1966 Ford and Mercury Factory Shop Manual

• Ford Custom
• Ford Custom 500
• Ford Galaxie 500
• Ford Galaxie 500 XL
• Ford Galaxie 500 7.0 Litre
• Ford Galaxie 500 Lt'd (LTD)
• Ford Ranch Wagon
• Ford Country Sedan
• Ford Country Squire



• Mercury Monterey
• Mercury Montclair
• Mercury Parklane
• Mercury Commuter
• Mercury Colony Park

• 240 cubic inch 6-cylinder
• 289 cubic inch V8
• 390 cubic inch V8
• 352 cubic inch V8 Hi-Perf.
• 390 cubic inch V8 Hi-Perf.
• 410 cubic inch V8 Hi-Perf.
• 427 cubic inch V8 Hi-Perf.
• 428 cubic inch V8 Hi-Perf.

• 3-Speed Manual Shift
• Overdrive
• Dual Range Automatic C6
• 4-Speed Manual Shift
• Dual Range Automatic C4
• Cruis-O-Matic (Ford)
• Multi-Drive (Mercury)

REMOVAL

1. Raise the car on a hoist.



2. Mark the drive shaft so that it may be installed in the same relative position. Disconnect the drive shaft from the rear U-joint flange.



3. Slide the front of the drive shaft out of the extension housing and off the output shaft. Insert the tool shown in Fig. 2, Part 6-1, into the extension housing to prevent the lubricant from leaking out of the transmission.



4. Remove the cap screw and lock washer that secures the speedometer cable retainer to the extension housing. Pull the speedometer cable out of the extension housing.



5. Remove the cotter pin, flat washer, and spring washer that secure the first and reverse shift rod to the shift lever.



6. Remove the nut, lock washer and flat washer securing the second and third shift lever to the transmission. Pry the lever away from the transmission and allow it to hang.



7. Disconnect the parking brake cable from the equalizer lever and separate the lever from the crossmember.



8. Remove the two bolts that secure the extension housing to the engine rear support.



9. Raise the rear of the engine high enough to remove the weight from the crossmember. Remove the crossmember attaching bolts. Remove the crossmember from the frame side supports and allow it to hang by the front brake cable.

SECONDARY FUEL BOWL AND METERING BODY

1. Remove the fuel bowl. Using a clutch-type screw driver, remove the metering body, plate, and gaskets (Fig. 20). Discard the gaskets.



2. Remove the balance tube washer and O-ring seal. Discard the O-ring seal.



3. Disassemble the fuel bowl by following Steps 7 thru 10 under Primary Fuel Bowl and Metering Block Disassembly in this section.

MAIN BODY

1. Remove the air cleaner anchor stud, and remove the secondary diaphragm link retainer.



2. Invert the carburetor and remove the throttle body retaining screws and lock washers. Lift off the throttle body and discard the throttle body gasket.



3. If the carburetor is equipped with an automatic choke, remove the choke rod retainer from the choke housing shaft and lever assembly. Remove the thermostatic spring housing and gasket; then, remove the choke housing and gaskets from the main body.
   
   Remove the choke housing shaft nut, lock washer, and spacer; and then remove the shaft and fast idle cam. Remove the choke piston and lever assembly.
   
   Remove the choke rod and seal from the main body. If necessary, remove the choke plate from the choke shaft and slide the shaft and lever out of the air horn.
   
   The retaining screws are staked to the choke shaft. If the tips of the screws are flared excessively, file off the flared portion to avoid damage to the threads in the choke shaft. Be careful not to damage the choke shaft or venturi while filing the screws.



4. Remove the secondary diaphragm housing and gasket from the main body. The housing must be removed before the cover can be removed. Remove the diaphragm housing cover; and then remove the spring and diaphragm, and the vacuum ball check from the housing.



5. Remove the accelerating pump discharge nozzle screw; and then lift the pump discharge nozzle and gaskets out of the main body. Invert the main body and let the accelerating pump discharge needle fall into the hand (Fig. 21).

• Car Identification
• Brakes
• Suspension, Steering, Wheels, Tires
• Rear Axle
• Clutch, Driveline
• Manual Transmission
• Automatic Transmission
• Engine
• Ingition System
• Fuel System
• Charging System
• Starting System
• Lights, Wiring, Horns, Instruments
• Ventilating, Heating, Air Conditioning, Radio
• Body, Doors, Windows
• Soft Trim, Convertible Top
• Maintenance Schedule
• Maintenance Operations
• Lubrication Charts