator out of adjustment. 

5. Grounded wiring from alterna. 

tor to regulator. 

6. Defective alternator. 

the engine oil pressure sending unit. 

3. Defective gauge. 

4. Defective oil pressure sending 

unit. 

3. Charging system malfunction 

4. Defective constant voltage regulator. 

5. Defective fuel tank sending 

unit. 

6. Poor ground between fuel tank 

and body. 

TEMPERATURE GAUGE 

ERRATIC OR INOPERATIVE 

1. Loose or broken wire from constant 

voltage regulator to the temperature 

gauge. 

2. Defective temperature gauge. 


temperature sending unit to the tem- 

perature gauge. 

4. Defective temperature sending 

unit. 


FUEL, TEMPERATURE, AND 

OIL PRESSURE GAUGES 

ERRATIC 

1. Loose or corroded constant 

voltage regulator ground. 


3. Broken or loose wire from or 

to the constant voltage regulator. 

4. Defective ignition switch. 

FIG. 5. 

Instrument Trouble Diagnosis Guide 

FIG. 6. 

Horn Trouble Diagnosis Guide

15-6 GROUP 15-Lighting System, Horns And Instruments 

OUTSIDE TURN SIGNAL 

LIGHTS INOPERATIVE 

1. Burned out bulbs, or loose 

socket connections. 

2. Open connection at turn signal 

flasher. 

3. Loose or broken wire from 

ignition switch to flasher. 

4. Defective flasher. 

5. Loose or broken wire from 

flasher to turn signal switch. 

6. Defective turn signal switch. 

7. Broken, shorted, or loose wires 

from switch to lights. 

INSTRUMENT PANEL 

TURN SIGNAL LIGHTS 

OPERATE INCORRECTLY 

I. Burned out bulb, or improper 

connection at socket. 

2. Loose, broken, or shorted wires 

from switch to lights. 

3. Inoperative outside turn signal 

lights (See above). 

TURN SIGNAL 

CANCELS IMPROPERLY 

I. Cam improperly positioned on 

steering wheel hub. 

2. Coil spring on switch plate assembly 

loose or weak. 

FIG. 7 

Standard Turn Signal Trouble Diagnosis Guide 

All TURN SIGNALS 

INOPERA TIVE 

I. Defective fuse. 

2. Open circuit between fuse panel 

and turn signal switch. 

3. Poor ground for turn signal 

relay and sequential flasher in luggage 

compartment. 

4. Defective turn signal switch. 

5. Open circuit between turn signal 

relay (dash panel) and turn signal 

switch. 

6. Open circuit in turn signal relay 

(dash panel). 

7. No electrical feed (open wire) 

between the turn signal relay (instrument 

panel) and the sequential flasher 

in the luggage compartment. 

8. Defective sequential turn signal 

flasher assembly (luggage compartment). 

LEFT OR RiGHT FRONT 

TURN SIGNAL DOES NOT 

OPERATE (TURN INDICATOR 

LIGHT REMAINS ON AND 

REAR LIGHTS OPERATE) 

1. Turn signal filament of bulb 

burned out. 

2. Corrosion or foreign matter on 

bulb or socket terminal. 

3. Open circuit between the bulb 

and the t urn signal relay. 

4. Defective turn signal relay or 

wiring in the luggage compartment. 

5. Loose connectors in wiring from 

luggage compartment to bulb(s). 

REAR TURN SIGNALS 

INOPERA TIVE-ONE SIDE, 

BOTH SIDES, OR INDIVIDUAL 

BULBS (FRONT LIGHTS 

FLASH CORRECTLY) 

I. Turn signal filament of bulb 

burned out. 

2. Open circuits in rear turn signal 

wiring between turn signal relay 

in luggage compartment and turn signal 

bulbs. 

3. Incorrect operation of the turn 

signal relay. 

4. Open circuit between the sequential 

flasher assembly and the turn signal 

relay. 

5. Defective sequential flasher 

assembly. 

FIG. 8. 

.Sequential-Turn SiQnal Trau ble DiaQnosis Guide -External Signals

PART 15-1-General Lighting System, Horns And Instruments Service 


LEFT INDICATOR BULB 

FLASHES FOR RIGHT OR 

LEFT TURN, OR LEFT ONLY 

INDICATOR BULB FLASHES 

FOR EMERGENCY FLASHER 

1. Open solenoid feed circuit between 

turn signal switch and the 

turn signal indicator relay (4 wire). 

2. Wire No. 50 (green-white stripe) 

and wire No. 49 (white-blue stripe), 

are reversed in connector to turn 

signal indicator relay (4 wire). 

3. Defective turn signal indicator 

relay (4 wire). 

BOTH INDICA TOR BULBS 

FLASH IN EITHER DIRECTION 

1. Open circuit between solenoid 

of emergency warning relay and the 

turn signal switch. 

2. Defective 

relay. 

emergency 

warning 

LEFT OR RIGHT INDICATOR 

BULB INOPERATIVE 

I. Defective bulb. 

2. Inadequate ground at bulb. 

socket. 

3. Open feed circuit between turn 

signal indicator relay (4 wire), and 

bulb. 

4. Defective turn signal indicator 



WILL NOT LIGHT 

I. Defective bulbs. 

2. Open circuit between turn signal 

relay (3 wire), and the turn signal 

indicator relay (4 wire). 

3. Open circuit between the turn 

signal indicator relay (4 wire), and 

the bulbs. 

4. Defective turn signal relay (3 

wire). 

S. Defective turn signal indicator 


ONE INDICA TOR BULB 

LIGHTS STEADY, BUT 

DOES NOT FLASH 

I. Defective turn signal bulb or 

bulbs in system. 


LIGHT STEADY, BUT DO 

NOT FLASH 

I. Defective turn signal indicator 

bulb or bulbs in system. 

2. Defective turn signal relay (3 

wire). 

FIG. 9. 

.Sequential Turn Signal Trouble Diagnosis Guide Instrument Ponel Bulbs 

FIG. 10- Windshield Wiper Trouble Diagnosis Guide


I. Defective electrical switch assembly 

at the foot pedal. 

2. Open circuit between foot pedal 

switch and wiper motor. 

3. Defective windshield wiper 

switch. 

4. Open circuit between windshield 

wiper switch and wiper motor. 

5. Defective wiper motor. 

FIG. ll-Foot-Pedal Windshield Washer System Diagnosis Guide 

1. No fluid in washer reservoir or 

lines. 

2. Broken or clogged water lines. 

3. Open circuit between switch and 

pump. 

4. Open circuit between washer 

pump and wiper motor. 

5. Defective wiper switch. 

6. Defective washer pump. 

7. Defective switch on wiper motor. 

8. Burned, corroded, or damaged 

switch plate in wiper motor. 

9. Defective wiper motor. 

FIG. 12- Electric Windshield Woshe r Pump-DioQnosis 

Guide

~ 

,gnatsuM Cougar 

thgiliaT thgiliaT Lens-Cougar 

Lens-Mustang 

,gnatsuM-thgiL Cougar 

thgiliaT thgiliaT Body-Cougar 

Body-Falcon 

noitatS Wagons 

thgiliaT Dor-Fairlane 

thgiliaT Body-Mustang 

thgiliaT Dor-Cougar 

pukcaB Light Body-Cougar, Mustang 

thgiliaT Dor-Mustang 

Taillight Body Lens and BulbsenalriaF 

Model 71 , 

and 

Falcon, Fairlane, Mercury Intermediate 

Transmission Control Selector Light- 

Console Transmission Control Selector 

Taillight Lens-Falcon, Mercury 

Tail Intermediate and Stop Light Bulbs-Except 

License Plate Light Assy. -Except 







...15-15 

15-15 









esneciL raguoC Plate and Bulb Station and/or Wagons 

Lens 

,15-16 


DESCRIPTION AND OPERATION 



harnesses. Schematics are shown 

in Group 19 of this manual. 

ORANGE 

(VACUUM 

SOURCE) 

- 

WHITE 

;1::;;; -, 

k, 

~.. 0 A 0 .."-- ./"" 

~---,:,:'/' , C5 

'/ "'-:=:-- 

~ ~~~ /'-. -~~ 

YELLOW 

~\\\\ 

J"" ~. 

RII"D"~~ "'!:LLOW 

, 

BUMP 

-~~ 

1675~ "":,\ PI: 

VAC 

MOT 

~ 

'.I~:::24 J¥~ 

'V~ I'" ' 

\ ,- 

/ .--/ YELLOW 

~BUMPER 

379352-5 

1 ';, 

GREEN 

HEADLIGHTS 

The Falcon and Mustang use two 

No.2 type sealed-beam headlights. 

SOLENOID VAOJUM 

i 

I 

RESERVOIR 

13A185 

VENT 

~;C;"'oi 

,. 

GREEN 

CONNECTOR 

13A169 

YELLOW 

," 

;) "" \ ~ ..."' MOTOR 

\ ... 

'1'\i: 

~;:~~;:- I:'~' 

~~~~~ 

~I 

PIN \ 

13A173 

j

15-10 GRO UP lS-Lighting System, Horns And Instruments 

light is in the lower position and the 

No. 2 light is in the upper position. 

The Cougar uses four sealed-beam 

headlights. The No. I light is in 

the inner position and the No.2 

light is in the outer position. 

A conventional beam selector 

switch is located on the floorboard 

at the left of the driver. 

Quick disconnect terminals are also 

provided at the left and right of 

the radiator support assembly. The 

terminals are color coded. Like 

colored terminals are connected together. 

HEADLIGHT COVERS 

-COUGAR 

The headlight covers are opened 

and closed by the use of vacuum 

motors. Refer to Fig. I for location 

of the headlight cover operating components 

and installation. Note the 

vacuum hose routing, connections and 

color codes. 

The headlight switch, when pulIed 

fulI out, connects the headlight circuit 

to a solenoid. The solenoid operates 

vacuum ports in a distribution valve 

which applies vacuum to the cover 

operating vacuum motors. The solenoid 

also opens a vacuum relief (exhaust) 

port to that side of the vacuum 

motor diaphragm to which vacuum 

is not applied. The vacuum exhaust 

port is vented through a tube into 

the passenger compartment in order 

to prevent engine oil fumes from entering 

the distribution valve. 

Two cover hinge springs, attached 

to each cover, function as over-center 

type springs, which help hold the 

covers in the open or closed position. 

Vacuum applied to either side of the 

vacuum motor diaphragm during 

opening or closing, overcomes this 

spring tension. 

Two reserve vacuum reservoirs 

provide vacuum storage which permits 

limited cycling of the headlight 

covers without the car engine running. 

In case of vacuum loss or solenoid 

failure, the covers can be opened or 

closed manually as follows: To open 

or close the covers, push in the 

plunger located on the vacuum distribution 

valve (View C, Fig. I), located 

behind the left headlights in the 

engine compartment; then, if the 

covers do not open, open them by 

hand while the plunger is in the in 

position. To reset the system for automatic 

operation, press inward on the 

end of the plunger so that the plunger 

return spring returns the plunger to 

the out position. 

The headlight covers should be 

open (raised) when washing the car 

to clean the headlights for safer nighttime 

driving. 

HORNS 

A pair of tuned horns are used. 

The horn button closes the circuit to 

the horns. One of the horns has a 

high-pitched tone; the other has a 

low-pitched tone. 

IN-VEHICLE ADJUSTMENTS AND REPAIRS 

HEADLIGHT ALIGNMENT 

All headlight adjustments should 

be made with a half-full tank 

plus or minus one gallon, with a person 

seated in the driver's seat and a 

person seated in the passenger seat, 

the car unloaded and the trunk empty 

except for the spare tire and jacking 

equipment, and recommended pressure 

in all tires. Before each adjustment, 

bounce the car by pushing on 

the center of both the front and rear 

bumpers, to level the car. 

To align the No. I headlights by 

means of a wall screen, select a level 

portion of the shop floor. Layout 

the floor and wall as shown in Fig. 2. 

Establish the headlight horizontal 

centerline by subtracting 20 inches 

from the actual measured height of 

the headlight lens center from the 

floor and addin~ this difference to the 

20-inch reference line obtained by 

sighting over the uprights to obtain 

dimension B (upper diagram Fig. 

3). Draw a horizontal line 2 inches 

below, and parallel to the headlight 

horizontal centerline. Then draw the 

headlight vertical centerlines on the 

screen as measured on the vehicle 

(dimension A, upper diagram Fig. 3). 

NO.1 HEADLIGHT HIGH 

BEAM ADJUSTMENT 

Adjust each No. I headlight beam 

as shown in Fig. 3 upper diagram. 

Cover the No.2 lights when making 

this adjustment. 

Some states may not approve of 

the 2-inch dimension for the No.1 

headlights. Check the applicable state 

law, as a 3-inch dimension may be 

required. 

NO.2 HEADLIGHT LOW 

BEAM ADJUSTMENT 

To align the No.2 headlights. a 

new wall chart is used. Dimension B 

for the No.2 lights will be different 

than B for the No. I lights. but dimension 

A which is measured on the car 

will be the same as for the No. I 

lights. Note that the line of adjustment 

of the No.2 lights is the horizontal 

centerline of the No.2 lights. 

Turn the headlights to low beam and 

adjust each No.2 light as shown in 

Fig. 3. 

Each headlight can be adjusted by 

means of two screws located under 

the headlight trim ring. Always bring 

each beam into final position by 

turning the adjusting screws clockwise 

so that the headlights will be 

held against the tension springs when 

the operation is comoleted (Fig. 4).

PART lS-2-Lighting System And Horns 15- 

FIG. 2. 

Floor and Wall Layout 

HEADLIGHTS 25 FEET 

FROM WAll 

NO.1 

LIGHT HIGH BEAM DIAGRAM 

14 DIMENSION "A" .\ 

NO.2 

LIGHT LOW BEAM DIAGRAM 

Kl192-C 

FIG. 3-Headlight 

Wall Screens

~ 

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0 '" 

N 

~ 

Co... 

rc 

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m 

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!!! 

j:illi 

, 

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'" 

«, 

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, t1. ~ "'O uO "'- ,,;1 

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PART 1 S-2-Lighting System And Horns 15-13 

REMOVAL AND INST ALLA TION 

HEADLIGHTS 

On the Cougar it will be necessary 

to open the hood and release the vacuum 

valve (place the valve in manual 

position) and manually open the headlight 

cover. 

1. Remove the screws and remove 

the headlight trim ring (Fig. 4). 

2. Place a hand over the headlight 

assembly and unhook the spring 

from the retaining ring. 

3. Remove the retaining ring by 

unhooking the ring from the clip located 

directly across the bulb from 

the spring hook. 

4. Pull the headlight bulb forward 

and disconnect the wiring assembly 

plug. 

5. Plug in the new bulb and place 

it in position, locating the bulb glass 

tabs in the positioning slots. 

6. Hook the retaining ring over 

the clip, then over the bulb and secure 

it with the existing ball-ring 

spring. 

7. Align the bulb with the wall 

screen. 

8. Install the trim ring in position 

and install the retaining screws. 

HEADLIGHT COVER VACUUM 

MOTOR-COUGAR 

REMOVAL 

Refer to Group 17 of this manual 

for illustration showing grille attaching 

parts. 

1. Open the hood and remove the 

four screws which retain the center 

grille panel to the hood latch support 

brace. 

2. Remove the headlight cover return 

springs. 

3. Remove two capscrews which 

retain the grille center. 

4. Remove two retaining screws 

from the grille outer end. 

5. Remove the two stud nuts which 

retain the grille outer end. 

6. Pull the grille assembly out 

from around the headlights. 

7. Disconnect the vacuum motor 

lower vacuum hose from the vacuum 

motor. Remove the through bolt and 

nut from the bottom of the vacuum 

motor. 

8. Disconnect the headlight wiring 

connectors from the headlights and 

lift out the vacuum motor assembly. 

INSTAllATION 

1. Position the vacuum motor assembly 

and, reaching under the car, 

install the retaining through bolt 

and nut. Connect the lower vacuum 

hose to the vacuum motor. 

2. Connect the upper vacuum hose 

to the vacuum motor and connect the 

headlight wiring connector plug. 

3. Position the grille in the 

grille opening and install the two 

retaining stud nuts. 

4. Install the two grille top retaining 

screws and the two capscrews 

which retain the grille center. 

5. Install the two headlight cover 

return springs. 

6. Install the vacuum motor to 

headlight cover retaining clip. 

7. Position the center grille panel 

to the grille and install the four center 

panel retaining capscrews. 

8. Start the engine and check 

headlights and headlight covers for 

proper operation. 

WIRING ASSEMBLY-DASH 

TO HEADLIGHT JUNCTION 

(14290 WIRING HARNESS) 

-FAIRLANE, FALCON, 

MERCURY INTERMEDIATE 

I. Disconnect the battery ground 

cable from the battery. 

2. Disconnect the harness plug connector 

at the dash panel. 

3. Open the wiring retainer along 

the left fender apron. 

4. Disconnect the alternator wiring 

connector. Remove the ground wire 

retaining screw at the alternator regulator. 

Disconnect the left headlight 

and parking light wiring connectors. 

5. Remove the wiring leads (blackyellow 

stripe and yellow wires) from 

the starting motor solenoid. Open the 

wiring retaining clips on the right 

fender apron. Disconnect the right 

headlight and the right parking light 

wiring connectors. 

6. Open the wiring retaining clips 

across the top of the radiator support 

and work the harness out from right 

to left. Remove the harness out 

through the hole at the alternator 

regulator. 

7. Position the new wiring assembly 

in the engine compartment, working 

from left to right through the routing 

hole in the left radiator side support 

near the alternator regulator. 

8. Connect the wiring leads to the 

starting motor solenoid. Install the 

wiring in the retaining clips on the 

right fender apron. Connect the headlights, 

parking light and horn connectors. 

Position the wiring in the retaining 

clips across the radiator support. 

9. Connect the left headlights, 

parking light and horn. Connect the alternator 

regulator wiring connector. 

Install the ground wire and radio 

suppressor ground wire retaining 

screw. 

10. Place the wiring harness in the 

wiring retainers along the left fender 

apron and connect the wiring connector 

at the dash panel. 

11. Connect the battery ground cable 

to the battery. 

12. Check operation of the headlights, 

parking lights and horns. 

WIRING ASSEMBLY-DASH TO 

HEADLIGHT JUNCTION- 

COUGAR AND MUSTANG 

1. Disconnect the battery ground 

cable. 

2. Disconnect two multiple connectors 

and one single connector under 

the instrument panel, push the 

grommet and connectors through the 

hole into the engine compartment. 

3. Disconnect the dual brake warning 

connector at the brake differential 

valve. 

4. Open the harness retaining clips, 

disconnect the wires from the starter 

relay, and disconnect the alternator 

wiring connector. 

5. Disconnect the headlight and 

parking light connectors, the voltage 

regulator wires and radio suppressor, 

and the horn leads. On the Cougar 

disconnect the headlight housing vacuum 

solenoid wire. 

6. Remove the screws retaining the 

headlight and regulator ground wires, 

open all harness retaining clips and 

remove the harness from the vehicle. 

7. Route the new harness and 

close all the retaining clips. 

8. Install the screws retaining the 

headlight and regulator ground wires. 

9. Connect the horns, the starter, 

the alternator and the headlight and 

parking light wires. 

10. Connect the voltage regulator, 

wire connector, radio suppressor and 

the dual brake warning connector. 

On the Cougar also connect the headlight 

vacuum solenoid wire. 

11. Push the multiple connectors 

through the dash, seat the dash grommet 

and connect the multiple connectors 

at the instrument panel. 

12. Connect the battery and check 

the operation of all connected parts. 

PARKING 

LIGHT HOUSING-ALL 

1. Open the hood and disconnect 

the connector between the radiator 

support and grille.


2. Remove the lead wires from the 

retaining clips and pull the wire 

down. 

3. Remove the two screws or retaining 

nuts from the housing retainer 

and remove the lamp assembly and 

housing retainer from the bumper or 

stone deflector extension. 

4. Remove the lens, gasket and 

bulb from the lamp housing. 

5. Install the bulb, gasket and 

lens in the housing. 

6. Position the housing and retainer 

to the bumper or stone deflector 

extension and install the retaining 

screws or nuts. 

7. Re-route the lead wires back 

to the connector at the radiator support 

and connect the connector. 

8. Position the lead wire in the 

retaining clips as required. 

PARKING LIGHT 

To replace the bulb, remove the 

lens retaining screws and the lens. 

HORNS 

Disconnect the horn wire from the 

terminal. Remove the horn mounting 

bracket to horn retaining screws and 

remove the horn. 

To install, mount the horn in position, 

then connect the horn wire to 

the horn terminal. 

HORN BUTTON 

1. Disconnect the horn wire connector, 

that has a yellow and a yellow-green 

wire in it, under the instrument 

panel, to the left of the 

steering column. 

2. Press down evenly on the horn 

button and turn counter-clockwise 

until it lifts out from the steering 

wheel. 

3. Remove the horn button and 

spring. 

4. The horn button contacts are integral 

with the turn signal switch and 

are removed with the switch. 

5. Install the horn button spring 

and button. 

6. Connect the horn wire connector 

under the instrument panel. 

DOME AND COURTESY 

LIGHT (S) 

On the Mustang Hardtop, the dome 

light bulb can be removed by removing 

the screws retaining the dome 

light lens. To replace the dome light 

bulb in the Falcon, Fairlane and 

Mercury Intermediate it is only necessary 

to snap out the dome light lens. 

To replace the courtesy light bulb 

for Mustangs (except Hardtops) pry 

the light assembly out of the lower 

rear quarter panel. On the Cougar 

the courtesy light is located in the 

upper rear quarter panel and the 

bulb can be replaced by snapping out 

the light assembly lens. 

INSTRUMENT LIGHTS 

The instrument cluster bulbs are 

retained in plug-in type sockets. The 

instrument cluster light bulbs can 

be replaced by pulling out the individual 

ligr,t sockets from the rear 

of the instrument cluster. 

On the Mustang and Cougar, bulbs 

on the right side of the cluster can 

be replaced by reaching under the instrument 

panel. Bulbs on the left side 

of lhe cluster are replaced by removing 

the four heater control retaining 

screws and positioning the heater control 

outward to provide access. 

WARNING LIGHT BULBS 

ROOF CONSOLE-XR-7 COUGAR 

I. Remove two console retaining 

screws. 

2. Pry the console downward to 

free the console retaining clips (two) 

from the roof. 

3. Replace either of the four bulbs 

(seat belt, door, parking brake or low 

fuel) as required. 

4. Snap the console into place and 

install the two retaining screws. 

TRANSMISSION CONTROL 

SELECTOR LIGHT (ON 

STEERING COLUMN)-FALCON, 

FAIRLANE AND MERCURY 

INTERMEDIATE 



2. Remove the horn ring and steering 

wheel. 

3. Remove the light bulb socket 

retaining scrl:w and pullout the bulb 

and socket assembly. Replace the 

bulb. 

4. Position the bulb and socket assembly 

and install the socket retaining 

screw. 

5. Install the steering wheel and 

horn ring. 




SELECTOR LIGHT-MUSTANG 

AND COUGAR 

I. Remove the four retaining 

screws from the selector lever cover 

and'dial indicator on the floor, 

2. Lift the lever cover assembly 

and replace the bulb. 

3. Position the cover to the floor 

and install the four cover retaining 

screws. 


SELECTOR LIGHT (ON 

CONSOLE)-MUSTANG AND 

COUGAR 

I. Pry the top finish pad cover 

from the console. 

2. Remove the two retaining 

screws from inside the glove box and 

remove the upper finish panel. 

3. Position the selector lever in the 

one position and remove the light socket 

and bulb from its retainer. 

4. Replace the bulb and install the 

socket in the retainer. 

5. Position the finish panel and install 

the retaining screws. 

6. Snap the finish pad cover into 

position. 

TAilLIGHT lENS-COUGAR 

1. Remove the luggage compartment 

rear trim panel. 

2. Remove the four bulb and 

socket assemblies from the light body. 

3. Remove the six nuts retaining 

the light assembly to the body back 

panel. 

4. Remove the light assembly and 

place it on a work bench. 

S. Remove ten nuts and remove 

the lens and door from the light body. 

Remove the lens from the door. 

6. Position the new lens in the 

door. 

7. Position the lens and door assembly 

to the light body and install 

the ten retaining screws. 

8. Position the light assembly to 

the car body and install the six light 

assembly retaining nuts. 

9. Plug in the light socket and 

bulbs. 

10. Install the luggage compartment 


TAILLIGHT LENS-MUSTANG 

I. Open the rear deck and remove 

the spare tire. 

2. Remove the bulb socket from 

the rear I ight body. 

3. Remove the six plastic covers 

from the ends of the bezel assembly 

studs and also remove the six retaining 

nuts. 

4. Pull the light body and lens 

from the studs and remove the assembly 

from the vehicle. 

5. Remove the six retaining screws 

from the lens and remove the lens 

from the body.

PART 15-2-Lighting System And Horns 15-15 

6. Position the lens to the light 

body and install the six retaining 

screws. 

7. Position the light body assembly 

to the bezel studs and install the 

six retaining nuts. Install the plastic 

covers on the ends of the studs. 

8. Plug the bulb and socket assembly 

into the light body. 

9. Replace the spare tire and 

close the rear deck lid. 

TAILLIGHT LENS AND/OR 

BULB-FALCON, MERCURY 

INTERMEDIATE-MODEL 71 

1. Remove four screws retaining 

the lamp assembly to the quarter 

panel. 

2. Remove the lens from the lamp 

assembly. Remove bulb if necessary. 

3. Position the lens to the lamp 

assembly. 

4. Position the lamp assembly to 

the quarter panel and install the retaining 

screws. 

TAIL AND STOP LIGHT 

BULBS-EXCEPT STATION 

WAGONS 

The tail and stoplight bulbs may 

be replaced, by opening the rear deck 

lid and pulling the socket and bulb 

assembly from the rear lamp body. 

On the Cougar, it will be necessary 

to remove the luggage compartment 

liner in order to remove light sockets. 

TAILLIGHT BODY. .COUGAR 

I. Remove the luggage compartment 


2. Remove the four bulb and socket 

assemblies from the light body. 



panel and remove the assembly. 

4. Remove the outer seal from the 

light body and also remove the four 

rubber ring gaskets from the bulb 

openings. 

5. Remove the ten retaining nuts 

and remove the lens and door assembly 

from the light body. 

6. If replacement of the light body 

is necessary transfer the six studs 

to the new light body. 

7. Cement the le~s seal to the 

light body. 

'I 

8. Position the lens I, and door assembly 

to the light b~y and install 

the ten retaining nuts. \. 

9. Install the rubber ring gaskets 

in the bulb openings. Cement the 

outer seal to the light body. 




II. Plug in the light socket and 

bulbs. 


rear trim panel. Check the operation 

of the lights. 

TAILLIGHT BODY-FALCON 

I. Open the rear deck lid. Disconnect 

the bulb and socket from the 

back of the taillight housing. 

2. Remove the four light body retaining 

screws and remove the light 

body from the quarter panel. 

3. Separate the gasket and lens 


4. Cement the gasket to the light 

body. Position the lens to the light 

body and position the light body to 

the quarter panel and install the 

four retaining screws. 

5. Connect the socket and bulb to 

the light housing. 

6. Close the rear deck and check 

the operation of the light. 

TAilLIGHT BODY, lENS AND/ 

OR BUlBS-FAIRlANE 

MODEL 71 

1. Remove the four door retaining 

screws and remove the door. 

2. Remove the four screws retaining 

the light assembly to the quarter 

panel. Remove the bulb socket from 

the light assembly and remove the 

light assembly. 

3. Remove the light body gasket. 

4. Remove the six lens retaining 

screws and remove the lens from the 

light body. 

5. Remove four screws and two 

back-up light lens retainers and gaskets 

from the taillight lens. 

6. Position the gaskets and backup 

lens to the rear light lens. Position 

the retainers and install the four lens 

retaining screws. 

7. Install a new lens in the light 

body and install the six lens retaining 

screws. 

8. Position the light body gasket. 

Position the light body to the quarter 

panel, insert the light bulb and socket 

assemblies into the light body and 

install the four light body retaining 

screws. 

9. Position the rear light door to 

the light body and install the four retaining 

screws. 

TAILLIGHT BODY 

-MUSTANG 

I. Remove the spare wheel and 

tire assembly. 

2. Unplug the bulb and socket from 

the light body. 


from the light body and bezel (doors) 

retainin~ studs. 

4. Remove the six nuts from the 

light body and bezel (doors) retaining 

studs. 

s. Pull the light body back and off 

the studs. The light bezels (doors) can 

be replaced if necessary at this time 

as the studs are on the bezel and 

these studs and nuts retain the light 

assembly to the body panel. 

6. Remove the gasket seal from the 

front of the lens. 

7. Remove the six lens retaining 

screws from the light body and remove 

the lens from the light body. 

8. Install a new gasket in the light 

body. Position the lens to the body 

and install the six lens retaining 

screws. 

9. If the bezels (doors) were removed, 

position the bezels to the body 

panel, using new seals. 

10. Position the seal to the lens and 

light body assembly. 

11. Position the light body assembly 

on the retaining studs and install 

the six retaining nuts. Install the six 

plastic stud covers. 



BACKUP LIGHT BODY- 

COUGAR AND MUSTANG 

I. Open the luggage compartment 

and remove the luggage compartment 

rear trim panel (Cougar only). 

2. Fold back the carpet and remove 

the cover over the quarter panel. 

3. Disconnect the backup light 

connector, push the grommet through 

the side of the inner panel, and pull 

the lead through the hole. 

4. Remove the nuts and retainer 

and remove the backup light from the 

lower body panel extension. 

5. Transfer the lens, bulb and gasket 

to the new light body, and install 

sealer to the new light. 


the lower body panel extension, 

position the retainer, and install the 

mounting nuts. 

7. Route the lead through the hole 

and push the grommet into place. 

8. Connect the backup light connector, 

check the operation of the 

light, install the quarter panel cover, 

and position the carpet. 


rear trim panel (Cougar only). 

TAilLIGHT DOOR-FAIRlANE 

All EXCEPT MODEL 71 

I. From inside the luggage compartment, 

remove the bulb and socket 

and disconnect the two wiring connectors. 

2. Remove the five light "~~emhlv


GROUP 15-Lighting System, Horns And Instruments 

to quarter panel retaining nuts and 

remove the light assembly. 

3. Remove one nut and one screw. 

Disconnect the back-up light bulb 

and remove the light body from the 

door and lens assembly. 

4. Remove four screws retaining 

the backup light lens and taillight 

lens to the door with the retainer. 

Remove both lenses. 

S. Position the taillight lens and 

backup lens to the door. Install the 


6. Position the light body to the 

door. Plug in the backup light bulb 

and install the one nut and screw. 


the quarter panel and install the five 

retaining nuts. 

8. Plug the taillight bulb and socket 

assembly into the light body and 

connect the two wiring connectors. 

TAILLIGHT DOOR-COUGAR 

1. Remove the luggage compartment 


2. Remove the four bulb and 

socket assemblies from the light body. 



panel. 

4. Remove the light assembly and 

place it on a work bench. 

5. Remove ten nuts and remove 

the lens and door from the light body. 

Remove the lens from the door. 

6. Position the lens in the 

door. 

7. Position the lens and door assembly 

to the light body and install 

the ten retaining screws. 




9. Plug in the light socket and 

bulbs. 



TAilliGHT 

DOOR-MUSTANG 

1. Open the rear deck and remove 

the spare tire. 

2. Unplug the bulb and socket 



from the light body and bezel (door) 

retaining studs. 

4. Remove the six nuts from the 

light body and bezel (doors) retaining 

studs and pull the light body from 

the studs. 

5. Remove the three door assemblies 

from the back panel and remove 

the seals from the doors. 

6. Install the three rubber seals 

on the door assemblies and install the 

door assemblies to the back panel. 

7. Position the light body to the 

retaining studs and install the six 


8. Install the six plastic stud 

covers. 



10. Install the spare tire, and 

check the operation of the lights. 

LICENSE PLATE LIGHT 

ASSEMBLY-EXCEPT COUGAR 

AND STATION WAGONS 

I. Open the rear deck lid and 

disconnect the license plate light 

lead wire and feed the wire through 

the rear panel. 

2. Remove the two screws attaching 

the light assembly to the bumper 

and remove the assembly. 

3. Remove the lens bezel, lens 

and gasket retaining screw and remove 

the bulb from the assembly. 

4. Install the bulb in the assembly. 

Position the gasket, lens and lens 

bezel to the assembly and install 

the retaining screw. 


the bumper and install the two retaining 

screws. 

6. Feed the lead wire thru the 

rear panel and connect the connector. 

LICENSE PLATE BULB 

AND/OR LENS 

On all vehicles except the Cougar 

and station wagon, the license plate 

bulb or lens can be replaced by removing 

one screw that retains the 

lens, lens bezel and gasket to the 

light assembly. 

On station wagons the bulb or lens 

may be replaced by prying the lens 

assembly from the bumper and then 

removing the bulb and socket assembly 

from the lens. 

For the Cougar license plate light 

only, it is necessary to open the rear 

deck and remove the luggage compartment 

liner and then pull the 

light socket from the rear panel.

Headlight Beam Selector Switch 

etaidemretnI 

dna Cougar. 


Section 

Page 

1 Description and Operation 15-17 

Headlight Switch 15-17 

Fuse Panel 15-17 

Mechanical Stoplight Switch 15-17 

2 Removal and Installation 15-22 

Headlight Switch-Except Mustang 

Headlight and 

Cougar Switch-Mustang and Cougar 15-22 

Ignition Switch-All Models 

Parking Brake Warning Switch-Cougar 

Dome Stoplight Dual Brake Light Switch-All Warning Switch Light Switch-All. 

, 








lartueN roiretnI pU-kcaB Map Light Start Light Switch-Mustang Switch-Cougar (Roof XR-7 Console) 

Turn Indicator Switch and Wire Assembly... 

Windshield Wiper/Washer Switch-Fairlane . 

Windshield Wiper/Washer Switch-Falcon .. 

Windshield Wiper Switch-Mercury 

Windshield Wiper Switch-Mercury 

etaidemretnI (Intermitent Wipers) 

Windshield Wiper Switch-Mustang 

.15-24 









,.15-25 




harnesses. Schematics are shown 


HEADLIGHT SWITCH 

A combination headlight switch 

and two circuit breakers is used (Fig. 

I). The headlight circuit is protected 

by an 18 ampere circuit breaker 

for the Mercury Intermediate and 

Fairlane, a 12 ampere circuit breaker 

for the Falcon and the Mustang. 

The tail, parking, license plate light 

and horn circuits are protected by a 

15 ampere circuit breaker. 

FUSE PANEL 

The fuse panel for the Falcon, 

Fairlane and Mercury Intermediate 

is mounted on the dash panel above 

the headlight dimmer switch. On the 

Mustang and Cougar the fuse panel is 

mounted above the accelerator pedal. 

Figs. 2 through 6 show the fuse locations 

in the panel and their respective 

values. 

MECHANICAL 

SWITCH 

STOP LIGHT 

The mechanical stoplight switch 

SFE 14 AMP FUSE: 

BACK.UP LIGHTS \ 

WINDSHIELD WASHER 

SEA T BELT WARNING 

RADIO 

TURN SIGNALS 

SFE 14 AMP FUSE 

HEATER 

~ 

14A HTR 

s;::] 

r 1 

~~s-f:--[T 

0 CIG 

l LTR. ~ 

" ~u~~ Wt.RN 

0 

~ 

7 o;A nnAA" 

nA 

/ AGA 2.5 AMP FUSE: 

INST. PANEL 

CLUSTER LIGHTS 

CLOCK LIGHT 

TACH().\ETER 

LIGHT 

ASH TRAY LIGHT 

TRANS. SELECTOR 

DIAL LIGHT 

RADIO LIGHT 

SFE 7.5 AMP FUSE: 

D~E, COORTESY, 

CARGO, MAP 

GLOVE BOX AND 

LUGGAGE C~P'T 

LIGHTS 


CIGAR LIGHTER 

EMERGENCY WARNING 

FLASHER 

CLOCK FEED, 

KNOB RELEASE BUTTON 

~ 


K1451-A 

K 2133-A 

FIG. 

Headlig ht Switch 

FIG. 2-Fuse Panel-Mercury Intermediate


GROUP 15-Lighti ng System, Horns And Instruments 

differs from the hydraulic switch formerly 

used. The switch assembly is 

installed on the pin of the brake pedal 

arm so that it straddles the master 

cylinder push rod. The switch assembly 

is a slip fit on the pedal arm pin 

and thus the switch assembly moves 

with the pedal arm whenever the 

brake pedal is depressed. 

The brake pedal arm pin has a designed-in 

clearance with the eye of 

the master cylinder push rod (Fig. 

7). Because of this clearance, whenever 

the brake pedal is pushed forward, 

the stop light switch contacts, 

moving with the pedal arm, are actually 

pushed against the end of the 

master cylinder push rod, through the 

switch actuating pin. It is this movement 

of the switch with respect to 

the actuating pin and master cylinder 

push rod that closes the switch 

contacts completing the circuit to the 

stoplights. 

When the brake pedal is released, 

the spring in the stop light switch returns 

the actuating pin to its normal 

position and the circuit to the stop 

lights opens. 

FALCON 

K 2134.'" 

FIG. 3-Fuse Panel. .Falcon

PART 15-3-Switches, Circuit Breakers And Fuses 15-19 


BACK.UP LIGHTS 

WINDSHIELD WASHER 

SEAT BELT WARNING 

RADIO 

TURN SIGNALS 

0 

0 

SFE 14 .AMP FUSE: 

HEATER 

14A ACCY 

- - 

14AHTR 

[] 

r'-" 

~7' 

- - 

2.5INST. LT, 

\--J. 

EMER. WARN. 

/ 

s:::J 

0 CIG 

L TR.- 

d'f- 

... 

...#' 

0 

7.SA D()y4,E 

20A 

AGA 2.5 AMP FUSE 

INST. PANEL 


CLOCK LIGHT 

ASH TRAY LIGHT 

TACHOMETER LIGHT 

RADIO LIGHT 

TRANS. SELECTOR 

DIAL LIGHT 

'SFE 7.5 AMP FUSE: 

DOME, COURTESY, 

CARGO, MAP 

GLOVE BOX, 

LUGGAGE COMP'T. 

LIGHTS 

DOOR OPEN WARNING 

LIGHT (TAXI) 


CIGAR LIGHTER 


FLASHER 

CLOCK FEED 

FAIRLANE 

FIG. 4-Fuse Panel-Fairlane



BACK.UP liGHTS 

SEAT BEL T WARNING 

(MODEL 65 ONLY) 

RADIO 

TURN SIGNALS 

DOOR AJAR WARNING 

0 

0 

- - 

14AACCY 

~ 

0 

AGA 2.5 AMP FUSE: 

INST. PANEL 


RADIO LIGHT 

TACHa.-4.ETER 

LIGHT 

SFE 14 At.\P FUSE: 

HEATER 

DEFROSTER 

14AHTR 

s::J 0 CIG 

LTR. - 

2.5INST. LT 

~ 

p"" 

7.5A DOME 

SFE 7.5 .AMP FUSE: 

Da.J.E, COORTESY 

MAP LIGHT 

GLOVE BOX AND 

LUGGAGE Ca.J.P'T 

LIGHTS 

CLOCK LIGHT 

SEAT BELT 

WARNING 

SF E 14 AMP FUSE: 

CIGAR LIGHTER 

EMER. WARN. 

20A 

COUGAR 

FIG. 5-Fuse Panel. -Cougar



BACK.UP 

LIGHTS 

RADIO 

P RN D L LIGHT 

TURN 

SIGNAL 


HEATER 

DEFROSTER 

14A HTR 

7.SA DOME 

AGA 2.5 AMP FUSE: 

INST. PANEL 


TACHOMETER LIGHT 

RADIO LIGHT 

(THIS CIRCUIT IS 

CONN ECTED INTO THE 

15 AMP C.B. IN THE 

HEADLIGHT SWITCH) 

SFE 7.5 AMP FUSE: 

D()J.E, COORTESY, 

MAP LIGHT 

GLOVE BOX AND 

LUGGAGE Ca.4P'T 

LIGHTS 

CLOCK LIGHT 

SEAT BELT 

WARNING 

DOOR AJAR WARNING 


CIGAR LIGHTER 


FLASHER 

MUSTANG 

FIG. 6. 

Fuse Panel-Mustang


'..,..~-::::..:::..- 

Kl582-A 

FIG. 7. 

Mechanical Stoplight Switch Operation 


HEADLIGHT SWITCH-EXCEPT 

MUSTANG AND COUGAR 


cable. 

2. To remove the control knob and 

shaft assembly, place the knob in the 

ful1 ON position. Then press the knob 

release button on the switch assembly 

(Fig. I). Pul1 the knob and shaft out 

of the switch assembly. 

3. Unscrew the mounting nut, remove 

the bezel and switch, then remove 

the junction block from the 

switch. 

4. To install the switch, connect 

the junction block to the headlight 

switch, position the switch in the instrument 

panel, and install the bezel 

and mounting nut. 

S. Install the knob and shaft assembly 

by inserting it all the way into 

the switch until a distinct click is 

heard. In some instances it may be 

necessary to rotate the shaft slightly 

until it engages the switch-contact 

carrier. 

6. Connect the battery ground cable. 

HEADLIGHT SWITCH 

AND COUGAR 

MUSTANG 



2. Remove two screws and lower 

the parking brake and air control. 

3. To remove the control knob and 

shaft assembly. place the knob in the 

full ON position. Then press the knob 

release button on the switch assembly 

(Fig. I). Pull the knob and shaft out 


4. Remove the switch bezel retaining 

nut and the bezel, then lower the 

switch assembly. Disconnect the wiring 

junction block from the switch 

and remove the switch. 


the junction block to the headlight 

switch, position the switch in the instrument 

panel, and install the bezel 

and the retaining nut. 

6. Install the knob and shaft assembly 

by inserting it all the way into 

the switch until a distinct click is 

heard. In some instances it may be 

necessary to rotate the shaft slightly 

u.ntil it engages the switch-contact 

carrier. 

7. Position the parking brake and 

air control and install the two retaining 

screws.c 


to the battery and check the 

switch operation. 

IGNITION SWITCH- 

ALL MODELS 



2. Insert the ignition key in the 

switch. Turn the switch to the accessory 

position. Insert a wire pin in 

the hole on the ignition switch. 

Slightly depress the pin while turning 

the key counterclockwise past 

the accessory position. This will 

release the lock cylinder from the 

sw itch assembly. Pull out the lock 

cylinder with the key. If only the lock 

cylinder is to be replaced, proceed to 

step 8. 

3. Remove the bezel nut with tool 

T65L-700-A. 

4. Lower the switch assembly from 

the instrument panel and remove the 

accessory wire retaining nut and remove 

the accessory and gauge feed 

wires from the switch.


, 

RETAINER 

FIG. 8-Headlight 

Switch 

K 1070-C 

Beam Selector 

5. Remove the insulated plug from 

the switch and remove the switch. 


the insulated connector plug to the 

switch. Install the accessory wire 

and retaining nut to the stud on the 

back of the switch. 

7. Position the switch in its retainer 

and install the bezel nut. 

8. Insert the key in the switch 

assembly and turn the key to the 

accessory position. Place the cylinder 

and key in the switch. Push the cylinder 

into the switch until it is fully 

seated then turn the key to the lock 

position. Turn the key to check the 

lock cylinder operation. 


to the battery and check the operation 


HEADLIGHT BEAM 

SELECTOR SWITCH 

Lay the floor mat back from the 

area of the switch, and remove the 

mounting screws (Fig. 8). Disconnect 

the wire terminal block from the 

switch. 

To install the switch, connect the 

terminal block to the switch and install 

the switch to the floor. Replace 

the floor mat. 

PARKING BRAKE WARNING 

SWITCH-COUGAR 

1. Disconnect the lead wire to the 

switch. 

2. Remove the nut and bolt retaining 

the switch assembly to the parking 

brake control assembly and remove 

the switch. 

3. Position the parking brake in 

the OFF position, then position the 

"witrh tn the Inwer end ill the nark- 

FIG. 9. 

Mechon icol Stoplight Switch Assem bly 

ing brake control rod and loosely 

install the retaining nut and bolt. 

4. Connect the lead wire to the 

switch assembly. 

5. With the parking brake in the 

OFF position, slide the switch up 

the brake control rod until the warning 

light goes out. Tighten the retaining 

nut and bolt to fasten the 

switch in position. 

6. Check the operation of the parking 

brake and switch. 

STOP LIGHT SWITCH-ALL 

1. Disconnect the wires at the con- 

"""tnr 

2. Remove the hairpin retainer. 

slide the stop light switch. the push 

rod and the nylon washers and bushing 

away from the pedal, and remove 

the switch (Fig. 9). 

3. Position the switch, push rod, 

and bushing and washers on the 

brake pedal pin, in the order shown 

in Fig. 9, and install the hairpin retainer. 

4. Connect the wires at the connector, 

and install the wires in the 

retaining clip (Fig. 9). 

DOME LIGHT SWITCH 

The dome light switch is part of



the headlight switch. It is actuated 

by rotating the switch control knob 

to the maximum counterclockwise 

position. The dome light and headlight 

switch is replaced as a unit 

(Fig. 1). 

DUAL BRAKE WARNING 

LIGHT SWITCH-ALL 

1. Disconnect the brake warning 

light wire from the switch (mounted 

on the pressure differential valve assembly). 

To prevent damage to the 

brake warning switch wire connector, 

expand ttk! plastic lugs to allow removal 

of the shell-wire connector 

from the switch body. 

2. Remove the switch from the 

pressure differential valve. 

3.. Install the new switch in the 

pressure differential valve. 

4. Connect the shell-wire connector 

to the brake warning light switch. 

Make sure that the plastic lugs on 

the connector hold the connector securely 

to the switch. 

Refer to Group 2, Part 1, Brakes 

for centralizing differential valve procedures 

NEUTRAL START SWITCH 

See Group 7 for replacement of 

the neutral start switch on cars 

equipped with automatic transmissions. 

BACK-UP 

LIGHT SWITCH 

On cars equipped with the steering 

column standard shift, the switch is 

located on the lower end of the steering 

column. 

On cars equipped with a shift lever 

directly over either the standard 

or automatic transmission, the backup 

light switch is located on the 

transmission. 

INTERIOR LIGHT SWITCH (S)- 

COUGAR XR-7 


cable. 

2. Remove the instrument cluster 

assembly from the instrument panel. 

3. Remove the nut(s) retaining the 

toggle switch(s) to the instrument 

panel. Pull the switch(s) to the cluster 

opening position the switch(s) to the 

the switch(s). 

4. Connect the switch(s) to the 

lead wire(s) and working through the 

opening position the switch (s) to the 

instrument panel and install the retaining 

nut(s). 

s. Install the instrument cluster 

in the instrument panel. 

6. Connect the battery ground cable. 

Check the operation of the 

switch(s). 

MAP LIGHT SWITCH- 

MUSTANG (ROOF CONSOLE) 

I. Remove the four console-to-roof 

retaining screws (two screws at the 

front and two screws at the rear). 

2. Remove the two switch-to-console 

retaining screws. Remove the 

ground wire retaining screw above 

the windshield. Disconnect the switch 

wi ring connectors and remove the 

switch. 

3. Position the new switch to the 

console and install the two switch-toconsole 

retaining screws. Position the 

ground wire above the windshield and 

install the retaining screw. Connect 

the switch wiring connectors. 

4. Position the console to the roof 

and install the four console-to-roof 


TURN INDICATOR SWITCH 

AND WIRE ASSEMBLY 

REMOVAL 

The emergency warning flasher 

switch and the turn signal flasher 

switch are integral parts of the same 

switch assembly. 



2. Remove the steering wheel hub. 

3. Remove the horn button (three 

screws). The springs will fallout. 

4. Remove the steering wheel retaining 

nut. 

S. Using tool 3600-AA, remove the 

steering wheel. 

6. Remove the turn signal switch 

lever. Remove the emergency flasher 

control knob. (Disconnect the setspeed 

switch wiring connector, if so 

equipped). 

7. Remove two steering column 

upper collar retaining screws and remove 

the upper collar. 

8. Disconnect the turn signal 

switch wiring multiple connector (near 

bottom of the steering column). It 

may be necessary to lower the hand 

brake control and left air vent control 

on some Mustang and Cougar 

models to provide access to the turn 

signal wiring connector. 

9. Remove the wires and terminals 

from the connector blocks. This can 

be done by depressing the tab on the 

wire terminal with an awl or, with an 

empty ball point pen refill cartridge; 

then, pull the wire and terminal from 

the connector block. Record the color 

code and location of each wire before 

re moving it from the connector block. 

Tape the wires together and attach 

a piece of heavy cord to the wires to 

help pull the wires through the steering 

column during installation. 

10. Remove the plastic cover from 

over the wires. 

II. Push the lower steering column 

collar down. Remove the wiring retaining 

clip. 

12. Remove the two screws retaining 

the switch in the steering 

column and pull the switch and wiring 

assembly out of the column. 

INSTALLATION 

I. Tape the wiring of the replacement 

switch assembly together and 

transfer the pull cord used during 

removal. 

2. Pull the wires down through the 

steering column with the cord, and 

position the switch to the steering 

column hub. 

3. Install the two screws retaining 

the switch assembly to the steering 

column hub. 

4. Install the wiring retaining clip 

on the steering column. 

S. Install the plastic cover over 

the wires. 

6. Press the switch wires into the 

connector blocks in their correct location 

recorded during removal. Plug 

the connector blocks together with the 

mating connector blocks at the dash 

panel. 

7. Pull the steering column collar 

up and snap it in position. 

8. Position the upper column and 


9. Install the emergency flasher 

retainer and knob. 

10. Install the turn signal lever. 

II. Position the steering wheel on 

the steering shaft and install the steering 

wheel retaining nut. 

12. Install the horn button with 

its springs and the three retaining 

screws. 

13. Install the hub. 

14. Connect the battery ground 

cable to the battery. 

IS. Check the operation of the 

turn signal emergency flashers and 

horns. 

WINDSHIELD WIPER/WASHER 

SWITCH-FAIRlANE 

I. Disconnect battery ground 


2. Remove the wiper switch control 

knobs. 

3. From the lower edge of the instrument 

cluster, remove the three 

screws which retain the switch assembly 

to the instrument panel. Disconnect 

the switch wiring connectors 

from the switch and remove the switch 

assembly.

PART 15-3-Switches, Circuit Breakers And Fuses 1 5-25 

4. Remove the retaining screw and 

plastic bar and separate the wiper 

and washer switch. 

5. Replace the wiper or washer 

switch as required. Position the two 

switches together and install the 

plastic bar and retaining screw which 

holds the two switches together so 

that when the washer switch is turned 

on it also actuates the wiper switch. 

6. Connect the wiring connectors 

to the switch assembly. Position the 

switch assembly to the instrument 

panel and install the three switch assembly 


7. Install the control knobs. 



WINDSHIELD WIPER/WASHER 

SWITCH-FALCON 

REMOVAL 


cable. 

2. Remove the wiper/washer 

switch control knobs and unplug the 

connectors at the switch. 

3. Remove the two switch retaining 

screws from the cluster and remove 

the switch from under the instrument 

panel. 

4. Remove the two screws from 

the switch assembly and separate the 

washer switch from the wiper switch. 

INSTALLATION 

1. Position the switches together 

and install the two assembly retaining 

screws. 

2. Position the switch to the back 

of the cluster and install the retaining 

screws. 

3. Connect the switch connectors 

and install the control knobs. 


and check the operation of the 

switch. 

WINDSHIELD WIPER SWITCH- 


(ST ANDARD) 

1. Disconnect the battery cable. 

2. Remove the wiper switch knob, 

bezel nut, and bezel. 

3. Pull out the switch from under 

the instrument panel. Disconnect the 

pI ug connector from the switch and 

remove the switch. 

4. Position the switch and connect 

the plug connector. 

5. Position the switch in the instrument 

panel and install the bezel, 

bezel nut, and knob. 

6. Connect the battery cable and 

check the operation of the switch. 

WINDSHIELD WIPER 

SWITCH-MERCURY 

INTERMEDIATE (INTERMITTENT 

WIPERS) 



2. Loosen the wiper control knob 

set screws and remove the knob. 

3. Remove the bezel nut and the 

bezel. 

4. Lower the switch assembly. Remove 

the three vacuum hoses from 

the switch. Disconnect the wiring connector 

(plug-in type) from the switch 

and remove the switch assembly. 

5. Plug the wiring connector into 

the switch. Using the color code provided 

on the switch and hoses, connect 

the vacuum hoses to the switch 

and position the switch assembly to 

the instrument panel. 

6. Install the bezel, the bezel nut 

and the switch knob. 



WINDSHIELD WIPER SWITCH- 





assembly. Remove the wire harness 

plug from the switch. 


the wiper switch to the instrument 

cluster and remove the 

switch. 

4. Position the new switch to the 

instrument cluster and install the two 

switch retaining screws. Plug the 

wire harness into the switch. Be sure 

that all terminals are properly engaged. 

5. Install the instrument cluster. 


to the battery and check the operation 

of instruments and controls. Make 

sure that the windshield wiper motor 

operates on both speeds and parks 

properly.

~ 

1 Diagnosis Speedometer and Testing Diagnostic Procedures 

rotoMsrepiW Wil Not Operate 

egakniL Test 

Test 

repiW Switch Circuit Breaker Test 

2 Description and Operation 

repiW Motor Park Switch Adjustment 

ysioN Wiper System 

erutarepmeT Gauge 

tnemurtsnI Voltage Regulator 

leuF Gauge 

nI Park Position 

rotoM Park Switch Test 

nruT liO liO etaidemretnI 

Presure Presure Indicator 

Indicator Indicator Light 

Gauge 

retemodepS Windshield 

tnemurtsnI ,gnatsuM-sneL Voltage Cougar Regulator 

and XR-7 

Fuel -Cougar, Gauge-Mercury Gauge-Fairlane 

Sending Cougar Unit 

XR-7 Intermediate 

and Mustang 

Charge Pressure 

Indicator-Mercury Switch 

Gauge-Cougar Intermediate 

XR-7 

Turn Mercury Mustang... Signal Intermediate Flasher .",.",." 

Unit 

Speedometer Mercury Mustang, Except 

Cougar Intermediate Cougar and Cougar XR-7 

Tachometer Speedometer 

Windshield Mercury Mustang Intermediate and Wiper Cable 

Cougar Motor 

XR-7 


5-4- 

Section 

Loose Cable Attaching Nuts ." ' ' 

Defective Speedometer Head Test , 

Defective Cable Core and Housing Test.. 

Defective Drive and Driven Gears Test ... 

Windshield Wiper Diagnosis Procedures.. 

Wiper Switch Test , 

Intermittent Wiper Operation , 

Wipers Current Will Draw Not Test Stop or Will Not Stay 

Charge Indicator Light-Except 

Charge Mercury Indicator Intermediate Gauge-Mercury 

Emergency Warning Flasher-Except 

Emergency Cougar Warning Flasher System- 

Cougar Wiper-Mercury Intermediate 

Foot-Operated Windshield Washer 

Electric System-Mustallg Windshield Washer and Cougar Pump- 

Cougar Adjustment Repairs 

34 In-Vehicle Removal Windshield Except and Adjustment Mustang Installation Wiper Blade and and , 

Instrument Panel Cluster~ Control Identification 

Instrument Lens-Fairlane Panel Control Identification 

Fuel Gauge and/or Temperature Gauge 

-Falcon 

Page 








, 15-29 



























15--35 







Section 

Fuel Gauge and Temperature Gauge 

Temperature Gauge-Mercury 

Pal!e 

,..15-37 

..15-37 

,..15-37 

...15-38 

Intermediate ...15-38 

Temperature Sending Unit 15-38 

Charge Indicator and/or Oil Pressure 

Oil Indicator Pressure Gauge-Mustang Sending Unit or Oil 


Electric Clock , 


Mustang and Cougar , , 15-39 

Cougar XR-7 (Console Mounted) , , 15-39 

Fairlane Falcon .., 15-39 





Sequential Turn Signal Relay and/or 

Emergency Flasher-Cougar Warning Flasher- 

Fairlane . 

Falcon, Falcon. Fairlane, Mercury Intermediate ... 

Windshield Mustang and Wiper Cougar Pivot Shaft and Link ... 


Windshield Mustang and Washer Cougar Pump-Falcon, 

Fairlane, Intermediate 

5 Major Repair Mercury Operations """..""""""""" 

Wiper Parts Repair Motor or Disassembly Replacement """. 

Wiper Electro-Pneumatic Motor Assembly Governor and

PART 15-4-lnstruments 


VISIBLE DEFECTS 

FORD-LOW SPEED 

FORO-HIGH SPEED 

Slight Needle Waver or 

Severe Needle Fluctuation 

(No Noise) 

1. Loose cable nut. 

2. Defective speedometer head. 

3. Bent cable core at attaching 

nut. 

4. Kinked or pinched cable housing. 

5. Excessive grease in speedometer 

head. 

6. Defective speed control regulator. 

TO GROUND, 

Inoperative 

1. Broken cable core. 

2. Defective drive and/or driven 

gear. 


AUDIBLE DEFECTS 

Clicking or Ticking (With 

Needle Waver), Grinding 

or Ringing 

I. Loose cable nut. 

2. Defective drive and/or driven 

gear. 


4. No lube on cable. 

FIG. 1 

High and low Speed Motor Test Connections 

CONNECT TO POSITiVe TERMINAL OF~ATTERY 

K 2141-A 

MERCURY INTERMEDIATE (INTERMITTENT SYSTEM) 

Using 0 self.powered test lomp 0; Rotundo ohmmeter, check the continuity through 

the switch term;nols. Continuity should exist only as indicated in the following 

chart. Reploce the switch if it 4oes not meet the specified requirements. 

SWITCH POSITION CONTINUITY BETWEEN TERMINALS 

Off (Park) 63.763 

"c.-, 58.589 

Low 58-63.763 

High 56-63.763 

Intermittent 63.763 

56.993 

58.590 

Washer On 950.951 

COLOR CODE OF WIRING TO WIPER SWITCH 

56 Blue 763 Orange.'.'ihite 

58 Wh;te 950 White.Black 

63 Red 951 Green.Black 

589 Orange 99:1 Brown-White 

590 Blue.White 

Using a self.pawered test lamp or Rotunda ohmmeter, check the continuity thraugh 

the switch terminals. Continuity should exist only as indicated ;n the fallowing 

chart. Replace the switch if it daes nat meet the specified requirements. 


Off (Park) 763.63 

'""" 28-58 

Law 763.63.58 

High 763-63-56 

Washer On 951-950 


28 Black 

56 Blue 

58 White 

63 Red 

763 Orange.White 

950 White-Black 

951 Green.Black 

K 1991-A 

FIG. 2- WiDer Switch Continuity Test Connections- 

.Mercury Intermediate

1 5-28 

SPEEDOMETER TESTS 

GROUP lS-Lighting System, Horns And Instruments 

FORD 

LOOSE CABLE ATTACHING 

NUTS 

1. Cable nuts should be tightened 

with pliers to approximately 18 to 25 

in-lbs. 

2. Cable nuts should start and run 

up freely by han,d for at least three 

to four turns. 

3. A loose cable nut can cause a 

bent cable core. Tightening will not 

always correct the problem. 

DEFECTIVE SPEEDOMETER 

MEA D TEST 

Before removing a speedometer 

head, disconnect the cable at the 

head and insert a short section of cable 

core in the head. Rotate the section 

of core to check for any dragging 

or noise. The speedometer shaft 

should turn freely and evenly. 

DEFECTIVE CABLE CORE 

AND HOUSING TEST 

1. To check for a kinked cable 

core remove and wipe dry. Lay the 

core out straight on a flat surface 

and roll it back and forth. Any kinks 

or damage will be seen. Then take 

an end in each hand, allowing core 

FAIRLANE 

FIG. 3-Wiper 

Using a self.powered test lamp or Rotunda ohmmeter, check the continuity through 

the switch terminals. Continuity should exist only as indicated in the fallowing 

chart. Replace the switch if it does not meet the specified requirements. 


Off (Park) 65.763 

56.63 

58.61 

Low 61-63.763 

56-58 

High 61.763 

56.S8 

Washer On 763.941 


56 Blue 

58 White 

61 Yellow 

63 Red 

65 Green 

763 Orange-'¥hite 

941 Black.White 

Switch Continuity Test Connections-Folcon 

MUSTANG 

K 2140.A 

Using a self.pawered lest lamp ar Ralunda ohmmeter, check the continuity through 

the switch lerm;nals. Canlinu;ly should exist only as indicated in the lallow;ng 

chart. Reploce the sw;lch if il does not meet the specified requirements. 


011 (Pork) 63.763 

28.58 

Low 58-63-763 

H;gh 56-63.763 

Wosher On 950A.951 

COLOR CODE OF WIRING TO WIP ER SWITCH 

28 Block 

56 Blue 

58 Wh;le 

63 Red 

763 Oronge-While 

Using a sell.pawered test lamp or Rotunda ohmmeter, check the continuity thrcugh 

the switch terminals. Continuity should exist only as indicated in the fallowing 

chart. Replace the switch if it does not meet the specified requirements. 

SWITCH POSITION 

CONTINUIT.Y BETWEEN TERMINALS 

Off (Park) 63.763 

28.58 

Law 58-63.763 

High 56-63.763 

Washer On 

58A-63A 


28 Black 

56 Blue 

58 White 

63 Red 

763 Orange.White 

K1983-A 

FIG. 4- Wiper Switch Continuity Test Connections-Fairlane and Mustang

PART 15-4-1 nstruments 

1 5-29 

to hang in approximately a 9-inch 

loop. Rotate both ends to be sure 

core turns evenly. 

2. Routing of the cable housing is 

particularly important where the cable 

leaves the speedometer head. The 

optimum routing would provide that 

the cable and housing take virtually 

no change of direction for at least 

a length of 8 inches from the speedometer 

head. 

3. When installing a new cable 

and housing it is necessary that the 

new assembly be guided and routed 

properly to eliminate any kinks. 

4. Proper lubrication of the cable 

core is accomplished by a light application 

of 85AZ-19581-A lubricant 

after the cable has been wiped clean. 

A light film is all that is required. 

DEFECTIVE DRIVE AND 

DRIVEN GEARS TEST 

1. A score nicked or gouged driven 

gear is usually indicative of a defective 

drive gear on those vehicles 

that have the drive gear integral 

with the transmission output shaft. 

The output shaft should be carefully 

inspected for imperfections and replaced 

if necessary. 

2. A driven gear with two or 

three adjoining teeth badly scored is 

indicative of improper assembly procedure. 

The gear should be inserted 

in the transmission while simultaneously 

turning the drive shaft. This 

will insure initial gear engagement 

and prevent gear damage. Force 

should never be used. 

3. Whenever a drive gear is replaced, 

a new driven gear should also 

be installed, regardless of its apparent 

condition 

ELECTRIC WINDSHIELD WIPER 

DIAGNOSIS AND TEST 

PROCEDURES 

Using a self.pawered test lamp or Rotundo ohmmeter, check the continuity through the switch 

terminals. Continuity should exist only as indicoted in the following chart. Replace the switch if it 

does not meet the specified requ;rements. 


Off (Pork) 63.763 

28.58 

Low 58-63.763 

High 56.63.763 

Washer On 

58A-63A 

COLOR COOE OF WIRING TO WIPER SWITCH 

28 Block 

50 Blue 

58 White 

63 Red 

763 Orange-White 

FIG. 5- Wiper Switch Continuity Test Connections. -Cougar 

K1993-A 

WIPERS WILL NOT 

OPERATE (ONE OR 

BOTH SPEEDS) 

Inoperative wipers may be due to 

a defective switch, wiring or motor. 

If the wipers fail to operate at both 

speeds, binding linkage could be the 

cause. 

Make a visual inspection of the 

wiper system for loose connections, 

burned or broken wires, and loose or 

missing parts. If the wires are burned, 

the circuit breaker in the switch is 

defective. Replace both the wiring 

harness and the switch. 

Motor Test 

Test the motor on the vehicle as

1 5-30 GROUP lS-Lighting System, Horns And Instruments 

FIG. 7- 

COUGAR 

Wiper Switch Circuit Breake r Test Connections. 


(WITHDUT INTERMITTENT SYSTEM) MERCURY INTERMEDIATE 

(WITH INTERMITTENT SYSTEM) 

-Mercury Intermediate and Cougar 

K1994-B 

shown in Fig. I. Check that the motor 

ground makes contact with the car. If 

the motor operates on both speeds in 

these checks, the switch or wiring is 

defective. Test the switch and wiring 

according to instructions given in 

Wiper Switch Test. If the wipers operate 

at one speed but not at the other, 

replace the motor. If the wipers will 

not operate at either speed, check the 

ground by running a jumper from the 

ground strap to ground. If the wipers 

still will not operate, test the linkage. 

linkage Test 

Check for correct linkage on the 

vehicle, then disconnect the linkage 

from the motor and move the linkage 

(wipers) through their complete 

strokes. If there is no bind in the 

linkage, replace the motor. Check the 

circuit breaker in the windshield wiper 

switch before the new motor is installed. 

Refer to Wiper Switch Circuit 

Breaker Test-High Current Pass Test. 

Wiper Switch Test 

Check the continuity between terminals 

of the switch as shown in Figs. 

2, 3, 4 and S. (As an alternate procedure 

plug a known good switch into 

the wiring harness and operate). If 

the switch is good, the wiring harness 

FIG. 8- Wiper Motor Current Draw Test Connections

~ 

PART 15-4-lnstruments 15-3 ] 

is defective. Check the continuity of 

the wires and repair or replace the 

defective wiring. Red 

/' 

~r~ 

Wiper Switch Circuit 

Breaker Test 

Connect the variable resistance unit 

of a Rotunda Volt-Amp Tester as 

shown in Figs. 6 and 7. Set the master 

control to maximum resistance position 

initially to pre~ent damage to the 

circuitry and ammeter. 

Low Current Pass Test. Adjust the 

variable resistance until the ammeter 

reads 7 1/2 amperes. 

The ammeter should indicate 7 1/2 

amperes for ten minutes. If the circuit 

will not indicate specified current 

for ten minutes (current drops to 

zero), the circuit breaker is defective. 

Replace the switch. 

High Current Pass Test. Adjust the 

master control until the ammeter indicates 

13 amperes. The circuit should 

open within 30 seconds (current drops 

to zero), otherwise the circuit breaker 

is defective and the switch must be 

reolaced. 

INTERMITTENT WIPER 

OPERATION (ONE OR 

BOTH SPEEDS) 

FIG. 9- 

It=:- 

:t~ 

g 

:HECK TO BE SURE MOTOR IS GROUNDEO 

"""--' 

y 

"White 

'MERCURY1NTERMEDIATE, 

FAIRLANE, FALCON ONLY 

(':IIASHER SWITCH TERMINAL) 

MERCURY INTERMEDIATE AND COUGAR 

-CONNECT TO POSITIVE 

TERMINAL OF BATTERY 

Wiper Motor Pork Switch Test Connections 

K1996.A 

Intermittent operation of the wipers 

may be due to a defective switch 

(circuit breaker), intermittent ground, 

loose connections, or a defective motor. 

Intermittent operation at both speeds 

may be due to an excessive effort 

caused by binding linkage or wrong 

wiper blades. Inspect the system for 

these defects. 


Disconnect the linkage. Test the 

motor on the vehicle for current draw 

at the speed at which intermittent operation 

occurs as shown in Fig. 8. 

If the current draw exceeds 3 amperes, 

replace the motor. If the current draw 

is less than 3 amperes, test the switch 

for continuity (refer to Wiper Switch 

Test), and its circuit breaker, for low 

current pass (refer to Wiper Switch 

Circuit Breaker Test). 

WIPERS WILL NOT STOP 

OR WILL NOT STOP IN 

PARK POSITION 

~ 

8RIDGE .;JI 

,l~":, 

~ 

/~ 

t;;~~/ r 

OWER 

ONT ACTS 

r;;;-=---' 

!~~ ~;' 

~ 

)\y 

~ 

~ 

I~ ~~ 

PAR;

15-32 GROUP5-Lighting System, Horns And Instruments 

Motor Park Switch Test 

Stop the wiper system with the 

ignition switch so that the wiper 

blades are not in park position. Connect 

jumper wires as shown in Fig. 9. 

Wipers should not run more than one 

full cycle and park. If the motor will 

not park or will not run to park position, 

the park switch is maladjusted 

or defective. If the motor stops correctly, 

the switch or wiring harness is 

defective (see Wiper Switch Test). 

NOISY WIPER SYSTEM 

Noisy system operation could be 

caused by loose or misaligned motor 

mounting, improper wiper arms or 

blades, or loose or worn linkage. 

Disconnect the linkage from the 

motor and run the motor to determine 

whether the noise is caused by the 

motor. Check the motor mounting for 

misalignment or grounding against 

cowl sheet metal. 

Visually inspect the linkage for loose 

attaching bolts, loose pivots in the 

linkage, and loose wiper arms or 

blades. 

WIPER MOTOR PARK 

SWITCH ADJUSTMENT 

With jumper wires connected as 

shown in Fig. 9, the motor should 

move to the park position. If it does, 

the motor is all right and the fault 

lies in the panel switch or wiring. If 

the motor does not park, proceed 

with the following park switch adjustment 

(Fig. 10). 

Remove the motor thru bolts and 

remove the motor cup and armature. 

Rotate the output shaft until the 

park switch lower contacts are firmly 

closed as shown. 

Rotate the adjusting screw clockwise 

until the park switch lower contacts 

just open. 

Rotate the adjusting screw counterclockwise 

one full turn. 

Check the bridge to assure that 

the legs are contacting the brush 

plate when the lower contacts are 

closed. 

Install the armature, motor cup 

and thru bolts. 




hames~e~. Schematics are shown 


All of the instruments are electrically 

operated except the speedometer. 

Brightness of the instrument panel 

lights is controlled by a rheostat 

on the lighting switch. 


REGULATOR 

The ;.;onstant voltage regulator 

(Fig. II) used with the fuel, temperature, 

and oil gauges maintains an 

average value of 5.0 volts at the 

gauge terminals. 

The regulator operates by means 

of a bimetallic arm and a heating 

coil. When the ignition switch is 

turned on, the heating coil heats the 

bimetallic amI causing it to bend 

and break the contacts, disconnecting 

the voltage supply from the heating 

coil. The bimetallic arm then cools 

and brings the contacts together 

again. The making and breaking of 

the contacts, causes a pulsating voltage, 

with an effective average value 

of 5.0 volts to be supplied to the 

gauges. Although these pulsations are 

quite rapid, there is in each gauge a 

bimetallic arm which changes temperature 

quite slowly, and this assures 

steady average readings. 

As the pulsating voltage would 

normally ~dU~ radio interference, a 

radio intt:rfcrcn~t: suppression choke 

is connected in serit:~ with the constant 

voltage regulator supply wire. 

FUEL GAUGE 

'rhe fuel gaugt: consists of a send- 

FIG. 7 7-lnstrument Voltage 

Regulator 

ing unit, located on the gas tank, 

and a remote register unit (fuel 

gauge) mounted in the instrument 

cluster. The remote register unit 

pointer is controlled by a bimetallic 

arm and heating coil. The sending 

unit is a rheostat that varies its resistance 

depending on the amount of 

fuel in the tank. The rheostat is operated 

by a float control. As the fuel 

level rises or falls the float control 

arm moved by the float, varies the 

resistance. 

TEMPERATURE GAUGE 

The temperature gauge system consists 

of a sending unit mounted at the 

top front of the engine on the V-8 

(Fig. 12 or 13), left rear of the engine 

on the six, and a remote register, 

unit, (temperature gauge) mounted 

in the instrument cluster. 

FIG. 72-Temperature 

Oil Pressu re Switch-S 

Engine 

Sender and 

Cylinde r 

Changes of engine temperature 

vary the resistance of the sending 

unit which in turn operates the temperature 

gauge. 

CHARGE INDICATOR LIGHT 

-EXCEPT MERCURY 

INTERMEDIA TE 

A red alternator charge indicator 

light is used. This light flashes on if 

the battery is discharging and the alternator 

is not supplying current.

PART lS-4-lnstruments 1 5-33 

When the ignition switch is closed, 

battery current flows through the 

charge indicator light and IS-ohm 

parallel resistor, and through the regulator 

voltage limiter contacts to the 

field. 

When the alternator builds up 

enough voltage to close the field relay 

contacts, full voltage is applied 

to the field, and the charge indicator 

light goes out. 

CHARGE INDICATOR GAUGE- 


The charge indicator gauge is an 

ammeter, which indicates whether 

the battery is being charged or discharged. 

The ammeter is non-adjustable 

and should be replaced if proven 

to be defective. 


LIGHT 

A red indicator light flashes on 

when the oil pressure is below a safe 

value. The light should come on when 

the ignition switch is first turned on, 

and it should go out when the engine 

comes up to speed. The light is connected 

between the oil pressure 

switch unit mounted on the engine at 

the left rear on the six, above the oil 

filter on the V-8 (Fig. 12), and the coil 

terminal of the ignition switch. 









warning systems and damaged sending 

units or gauges. 


GAUGE 

The meter-type oil pressure gauge 

consists of a sending unit on the engine 

above the oil filter on the V-8 

(Fig. 12), at the left rear on the six, 

and a remote register unit in the instrument 

cluster. 

The sending unit operates by varying 

resistance according to actual 

oil pressure against it, which in turn 

operates the oil pressure gauge. 

TURN INDICATOR 

The turn indicator uses the dual 

filament parking lights as indicator 

lights. 

The turn indicator flasher is located 

in the back of the instrument 

Danel. The emergency warning flasher 

is located on the right side of the 

upper steering column hub. 

On the Mustang the flasher is 

mounted on the front side of the air 

duct. 


FLASHER-EXCEPT COUGAR 

The emergency warning flasher system 

is controlled by the emergency 

warning switch portion of the turn 

signal switch assembly in the steering 

column. A separate flasher assembly 

is provided for this system. All 

turn signal lights can be made to 

flash at the same time by pushing in 

the actuating knob of the emergency 

warning switch located on the side 

of the steering column. 


FLASHER SYSTEM-COUGAR 

The emergency flasher warning 

system is controlled by a push-pull 

switch located on the right hand side 

of the steering column opposite the 

turn signal indicator lever, and is part 

of the turn signal switch. 

The system utilizes the sequential 

turn signal flasher by the use of relays 

and unique wiring routing. 

Signal lights can be made to flash 

at the same time by closing the contacts 

of the switch by pushing the 

switch plunger in. The canceling action 

is obtained by manually pulling 

the switch plunger out from the 

steering column. 

SPEEDOMETER 

The speedometer is connected to 

the output shaft of the transmission 

by means of a flexible shaft, and a 

drive gear located inside the transmission. 

The flexible shaft drives the 

speedometer which registers speed in 

miles per hour and also drives an 

odometer which records distance 

traveled in miles and tenths of a mile. 

WIPER- 

WINDSHIELD 


The Mercury Intermediate wiper 

provides high and low speed constant 

wiping action, and also intermittent 

low speed (6-30 cycles per 

minute) intermittent wiping action. 

This low speed operation is based 

not on a low speed wiping stroke but 

on an adjustable dwell period in the 

park position. 

The intermittent wiper is operated 

through the use of a dual knob. The 

outer or large knob, when in the center 

Dosition. turns the system off. 

OIL PRESSURE SWITCH 

- TEMPERATURESENOER - --K 1627.A 

FIG. 13-Temperature and Oil 

Pressure Sender-6 Cylinder Engine 

When turned fully clockwise, the 

wiper is in the constant high speed 

setting. When turned fully counterclockwise, 

the wiper goes to the 

low speed range. The intermittent 

wiper action is controlled by the 

inner, or small knob. 

The intermittent wiper control is 

an electro-pneumatic system, a governor 

located in the engine compartment, 

that allows selection of either 

varying dwell between wipe cycles or 

continuous wiper action thru application 

of variable opposing vacuum and 

pressure within the system. 

With the control selector in the instrument 

panel turned to intermittent 

wiper control, engine manifold vacuum 

is applied to the upper chamber 

of the governor (Sketch I, Fig. 14). 

Atmospheric pressure in the lower 

chamber then moves the diaphragm 

upward. Simultaneous rotation of the 

governor valve cam thru the spiral 

action of the follower applies manifold 

vacuum to the diaphragm of the 

normally closed electrical switch. The 

switch diaphragm is moved downward 

compressing the diaphragm 

spring and moving the switch into the 

park position. The wiper blades then 

move to the park position and remain 

there. (Sketch II, Fig. 14). 

Rotation of the governor valve 

cam that applied vacuum to the governor 

switch also opened the upper 

governor chamber to atmosphere. 

The compressed diaphragm spring 

applies downward pressure to the diaphragm 

creating super atmosphere in 

the lower chamber. This is allowed 

to bleed off thru a variable orifice 

in the cuntrol selector. The size of 

this orifice is determined by the position 

of the intermittent selector (inner 

knob) and establishes the length 

of wiper cycle dwell (Sketch II, Fig. 

1.1\

1 5-34 

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PART 15-4-lnstruments 


As the diaphragm moves downward, 

the governor valve cam is rotated 

thru the spiral action of the 

cam follower, opening the lower 

chamber of the electrical switch diaphragm 

to atmosphere. The compressed 

diaphragm spring moves the 

switch into the closed position, actuating 

the wiper motor. Simultaneously, 

the rotational movement of 

the valve cam applies manifold vacuum 

to the upper chamber of the 

governor, thus beginning a new cycle. 

If the engine is subjected to sudden 

acceleration as in passing, the available 

manifold vacuum will be greatly 

reduced. When the vacuum loss 

becomes sufficient to allow the electrical 

switch diaphragm spring to 

overcome the vacuum, the switch 

will be moved to the closed position 

providing continuous wiper operation. 

This will continue until the engine 

has returned to an operating 

condition that will provide normal 

manifold vacuum. The wipers will 

then return to whatever wiper cycle 

dwell has been previously selected. 

In the same manner as above, under 

engine acceleration, if any loss 

of vacuum or pressure in the intermittent 

control system occurs due to 

a mechanical failure or malfunction, 

the wipers will automatically shift to 

continuous operation, thereby rendering 

the system fail safe (Sketch III, 

Fig. 14). 

FOOT-OPERATED WINDSHIELD 

WASHER SYSTEM-MUSTANG 

AND COUGAR 

The windshield washer system utilizes 

a foot operated bellows type 

pump and electrical switch assembly, 

co-ordinated with the wiper motor 

through the electrical windshield wiper 

switch. Pump operation is obtained by 

depressing and releasing the foot 

pedal with a pumping action to eject 

a spray of water onto the windshield 

glass. 

The washer pump system is co-ordinated 

with the windshield wipers by 

means of a switch attached to the 

washer pump which is actuated when 

the pump pedal is depressed. Closing 

of the switch contacts completes a 

circuit which operates the wiper motor 

at low speed. When the pump 

pedal is released, the contact positions 

are changed causing the wiper 

motor to cycle to the OFF (Park) 

position. 

ELECTRIC WINDSHIELD 

WASHER PUMP-EXCEPT 


The windshield washer pump for 

the Falcon, Fairlane, Mercury Intermediate 

and Mustang is an electrically 

powered system consisting of a 

control switch, washer pump, washer 

reservoir, and water lines. The washer 

pump is designed to eject an interrupted 

stream of fluid only when 

the windshield wiper motor is in 

operation and as long as the control 

switch is held in the closed position. 

IN-CAR ADJUSTMENTS AND REPAIRS 

WINDSHIELD WIPER 

BLADE ADJUSTMENT 

Turn the ignition switch to the ac. 

cessory position momentarily, with 

the wiper switch off. After bringing 

the pivot shafts to their park positions, 

install the wiper blades so 

that they lie flat against the lower 

edge of the windshield. 


INSTRUMENT ClUSTER- 

EXCEPT MUSTANG AND 

COUGAR 

1. Disconnect the battery cable. 

2. Disconnect the speedometer cable 

from the speedometer head. 

3. Remove the screws retaining 

the instrument cluster assembly 

to the instrument panel and tilt the 

cluster forward. 

4. Disconnect the wiring and the 

bulb sockets and remove the cluster 

assembly. 

s. Position the cluster and connect 

the wiring and the bulb sockets. 

6. Install the instrument cluster assembly 

to the instrument panel with 

the six retaining screws. 

7. Connect the speedometer cable 

and the battery cable. 

8. Check the operation of all 

gauges, lights, and signals. 

To replace the fuel gauge, temperature 

gauge, oil pressure gauge, 

charge indicator gauge, and speedometer, 

it is necessary to remove the 

instrument cluster assembly. 

INSTRUMENT CLUSTER 

COUGAR AND COUGAR XR-7 

REMOVAL 

Instrument cluster components are 

accessible by removing the cluster as 

an assembly. 



2. Cover the steering column to 

prevent paint damage. 

3. Remove the instrument panel, 

front pad assembly retaining screws 

and remove the pad assembly. 


the heater control assembly to 

the instrument panel and position the 

control assembly outward. 

S. Reaching through the heater 

control opening, disconnect the speedometer 

cable from the speedometer. 

6. Remove the three ash tray receptacle 

retaining screws. Disconnect 

the cigar lighter element wiring connector 

and remove the ash tray 

receptacle. 

7. Reaching through the ash tray 

opening, remove the nut and washer 

which retains the inboard end of the 

instrument cluster to the instrument 

panel. 

8. Re move the seven external 

screws retaining the instrument cluster 

to the instrument panel. 

9. Position the cl uster assembly 

outward, disconnect the two multiple 

connectors and remove the instrument 

cluster assembly. 

INSTALLATION 

1. To install, position the cluster 

assembly on the steering column and 

connect the multiple connectors. 

2. Position the cluster assembly 

to the instrument panel and install 

the seven external retaining screws. 


opening, install the instrument cluster 

assembly inboard end retaining nut 

and washer. 

4. Position the ash receptacle and 

install the three retaining screws. 

5. Reaching through the heater 

control opening, connect the speedometer 

cable to the speedometer.

1 5-36 GROUP lS-Lighting System, Horns And Instruments 

6. Pos ition the heater control to 

the instrument panel and install the 


7. Position the front instrument 

panel pad and install the pad retaining 

screws. 



9. Check the instruments and cluster 

bulbs for proper operation. Remove 

the steering column protective cover. 

INSTRUMENT CLUSTER 

-MUSTANG 

Instrument cluster components are 

accessible by removing the cluster as 

an assembly. 






the heater control assembly to the 

instrument panel and position the control 

assembly outward. 

4. Reaching through the heater control 

opening, disconnect the speedometer 

cable from the speedometer. 

5. Remove the three ash tray receptacle 

retaining screws. Disconnect 

the cigar lighter element wiring connector 

and remove the ash tray receptacle. 


opening, remove the nut which retains 

the inboard end of the instrument 

cluster to the instrument panel. 

7. Remove the six external screws 

retaining the instrument cluster to the 

instrument panel. 

8. Position the cluster assembly outward, 

disconnect the two multiple 

connectors and remove the instrument 

cluster assembly. 

9. To install, position the cluster 

assembly on the steering column and 

connect the multiple connectors. 

10. Position the cluster assembly to 


six external retaining screws. 


opening, install the instrument cluster 

assembly inboard end retaining nut 

and washer. 

12. Position the ash receptacle and 

install the three retaining screws. 


control opening, connect the speedometer 

cable to the speedometer. 

14. Position the heater control to 



15. Connect the battery ground cable 


16. Check the instrument and cluster 

bulbs for proper operation. Remove 

the steering column protective 

cover. 

INSTRUMENT PANEL CONTROL 

IDENTIFICATION LENS- 

FAIRLANE 


cable. 

2. Remove the radio knobs and 

nuts. 

3. Disconnect the speedometer cable. 

4. Remove the screws from the 

cluster assembly and position it outward. 

5. Disconnect the bulbs, constant 

voltage regulator and ground wire, 

clock and the fuel gauge. Move the 

cluster assembly to a bench. 

6. Remove the clock knob and the 

screws retaining the rear cluster cover 

which retains the speedometer, 

clock, fuel gauge. and bulbs for the 

alternator, oil pressure, and hot and 

cold water temperature. 

7. Remove the screws from the 

right side front of the cluster. Remove 

the mask and the lens. 

8. Insert and position the new lens 

and retaining screws. 

9. Position the rear cover assembly 

to the front of the cluster and 

install the retaining screws. Install 

the clock knob and screw. 


and connect all leads and bulbs. 

II. Position the cluster assembly 



12. Position the radio to the cluster 

and install the nuts and bulbs. 



the operation of all disconnected 

parts. 

IN STRUMENT PANEL 

CONTROL IDENTIFICATION 

LENS-MUSTANG, COUGAR 

AND COUGAR XR-7 

I. Remove the instrument cluster 

from the instrument panel (in this 

part). 

2. Remove the nine cluster rear 

housing retaining screws and remove 

the rear cl uster housing and gauges. 

3. Remove three lens retaining 

screws and remove the lens and mask. 

4. Position a new lens and mask in 

the cluster and install the three lens 


5. Position the rear housing to the 

cluster and install the nine rear housing 


6. Install the instrument cluster in 


7. Check the gauge operation. 


REGULATOR-MERCURY 

INTERMEDIATE 


cable. 

2. Disconnect the two leads from 

the regulator. 

3. Remove the regulator mounting 

screw and the regulator. 

4. Transfer the radio choke to the 

new regulator and install the regulator. 

5. Connect the regulator leads. 


the regulator operation. 


REGULATOR-FALCON 



2. Disconnect the two spade wiring 

connectors from the regulator. 

3. Remove the screw which retains 

the regulator to the back of the instrument 

cluster and remove the regulator. 

4. Position the replacement regulator 

on the back of the instrument 

cluster and install the regulator retaining 

screw. 

5. Connect the wiring connectors to 

the regulator terminals. 



7. Check the instruments for proper 

operation. 


REGULA TOR-FAIRLANE 


cable. 

2. Remove the radio knobs, mounting 

nuts and radio. 


the cluster assembly to the instrument 

panel. Position the cluster outward. 

S. Disconnect the wire leads and 

remove the mounting screw from the 

constant voltage regulator and remove 

the regulator. 

6. Position the new constant voltage 

regulator, install the mounting 

screw and connect the wire leads. 





and install the nuts and knobs. 

9. Connect the speedometer cable. 



parts.

PART lS-4-lnstruments 15.37 


REGULA TOR-MUST ANG 


from the instrument panel. 

2. Remove the wiring connectors 

from the regulator terminals. 

3. Remove the regulator retaining 

screw and remove the regulator. 

4. Position the new regulator and 

install the retaining screw. 

5. Connect the wiring connectors to 

the regulator terminals. 

6. Install the instrum~nt cluster to 



IN STRUMENT VOLTAGE 

REGULATOR-COUGAR 

1. Disconnect the ground cable 

from the battery. 


the heater control to the instrument 

panel and position the control 

assembly outward. 


control opening, disconnect the spade 

connectors from the constant voltage 

regulator (located to the left of the 

speedometer). 

4. Remove the nut and washer 

which retains the regulator to the 

stud on the back of the instrument 

cluster. 

S. Position the replacement regulator 

on the mounting stud and install 

the retaining nut and washer. 

6. Connect the wiring connectors 

to the regulator. 

7. Position the heater control to 






FUEL GAUGE AND/OR 

TEMPERA TURE GAUGE 

-FALCON 

REMOVAL 

I. Disconnect the ground cable 

from the battery. 

2. Disconnect the speedometer cable 

from the spet:dometer. 

3. Cover the steering column to prevent 

paint damage. 

4. Disconnect the windshield washer/wiper 

switch wiring connt:ctor 

plugs. 

5. Remove thl heater control 

knobs. 

6. Remove the two heater controlto-instrument 

panel retaining screws. 

7. Remove the six screws which retain 

the instrument cluster tv the instrument 

pant:l. 

8. Remove two nuts at the lower 

edge of the heater control which retain 

the control to the instrument 

cluster. 

9. Disconnect the bulb and wiring 

connector and remove the instrument 

cl Uster. 

10. Removc the screws which retain 

the rear cluster cover to the 

cluster. 

II. Remove the four nuts which retain 

the fuel and temperature gauges 

to the covcr and remove the temperature 

or fuel gauge as required. 

INSTAL. 

ATION 

I. Position the gauge assembly to 

the cluster cover and install the gauge 


2. Position the cluster cover assembly 

to the cluster and install the cluster 

cover retaining screws. 

3. Secure all bulbs and wiring connectors 

in the cluster cover. 

4. Position the heater control on 

the cluster and install the two heater 

control retaining nuts. 


the instrument panel, connect the wiring 

connectors and install the clusterto-instrument 


6. Install the two top heater control 


7. I nstall the heate r control knobs. 

8. Connect the windshield wiper / 

washer switch wiring connector. 

9. Coilnect the speedometer cable 

to the speedometer. 



II. Check the operation of instruments 

and controls. 

FUEL GAUGE AND 

TEMPERA TURE GAUGE- 

COUGAR, COUGAR XR-7 

AND MUSTANG 

The fuel and tcmpcrature gaugcs 

are replal:Cd as a unit. 

I. Remove the instrument cluster. 

Sec Instrumcnt Cluster Asst:mbly - 

15-38 GRO UP 15-Lighting System, Horns And Instruments 

9. Install the new fuel gauge with 

mounting nuts. 

10. Position the speedometer and 

install the retaining screws at the 

rear. Install the four rubber insulators 

in the front. 


to the front of the cluster and 

install the retaining screws. Install 

the clock knob and screw. 

12. Position the cluster assembly. 

Connect all of the wire leads and 

bulbs. 





and install the mounting nuts and 

knobs. 

15. Connect the speedometer cahie. 


the operation of all disconnected parts. 

FUEL SENDING UNIT 

Remove the fuel from the fuel 

tank. 

2. Disconnect the fuel gauge sending 

unit wire from the sending unit. 

3. Loosen the hose clamp and disconnect 

the tank line at the sending 

unit. 

4. Remove any dirt that has accumulated 

around the sending unit 

so that it will not enter the tank. 

5. Turn the sending unit retaining 

ring counterclockwise and remove 

the unit, retaining ring, and mounting 

gasket. 

6. Clean the fuel gauge sending 

unit mounting surface at the fuel 

tank. 

7. Position the sending unit and 

mounting gasket on the fuel tank and 

secure with the retaining ring. 

8. Connect the sending unit wire 

and the fuel tank line. 

9. Fill the tank with the fuel removed. 

10. Check the fuel gauge operation 

and check for leaks. 

TEMPERA TURE GAUGE- 


REMOVAL 

6. Disconnect the wiring connector 

plug and remove the cluster assembly 


7. Remove the ten cluster rear 

cover retaining screws and remove the 

cluster rear cover. 

8. Disconnect the gauge wiring 

connectors. Remove the two gauge 

retaining nuts and insulators. Remove 

the gauge. 

INST ALLA TIO N 

1. Position the gauge in the 

cluster cover and install the retaining 

nuts and insulators. Connect the 

gauge wiring connectors. 

2. Position the cluster rear cover 

to the cluster and install the ten retaining 

screws. 

3. Install the clock reset knob. 


the instrument panel and connect the 

clock wires. the cluster multiple wiring 

connector and the speedometer 

cable. 

5. Install the cluster assemblyto-instrument 




7. Check the operation of the instruments 


TEMPERA TURE SENDING UNIT 

I. Disconnect the temperature sending 

unit wire from the sending unit. 

2. Prepare the new temperature 

sending unit for installation by applying 

a small amount of conductive 

water resistant sealer C3AZ-19554- 

B, to the threads. 

3. Remove the temperature sending 

unit from the cylinder head and 

immediately install the new temperature 

sending unit. 

4. Connect the wire to the temperature 

sellding unit. 

5. Start the engine and check the 

sending unit operation. 



2. Remove the clock reset knob. 



4. Remove the eight instrument 

cluster-lo-instrument panel retaining 

screws. 

5. Position the clutch outward. 

Disconnect the clock wires. Disconnect 

the speedometer cable from the speedometer. 


AND/OR OIL PRESSURE 

INDICATOR GAUGE- 

MUSTANG 

I. Remove the instrument cluster 


2. Remove the nine cluster rear 


the cluster rear housing. 

3. Remove the four nuts retaining 

the gauges in their housing and remove 

the gauge to be replaced. 

4. Position the gauge in the housing 

and install the four retaining 

nuts. 

S. Position the cluster rear housing 

assembly to the cluster and install 

the nine retaining screws. 

. 6. Install the instrument cluster in 


7. Check the gauge operation 

01 L PRESSURE SENDING UNIT 

OR OIL PRESSURE SWITCH 

To replace the unit, disconnect the 

wire from the terminal. Remove the 

unit from the engine. Apply conductive 

sealer C3AZ-19554-B to the 

threads of the new unit and install 

the unit. Connect the wire to the terminal 

and check the operation of the 

unit. 









warning systems and damaged 

sending units or gauges. 


GAUGE-MERCURY 

INTERMEDIATE 

I. Disconnect the battery. 

2. Disconnect the speedometer cable. 



panel and position it outward. 

4. Disconnect the bulbs, temperature 

gauge, fuel gauge, constant 

voltage regulator, and charge indicator 

and remove the assembly to 

a bench. 


the back cover of the cluster to the 

front of the cluster. There is no clock 

in this cluster. The light for the oil 

pressure indicator is in the charge indicator 

gauge. 

6. Remove the nuts retaining the 

charge indicator gauge. 

7. Position the new gauge and 

install the retaining nuts. 

8. Position the rear cover to the 

front of the cluster and install the retaining 

screws. The rear cover retains 

all the gauges and the speedometer 

head. 


and connect all leads and bulbs. 

10. Install the cluster assembly 

to the instrument panel and secure it 

with screws. 

II. Connect the speedometer cable 



pa rts. 


GAUGE-COUGAR XR-7 


cable.

PART 15-4-lnstruments 15-39 


assembly (in this part). 

3. Remove the nine rear cluster 


the cluster housing. 

4. Disconnect the two push on 

connectors and remove the two charge 

indicator gauge retaining nuts and 

remove the gauge. 

S. Position the gauge assembly 

to the cluster housing and install the 

two retaining nuts and connect the 

push on connectors. 

6. Position the cluster rear housing 

assembly and install the nine 


7. Install tll.:. instrument cluster 

in the instrument panel. 


cable and check the operation of the 

gauge. 

ELECTRIC CLOCK-MUSTANG 

AND COUGAR 


(in this section). 

2. Remove the clock re-set knob 

and nut. 

3. Disconnect the wiring connector 

from the clock. Remove three clock 

retaining screws and remove the clock. 

4. Position the clock to the instrument 

cluster. Install the three retaining 

screws and connect the wiring connector. 

S. Install the instrument cluster in 

the instrument panel. Install the clock 

reset knob. 

4. Remove the two clock retaining 

screws and remove the clock from underneath 

the instrument panel. Use care, 

as the clock hands are unprotected. 

s. Carefully position the replacement 

clock to the instrument panel and 


6. Connect the clock wiring connector 

to the cloc k. 

7. Install the clock set knob and 

set the clock. 



ELECTRIC CLOCK 

FALCON 



2. From underneath the instrument 

panel, disconnect the clock wire connectors 

(blue and blue-red wires). 

3. Remove the nut and washer with 

spacer assembly which retains the 

clock to the instrument panel. 

4. Pul\ the clock wires through 

the instrument panel and remove the 

clock. 

5. Position the replacement clock 

to the instrument panel and route the 

clock wires through the instrument 

panel. 

6. Install the spacer, nut and 

washer assembly which retains the 

clock to the instrument panel. 

7. Connect the clock wiring connectors. 



6. Check the clock operation. ELECTRIC CLOCK- 


ELECTRIC CLOCK-COUGAR 

XR-7 (CONSOLE MOUNTED) 

1. Remove the radio control knobs. 

2. Remove the two screws which 

retain the console front pad. Pry out 

the pad (four retaining clips). 

3. Disconnect the two wiring connectors 

and the bulb from the clock. 

4. Remove the three nuts which 

retain the clock to the pad and remove 

the clock from the pad. 

5. To install the clock, position it 

to the console pad and install the 

three retaining nuts. 

6. Connect the two clock wiring connectors 

and the clock bulb. 

7. Snap the console pad in place 

at the radio and install the two pad 

retaining screws and the radio control 

knobs. 

ELECTRIC CLOCK-FAIRLANE 



2. Remove the clock set knob. 

3. Disconnect the clock wiring connector 

from the clock. 


cable. 

2. Remove the clock reset knob 

(one screw). 

3. Disconnect the clock wire and 

light socket. 

4. Remove the clock retainin~ 

screws and remove the clock. 

5. Position the new clock and 

install the retaining screws. 

6. Install the light socket and wire 

lead. 

7. Install the reset knob, connect 

the battery cable, set the clock and 

check its operation. 

TURN SIGNAL FLASHER 

UNIT-MUSTANG 

1. If equipped with air conditioning, 

remove the three ash tray retaining 

screws and remove the ash tray 

to provide access. 

2. Push in and twist the flasher 

unit, then pull outward. 

3. Disconnect the flasher wiring 

leads from the flasher and remove the 

flasher. 

4. Connect the wiring leads to 

the flasher. Position the flasher and 

push in with a twisting motion to 

lock it in place. 

5. Install the ash tray if removed. 

6. Check turn signals for proper 

operation. 

TURN SIGNAL FLASHER 

UNIT-FALCON, FAIRLANE AND 


I. Reaching behind the instrument 

panel, push in and twist the flasher 

unit; then, pull outward. 

2. Disconnect the flasher wiring 

leads from the flasher and remove the 

flasher unit. 

3. Connect the flasher wiring 

leads to the flasher. Position the 

flasher and push in with a twisting 

motion to lock it in place. 


operation. 

SEQUENTIAL TURN SIGNAL 

RELAY AND/OR FLASHER- 

COUGAR 

I. Open the luggage compartment 

door. 

2. Fold back the floor mat and 

from over the left quarter well remove 

the retaining screws from the left 

quarter panel well cover and remove 

the panel. 

3. Disconnect five multiple wiring 

connectors and remove the relay 

assembly from its two retaining hooks 

in the quarter panel. 

4. Carefully unwrap or cut the 

sound deadening insulation from 

around the relay assembly. 

5. Remove two screws and nuts 

and remove the relay or flasher assembly 

from its rubber mounting 

pad. 

6. Position the new relay or 

flasher to the mounting pad and 

install the retaining screws and nut$. 

7. Position the sound deadner insulation 

around the assembly and 

wrap it with tape. 

8. Connect the five multiple wiring 

connectors and position the relay 

assembly on the hooks in the quarter 

panel. 


operation. 

10. Install the quarter panel 

well cover and floor mat. 


FLASHER-EXCEPT COUGAR 

Pull the flasher unit from the retaining 

clip, and disconnect the wire. 

Refer to Group 19 for location of the 

flasher unit.

1 5-40 


SPEEDOMETER-MERCURY 

INTERMEDIATE 

REMOVAL 

INST ALLA TION 

1. Position the speedometer and install 

the two retaining screws. 

2. Position the cluster rear housing 

assembly to cluster housing and 

install the ten retaining screws. 

3. Install the clock set knob. 

4. Position the cluster assembly at 

the instrument panel opening. Connect 

the clock, main wiring connector 

and the speedometer cable. 

5. Position the cluster assembly in 


eight cluster assembly retaining 

screws. 



7. Check the operation of the instruments 


SPEEDOMETER-MUSTANG 

COUGAR AND COUGAR XR-7 




assembly. Remove the trip reset knob 

(if so equipped). 



the rear cl uster housing and gauges. 

4. Remove the two speedometer retaining 

screws and remove the speedometer 

from the rear cluster housing. 

5. Position the speedometer in the 

rear cluster housing and install the 

two retaining screws. 

6. Position the rear cluster housing 

to the cluster and install the nine 

retaining ~crews. 


the instrument panel. Install the trip 

reset knob (if so equipped). 

FIG. 15 Speedometer Driven Gear Retainer and Mounting 

8. Check speedometer operation IS. Connect the battery ground 


SPEEDOMETER-FAIRLANE 

disconnected parts. 



2. Remove the clock set knob. 

3. Cover the steering column to prevent 

paint damage. 

4. Remove the eight instrument 

cluster retaining screws. 

5. Position the instrument cluster 

outward. Disconnect the clock wire, 

speedometer cable, two warning light 

bulbs and the main wiring connector. 

Remove the instrument cluster assembly. 

6. Remove the ten screws which retain 

the rear cluster cover to the 

cluster housing and remove the 

cluster rear cover. 

7. Remove the two speedometer retaining 

screws and remove the speedometer. 

1. Disconnect t!;le battery ground 

cable. 

2. Remove the radio knobs, 

mounting nuts, and radio. 

3. Disconnecthe speedometer cable. 



panel. Position the cluster assemblyoutward. 

5. Disconnect the bulbs, constant 

voltage regulator and its ground 

wire, the clock and the fuel gauge. 

6. Remove the cluster assembly to 

a bench. 

7. Remove the clock knob and the 

screws retaining the rear cluster cover. 

The cover retains the speedometer, 

clock, fuel gauge, the bulbs for 

the alternator charge indicator, oil 

pressure, and the hot and cold engine 

temperature indicators. 


the speedometer head to the cover 

and the four rubber insulators. Remove 

the speedometer head. 


install the retaining screws at the 

rear. Install the four rubber insulators. 


to the front of the cluster. Install 

the retaining screws. Install the 

clock knob. 

Connect 11. Position all leads the and cluster bulbs. assemblv. . 


to the instrument panel. Install the 



and install the mounting nuts and 

knobs. 


SPEEDOMETER -FALCON 

Disconnect the battery ground 

cable. 

2. Disconnect the speedometer 

cable. 


assembly. 

4. Remove the six screws retaining 

the instrument cluster back plate 

assembly and remove the back plate 

assembly. 


the speedoh1eter, the two screws 

retaining the speedometer dial to the 

back pia te, and remove the speedometer 

assembly. 


install the two speedometer dial retaining 

screws and the two speedometer 


7. Position the back plate assembly 

and install the six retaining 

screws. 

8. Install the instrument cluster assembly 

to the instrument panel. 

9. Connect the speedometer cable, 

avoiding sharp bends. 


cable. 

SPEEDOMETER CABLE 

To replace the speedometer drive 

cable, disconnect the cable housing 

from the speedometer, and pull the 

cable out of the housing. Wipe off 

all of the old lubricant. Lubricate 

the new cable with cable lubricant 

B5AZ-19581-A (do not over lubricate), 

insert it all the way into the 

housing, and twist it slightly to make 

sure that the sQuared drive is

PART 15-4-lnstruments 15-4 

engaged in the speedometer driven 

gear. If a speedometer cable is broken, 

it will be necessary to disconnect 

both ends of the cable housing in 

order to remove the broken sections. 

Tighten the mounting bolt to 3-4 1/2 

foot-pounds torque (Fig. 15). 

The speedometer driven gear is 

held on to the speedometer cable 

housing by a retainer clip. When replacing 

the driven gear, make certain 

that the gear is secure by placing 

the gear in position before inserting 

the retainer clip through the gear 

slots. 

TACHOMETER-MERCURY 

INTERMEDIATE 

Disconnect the battery ground 

cable. 

2. Remove the eight retaining 

screws from the cluster and position 

the cluster assembly out. 

3. Disconnect the tachometer, 

speedometer cable and the park and 

seat belt bulbs. 

4. Disconnect the multiple conconnector 

and remove the cluster assembly. 

5. Remove the two retaining screws 

from the tachometer and remove the 

tachometer from the cluster. 

6. Position the tachometer to 

the cluster and install the retaining 

screws. 

7. Connect the tachometer, speedometer 

cable and park and seat belt 

bulbs. Also, connect the multiple 

connector. 

8. Position the cluster to the 

instrument panel and install the 

eight retaining screws. 



tachometer. 

T A CHOMETER-MU 5T ANG 

AND COUGAR XR-7 




assembly (Refer to Part 4). 



the rear cluster housing and gauges. 

4. Remove the two tachometer retaining 

nuts and remove the speedometer 

from the rear cluster housing. 

S. Position the tachometer in the 

rear cluster housing and install the 

two retaining nuts. 

6. Position the rear cluster housing 

to the cluster and install the nine 




R. Check tachometer oneration 

WINDSHIELD WIPER MOTOR 

FALCON, FAIRLANE AND 


1. Disconnect the wiper motor wiring 

connector. 

2. Remove the wiper arm and 

blade assemblies. 

3. Remove the cowl top grille panel 

retaining screws and remove the cowl 

top grille. 

4. Remove the wiper link retaining 

clip from the wiper motor arm. 

5. Remove the four wiper motor retaining 

bolts and remove the wiper 

motor and mounting bracket. 

6. Transfer the wiper motor mounting 

bracket and related parts to the 

replacement wiper motor. 

7. Position the wiper motor and 

mounting bracket to the dash panel 

and install the four retaining bolts. 

8. Position the wiper link on the 

motor drive arm and install the retaining 

clip. 

9. Install the cowl top grille panel. 

10. Connect the wiper motor wiring 

connectors. 

11. Check the wiper motor operation. 

12. Install the wiper arm and 

blade assemblies. 

WINDSHIELD WIPER MOTOR- 



cable. 

2. Remove the courtesy light. If 

the vehicle is equipped with a hang 

on air conditioner, lower the air conditioner 

to the floor. 

3. Disconnect the wiper motor plug 

connector. 

4. Remove the nut retaining the 

pivot arm and wiper arms to the 

motor. 

5. Remove the bolts and star washers 

retaining the motor to the mounting 

bracket, and remove the motor. 

6. Position the fIat washers to 

the motor, position the motor to the 

mounting bracket and install the retaining 

bolts and star washers. 

7. Position the pivot arm and wiper 

arms to the motor. and install the retaining 

nut. 

8. Connect the motor wire plug, 

connect the battery, check the motor 

operation, and install the courtesy 

light. 

WINDSHIELD WIPER PIVOT 

SHAFT AND LINK-FALCON, 

FAIRLANE AND MERCURY 

INTERMEDIATE 

1. Remove the wiper arms and 

hlades 

2. Remove the cowl top grille panel 

retaining screws and remove the cowl 

top grille panel. 

3. Remove the drive arm to pivot 

retaining clip. 

4. Remove the three retaining screws 

from each pivot and remove the pivot 

shaft and link assembly. 

5. Transfer the right pivot if necessary 

(the left pivot is part of the 

link assembly). 

6. Position the pivot shaft and link 

assembly in the cowl and install the 

pivot shaft retaining screws. 

7. Position the left link on the 

motor drive arm and install the retaining 

clip. 

8. Install the wiper arms and 

blades. 

9. Check the wiper operatiun. 

10. Install the cowl top grille 

panel. 

WINDSHIELD WIPER PIVOT 

SHAFT AND LINK-MUSTANG 

AND COUGAR 

,[F' 

SIDE 



2. Remove the wiper arm and 

blade assembly. 

3. Remove the four screws which 

retain the heater control to the instrument 

panel IInd position the heater 

control outward. 

4. Remove the I.:lip which retains 

the link to the motor drive. 

5. Working through the heater 

control opening, remove the three pivot 

shaft retaining bolts. Remove the 

pivot and link out th rough the heater 

control opening. 

6. Install a new gasket on the 

pivot. Position the pivot through the 

heater control opening and install 

the three retaining bolts. 

7. Install the I.:lip which retains 

the link to the motor drive. 

8. Install the heater control assembly. 

9. Install the arm and blade assemblv. 

RIGHT SIDE 

I. Dis(;onnt:(;t the battt:ry gr\)UI1(1 

cable from tht: battt:ry. 

2. Remove the wipt:r arm and bl:lo\: 

asst:mbly. 

3. Removt: the glove box I:,..., 

rt:taining s(;rews and remove th\: gllWC 

box liner. 

4. Working through the glove box 

opt:ning, rt:move the thret: bolts whi(;h 

retain the pivot assembly to tht: cowl 

panel. Rt:move tht: clip whil.:h retains 

the link to the wiper motor drive and

15-42 GROUP5-Lighting System, Horns And Instruments 

remove the pivot and link assembly 

out through the glove box opening. 

5. Install a new gasket on the 

pivot. Position the pivot and link assembly 

through the glove box opening 

and install the three pivot retaining 

bolts. Install the link retaining 

clip on the wiper motor drive. 

6. Install the glove box liner. 


cable on the battery. 

8. Install the wiper arm and 

blade asembly. 

WINDSHIELD WASHER PUMP- 

FALCON, FAIRLANE AND 


1. Disconnect the washer pump 

wiring connectors. 

2. Remove the inlet and outlet 

hoses from the washer pump. Position 

the inlet hose upward to prevent draining 

the washer reservoir. 

3. Remove the two screws which 

retain the washer pump to the fender 

apron and remove the washer pump. 

4. Position the washer pump to 

the fender apron and install the two 


5. Connect the inlet and outlet 

hoses to the washer pump. 

6. Connect the washer pump wiring 

connectors. 

MAJOR REPAIR OPERATIONS 

WIPER MOTOR DISASSEMBLY 

I. Remove the gear cover retaining 

screws, ground terminal and cover(Fig.16). 

2. Remove the gear and pinion retainer. 

3. Remove the idler gear and pinion 

and thrust washer. 

4. Remove the motor through 

bolts, motor housing, switch terminal 

insulator sleeve, and armature. Do 

not pound the motor housing magnet 

assembly as the ceramic magnets 

may be damaged. 

5. Mark the position of the output 

arm with respect to the output shaft, 

for assembly. Remove the output 

arm retaining nut, output arm, 

spring washer, flat washer, output 

gearshaft assembly, thrust washer, 

and parking switch lever and parking 

switch lever washer. 

6. Remove the brushes and brush 

springs. 

7. Remove the brush plate and 

switch assembly, and remove the 

switch contact to parking lever pin 

from the gear housing. 

PARTS REPAIR OR 

REPLACEMENT 

All parts on both the single-speed 

and two-speed wiper are replaced 

and not repaired. 

WIPER MOTOR ASSEMBLY 

I. Install the parking switch lever 

washer. 

2. Install the parking switch lever 

on the gear and pinion shaft with the 

cam rider pointing toward the gear 

housing output shaft hole. Make certain 

that the lever bottoms against 

the casting. 

3. Apply a film of Sun Prestige 

grease to the output gear teeth and 

shaft bearing surface. Insert the shaft 

in the bearing. Make certain that 

the parking switch lever is clear of 

the cam and gear assembly. 

4. Place the spacer washer and 

spring washer on the shaft, position 

the output arm on the shaft in the 

FIG. 16-Disassembled Wiper Motor 

1632-8

PART 5-4-1 nstru m ents 1 5-43 

marked position from which it was 

removed, and install the mounting 

nut. 

s. Position the brush springs and 

brushes in the holders and wrap wire 

around them to hold them in the 

fully retracted position. Push the insulated 

brush connector onto the 

switch terminal. 

6. Place the switch-contact to 

parking-lever pin in the gear housing. 

Position the brush plate assembly 

to the housing and install the 

mounting screws. 

Make the park switch contact 

points adjustment covered under 

Wiper Motor Park Switch Test and 

Adjustment in Section 1. 

7. Apply Sun Prestige grease to 

the ball bearing in the end of the 

armature shaft. Position the armature 

shaft in the gear housing and 

remove the brush retracting wires. 

8, Holding the armature in position, 

install the terminal insulating 

sleeve, motor housing and magnet 

assembly, and through bolts. Seal 

the area where the terminal insulator 

sleeve seats against the motor and 

gear housings. 

9. Apply Sun Prestige grease to 

the worm gear and idler gear, and 

install the idler gear, thrust washer 

and retainer. 

10. Apply a generous amount of 

Sun Prestige grease to the area 

around the end of the armature 

shaft. Install the gear housing cover 

and ground terminal. 

ELECTRO-PNEUMA TIC 

GOVERNOR AND CONTROL 

SELECTOR 

INTERMEDIATE 

SWITCH-MERCURY 

The electro-pneumatic governor 

and the control selector switch are 

serviced as assemblies only. Should 

any internal component become defective 

the complete assembly must 

be 

replaced. 

In the event of sus~cted partial 

or total blockage of internal passages, 

light air pressure may be applied 

in an attempt to remove the 

cause 

of blockage. 

Although the vacuum hoses are an 

integral part of the wiring harness 

assembly, individ ual hoses may be replaced 

if required.

1 5-44 

MERCURY INTERMEDIATE, FALCON, FAIRLANE, AND MUSTANG - BULB CHART 

light Description 

Ash Receptacle, 

- 

1ar Lightor 

Backup Lights-Sedan 

Station Wagon 

Courtesy Lamp 

(Console) 

(Convertible and Inst. Panel 

(Door Mounting or Armrest) 

- 

Mercury Intermediate Falcon Fairlane Mustang 

Bulb Candela or Bulb Candela or Bulb Candela or Bulb Candela or 

No. Wattage No. Wattage No. Wattage No. Wattage 

1445 1.5C. 1895 2C. 

Ti56 

1156 

631 

631 

Cargo Lamp (Station --- Wagon) 

1003 

Dome Lamp 

1003" 

Engine Compartment 

631 

Glove Compartment or Console 1 1895 

-- --.,-i 

Headlamps Hi.Lo Beam (Outer or Upper) : 4002 

Hi Beam (Inner or Lower) i 

~~ 

4001 

32C. 

32C. 

6C. 

6C. 

15C. 


6C. 

2C. 

37.5.50W 

37.5W 

6C. 

6C. 

4.32C. 

30W 

4.32C. 


1076 



631 6C 631 

1003 

1003 

631 

1895 

6012 

97 

rn 

631 

""i""i57 

4405" 




6C. 

2C. 

40.50W 

4C. 

6C. 

6C. 

4.32C. 

30W 

4.32C. 

631 

1003 

1003 

631 

1895"" 

4002 

4001 

97 

631 

631 


44ii5 

1W 

32C. 

32C. 

6C. 

6C. 



6C. 

2C. 

37.5-50W 

37.5W 

4C. 

6C. 

6C. 

4.32C. 

30W 

4.32C. 

1142 

1895 

631 

1004 ~ 

1003 

631 

1445 

6012 J: 

97 

~ 

631 

1157.A 

4405 


2IC. 

2C. 

6C. 



6C. 

1.5C. 

40.50W 

4C. 

6C. 

6C. 

412c: 

3aW 

4-32C. 

BULB CHART (Continued) 

light Description 

, 

, Instrument 

Cock & Ignition 

Panel Illumination 

Key - 

Mercury Intermediate Falcon 

Fairlane Mustang 

Bulb Candela or Bulb Candela or Bulb Candela or Bulb Candela or 

No. Wattage No. Wattage No. Wattage No. Wattage 

1895 

1895 

1895 

1893 

326. 

32c:- 

""iC:- 

""iC:- 

""iC:- 

1.9C. 

""iC:- 

1.5C. 

2C. 1 

3C. 

2C. 

2C. 

1.5C. 

~ 

1.5C. 

2C. 

1895 

1895 

1895 

1895 

1895 

1445 

1895 

2C. 

2C. 

2C. 

2C. 

2C. 

1.5C. 

2C:"-- 

1895 ,1) 

1895 

1895 

1893 

1895 

1445 

~ 

2C. 

2C. 

2C. 

l.9C. 

2C. 

- 

l.5C. 

2C. 

1895 2C. 

2C. 

1895 K 

1895 K 

1895 2C. 

1895 

1895 

1895 

1895 

1895 

2C. 

2C. 

2C:-- 

2C. 

2C ~ 

1895 

1895 

1895 

1895 

257 

2 R.PO 

~ 1895G Bl 

2C. 

2C. 

~ 

~ 

1.6C. 

1895 

2C. 

1895 2C. 

1895 2C. 

257 

1.6C. 

1891 2C. 

>[ States of Minnesota and Wisconsin

I 

PART lS-S-Specifications 15-45 

COUGAR BULB CHART 

I 

Light Description 

I Headlight-Hi-lo Beam (Outer) 

I Headlight-Hi Beam (Inner) 

I , Front Parking - and Turn Signal - 

! Rear and St. 00 and -- Turn Signal 

! License Plate 

i 

, "C" 

Map Light 

Pillar Light 

Auto- Trans. Quadrant 

: Turn Signal Indicator 

Door Cou~tesy 

Luggage Compartment 

Glove Compartment 

Back-up Light 

Dome 

! Speedometer 

Bulb 

No. 

4002 

4001 

1157A 


~ 

631 

1003 

158 

53X 

1816 

631 

631 


1816 

1445 

Candela or 

Wattage 

37.5 & 50 Watts 

37.5 Watts 

4.32C. 

4.32C. 

4C. 

6C. 

l5C. 

2C. 

lC. 

3C. 

6C. 

6C. 

32C. 

3C. 

1.5C. 

Light Description 

i Gages 

i Hi. Beam 

I Turn Signal I Clock - 

1:1) Turn Signal Indicator 

Courtesy Light 

Hand Brake Signal 

Radio AM 

SpQtlight 

Console Light 

Low Fuel Warning 

Emergency Flasher Warning 

Door Lock Warning 

Seat Belt Warning 

Bulb 

No. 

1895 

1895 

1895 

1895 

1895.G 

631 

1895 

1893 

4405 

1816 

1445 

1445 

256 

For States of Minnesota and Wisconsin 

1445 

Candela or 

Wattage 

2C. 

2C. 

2C. 

2C. 

2C. 

6C. 

2C. 

1.9C. 

30 Watts 

3C. 

1.5C. 

1.5C. 

1.6C. 

1.5C. 

CIRCUIT PROTECTION 

Ash Tray Light 

Back Up Light 

Cargo Light 

Cigar Lighter 

Clock 

Clock Light 

Courtesy Lights 

Dome Lights 

MERCURY INTERMEDIATE, FALCON, FAIRLANE. COUGAR AND MUSTANG 

Protective Device - Fuses in Amperes 

Fuse Panel Circuits 

Door Ajar Warning (Door Dpen Warnini. Fairlane Taxi) 

Seat Belt Warning Light (Inst. or Safety Cony. Panel) 

Seat Belt Warning -Cougar Model 65B Only 

Tachometer Light 

Transmission Sel( ictal Light 

Turn Signals 

Windshied Washers 

Mercury 

Intermediate 

AGA.2.5 

SFE.14 

SFE.7.5 

SFE.20 

SFE.20 

AGA.2.5 

SFE.7.5 

SFE-7.5 

SFE-20 

SFE-7.5 

SFE-14 

AGA-2.5 

SFE-7.5 

SFE-7.5 

SFE-14 

AGA-2.5 

SFE-14 

AGA.2.5 

I .~. ~. 

i AGA.2.5 

~l4 

~ 

SFE.7.5 I SFE.7.5 I SFE.7.5 I SFE-7.5 

SFE.7.5 SFE.14 I V'-"- ~~~- 7 ~ 

SFE.20 SFE.20 SFE.14 SFE.20 

SFE.7.5 SFE.7.5 SFE.7.5 SFE.7.5 

SFE-14 SFE.14 I SFE.14 l-sfm

1 5.46 GROUP 15-Lighting System, Horns And Instruments 

CIRCUIT PROTECTION -MERCURY INTERMEDIATE, FALCON, FAIRLANE, COUGAR AND MUSTANG (Continued) 

Miscellaneous Circuits 

Headlights 

Tail lights, Stop Lights, license lights, 

Parking Lights and Horns 

Taillights (Cougar) 

Emergency Warning Flasher 

Windshield Wipers 

Intermittent Windshield 

Wipers 

Convertible Top 

Power Windows, Power Seats and 

Back Window Control 

Overdrive 

Ai r Condi1ioner (Integrated) 

Air Conditioner (Economy) 

Speed Control 

Motors: Windshield Wiper, Convertible 

Top, Power Windows and Power Seats 

Transmission Selector Light (Console) 

Parking Brake Warning 

Location 

I n Headlight Switch 

I n Headlight Switch 

Near Left Rear Light Assy. 

Windshield Wiper Bracket 

Windshield Wiper Switch 

Windshield Wiper Switch 

Between Starter Relay and 

J unction Block 

On Starter Relay 

Clip to Overdrive Relay 

Acc. Terminal Ignition Switch 

In-line From Acc. Terminal Of 

Ignition Switch 

In-Line From Acc. Terminal Of 

Ignition Switch 

Integral Part of Motor 

In. Li ne 

In.Line 

Protective Device-Fuse or Circuit Breaker (C.B.) in Amperes 

-- 

Mercury 

Intermediate 

+.ff 

t7ff 

18 C.B 

15 C.B 

Safety 

Link 

Falcon 

12 C.B. 

15 C.B. 

- 

6 C.B. 

Fairlane 

18 C.B. 


- 

6 C.B. 

Safety 

link 

20 C.B 20 C.B 2O"""C:B 

-I 

25 CoB. ' 

25 C.B. 

AGC-15 AGC-15 

~ 

Cougar 

18 C.B. 

15 C.B 

tiC.B. 15 6 C.B. 

Mustang 

12 C.B. 


- 

6 C.B. 

Safely 

Li nk 

SFf2O 

I 25 C.B. ! 25 C.B. 

AGC.15 

SFff5 

AGC-15 

SFE.7.5 

C.B C.B C.B C.B ""C:B 

~ 

AGW-4 

AGW-4 

AGW-4 

AGW-4 

AGW-4 

i SFE.7.5 I SFE.7.5

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