Ford F100 1959, Shop Manual

Page 1: ......

Page 2: ...was created from the original Ford Motor Company s publication Every effort has been made to use the original scanned images however due to the condition of the material some pages have been modified...

Page 3: ......

Page 4: ...criptions and specifications contained in this manual were in effect at the time the manual was approved Jar printing The Ford Division 0 Ford Motor Company reserves the right to discontinue models at...

Page 5: ...SHOP MANUAL I G RO UP I ENGINES PAGE PAR T 1 1 GENERAL ENGINE SERVICE 1 2 PART 1 2 223 SIX ENGINE 1 20 PART 1 3 MEDIUM AND HEAVY DUTY V S ENGINES 1 42 PART 1 4 SUPER DUTY V S ENGINES 1 73 PART 1 5 SPE...

Page 6: ...be traced to a definite system by a simple check the possible systems that could be at fault are listed in the order of their probable occurrence therefore in most cases the checks should be made in t...

Page 7: ...moved from one spark plug at a time until all cylinders have been checked Ground the spark plug wire removed If the engine speed changes when a particular cylinder is shorted out that cylinder was del...

Page 8: ...Determine if the trouble exists when the engine is cold at normal operating temperatu re or at all engine temperatures ENGINE COLD Check the Exhaust gas control valve Part 1 1 Fuel system Part 2 2 Co...

Page 9: ...Tires Part 7 3 Wheel alignment Part 7 3 Brakes Temperature sending unit Part II I Temperature gauge Part I I I Exhaust gas control valve Part I I Cylinder head bolt torque Part 1 2 1 3 or 1 4 T empera...

Page 10: ...ystem filter X ELECTRICAL Oil generator rear bearing through oil cup 223 Six X Replace fuel system filter element X Check generator output X Part 10 C lean c arbureto r fuel bowl s nd adjust Check sta...

Page 11: ...gasket leak a defect in the ignition system or a weak valve spring Gradual drop in reading Excessive back pressure in he exhaust at engine idle system Intermittent fluctuation An occasional loss of po...

Page 12: ...is operated at high rpm Free slUck valves with a pene trating oil and graphite mixture VALVE ROCKER ARM SHAFT ASSEMBLY Clean all the parts thoroughly Make sure that all oil passages are open Check th...

Page 13: ...V S and all SO V S engines exhaust only on 292 HD V S engines Cylinder Head Flatness Check the flatness of the cylinder head gasket surface Fig 4 Specifications for flatness are 0 006 inch maximum ov...

Page 14: ...edge of the valve face lower the valve seat If the blue is transferred to the bottom edge of the valve face raise the valve seal After refacing the valve seal it is good practice to lightly lap in th...

Page 15: ...eated and tighten the set screw then permit the valve to drop away from its seat until the tool con lacts the upper surface of the valve guide Position a dial indicator wit h a flat tip against the ce...

Page 16: ...e rocker arm 1 0 one side and secure it in this position Make sure the push rod is in the tappet socket then install a dial indicator in such a manner as to have the actuating point of the indicator i...

Page 17: ...the camshaft journals should be ground for under size bearings or the camshaft re placed and or the bearings should be replaced Bearings are available pre fin ished to size for standard and undersize...

Page 18: ...ucks with an automatic transmission is covered in Group 4 or 5 CRANKSHAFT Handle the cranksbaft with care to avoid possible fractures or dam age to the finished surfaces CLfANING AND INSPECTION Clean...

Page 19: ...ssive wear wavy ring lands frac tures and or damage from detona tion or pre ignition Check the piston to cylinder bore clearance with a tension scale and ribbon and the ring side clearance following t...

Page 20: ...pical TABLE 4 Piston Clearance Chart 4 4 POUNDS o 1 2 2 o z o 8 7 6 5 EXAMPLE 2 o 1 1 002 00 1 1 1 1 J 1 i i 0 00 002 00 CLEARANCE IN INCHES 0008 EXAMPLE 0026 EXAMPLE 00 4 RISBoi 004 RIBBON 0035 RIBBO...

Page 21: ...he cylinder bore in which it is going to be used Push the ring down into the bore area where normal ring wear is not en countered Use the head of a piston to position the ring in the bore so the ring...

Page 22: ...refin ishing cylinder walls only when the A AT fUGHT ANGLE TO CENTERliNE Of ENGINE B PARAllEL TO CENTERltNE Of ENGINE OUT Of ROUNO DIFFERENCE BETWEEN A AND B 2 TAPER OIFFERENCE BETWEEN THE A MEASUREME...

Page 23: ...ENGINE Wash all parts in a solvent and dry them thoroughly Use a brush to clean the inside of the pump housing and the pressure relief valve chamber Be sure all dirt and chips are removed Remove old g...

Page 24: ...fold center section between the carburetor and exhaust manifold A thermostatically con trolled valve located in the exhaust manifold Fig 3 directs exhaust gases into this area to provide the heat nece...

Page 25: ...rews The camshaft is supported by four insert type bearings pressed into the block and is driven by a sprocket and timing chain in mesh with a sprocket on the crankshaft Camshaft thrust is controlled...

Page 26: ...erature before contacting contaminating vapors orig inating in the crankcase This warm ventilating air minimizes the forma tion of crankcase sludge The ventilat ing air moves down past the push rods i...

Page 27: ...nsmission oil cooler inlet and outlet lines at the engine 5 Attach the engine lifting hook Fig 7 Remove the engine right and left front support to frame bracket bolts Lift the engine out of the engine...

Page 28: ...scon nectthe exhaust manifold at the muf fler inlet pipe and remove the inlet pipe to engine bracket bolt Discon n ect the ge nerator wires at th e generator Disconnect the flexible fuel line at the f...

Page 29: ...GINE REAR SUPPORT REPLACEMENT 1 Remove the nut bolt lower in 1 25 umn cover plates and the master cyl inder inspection cover Install the driver s seat assembly 10 Fill and bleed the cooling sys tem Fi...

Page 30: ...cylinder head and that none of the steel gaskets have become dislodged 3 Install the attaching washers and bolts then lighten the bolts to 23 28 foot pounds torque tightening from FIG l4 Valve Push R...

Page 31: ...ration Install the manifold assembly YUNDER HEAD REMOVAL 1 Drain the cooling system Re move the air cleaner Ihen tape the carburetor air horn closed Discon nect the radiator upper hose at the radiator...

Page 32: ...r s between the cylinder head spring pad and the valve spring to bring the assembled height to the recommended dimension of 12 2 11 6 inches Do not Install spacers un less net essary Use of spacers in...

Page 33: ...cker arm cover gasket with oil re sistant scaler and lay the cemented side of the gasket in place in the cover Install the cover making sure Ihat the gasket seats evenly all around the head Inslall th...

Page 34: ...ket retaining bolt 4 On all models remove the cap screw and washer from the end of the crankshaft then remove the damper Fig 23 FIG 23 Damper Removal INSfAUAfiON 1 Lubricate the crankshaft with an oil...

Page 35: ...point on the block and measure rom this point to the chain Fig 27 Rotate the crankshaft in the opposite direction to take up the slack on the right side of the chain then force the PART 1 2 223 SIX E...

Page 36: ...ll the woodruff key in the camshaft 2 Raise the engine enough to align it with the engine front support brackets Install the right and left support bracket retaining bolts Re move the engine lifting b...

Page 37: ...ng tool can be used if desired As each tap pet is installed secure it in the up position 3 After the tappets are installed install the camshaft and related parts EJ FLYWHEEL CRANKSHAFT CONNECTING RODS...

Page 38: ...lled re move the main bearing inserts from the block and the bearing caps and or the connecting rod bearing in serts from the connecting rod and cap Install new bearings following the procedure in Sec...

Page 39: ...play 6 Check the clearance of each connecting rod bearing following the procedure under Connecting Rod Bearing Replacement in Section 8 If the bearing clearances are satisfac tory apply a light coat...

Page 40: ...piston is at the top of its stroke and carefully remove the cloth with the cuttings 3 Turn the crankshaft until the connecting rod being removed is down Remove the hex head nUlS from the connecting r...

Page 41: ...the same cylinder from which they were removed or to which they were fit ted Each connecting rod and bearing cap is numbered from 1 to 6 begin ning at the front of the engine The numbers on the connec...

Page 42: ...e minimum diameter with minimum clearance interfer ence may result causing an early fail ure It is not recommended that bearings be fitted to a crankshaft journal which eltceeds the maximum out of rou...

Page 43: ...CEMENT 1 Drain the crankcase Remove the oil level dip stick distributor crankcase ventilation tube flywheel housing inspection cover oil pan and oil pump screen and inlet tube Remove the cap from the...

Page 44: ...ighten the plug to 33 38 foot pounds torque 3 Slide the drive gear and shaft assembly inlo the housing Inslall the dri ven gear Check the end play of the gears Part I I 4 Apply sealer to both sides of...

Page 45: ...ll and tighten the clamp Slide the outlet pipe into 1 41 INSTAllATION 1 Make sure the two elongated holes in the oil filter anti drain back diaphragm are in the up position Fig 49 2 Clean the cylinder...

Page 46: ...h with its own separate inlet connection to the car buretor Fig 6 The right barrel s of the carburetor feeds Nos 2 3 5 and 8 cylinders and the left barrel s feeds Nos 1 4 6 and 7 cylinders A 292 HD V...

Page 47: ...consists of a serrated spring and two Chrome plated steel rails VALVE TRAIN The intake and exhauSt valve as semblies used in the MD V S engine and the intake valves of the HD V S engines are the rota...

Page 48: ...517 1 enters the engine A by pass provides oil to the engine in case the filter ele ment becomes clogged The by pass is located in the hollow center bolt of the filter and consists of a spring loaded...

Page 49: ...nd rear oil seals Connecting rod bearings arc lubri cated by passages drilled from the crankshaft main journals to Ihe con necting rod journals of the crank shaft Cylinder walls arc lubricated by oil...

Page 50: ...300 A Raise the engine slightly then carefully pull the engine from the tra nsmission Lift the engine out of the engine compartment Install the engine on a work stand Fig II or 12 On a 302 or 332 eng...

Page 51: ...b forward Drain the cooling system and the crankcase 2 Remove the clamps holding the throttle choke and accelerator cables and the healer hoses to the radiator Remove the fan assembly and the five bel...

Page 52: ...e rear flange of the engine rear cover plate will clear the slots Remove the removable cross member 3 Remove the air cleaner Discon nect the battery ground cable the water temperature and oil pressure...

Page 53: ...IAR SUPPORT The engine rear support is shown in Fig 16 REMOVAL Remove the nut boh lower in sulator and spacer from each rear suppon Raise the rear of the engine thcn remove the insulators INSTALLATION...

Page 54: ...haust gas control valve if applicable Disconnect the muffler inlet pipe from the manifold Remove the manifold bolts 2 Remove the spark plug heat shields then remove the manifolds Installation 1 Lightl...

Page 55: ...ock Do not pry between the head and block Remove the head gasket US MANIFOLD FIG 19 CYUnder Head Holding Fixtures FIG 2D Valve Spring Retainer Locks Removal or Installation VALVE ROCKER ARM SHAn DISAS...

Page 56: ...e earonee F ree LOCKS 6 FIG NO ii o rO Free Turn 1335 A lng Type Valve A ne mbly CYLINDER HEA 1 On Ihe exh D ASSEMBLY V S engines aust valves of all HD be we measure th th en the end of th e clearance...

Page 57: ...n remove the holding fix lUres Coat the cylinder head bolt threads with water resistant sealer and install the bolts The cylinder head bolt tightening procedure is per formed in three progressive step...

Page 58: ...heads on a 292 engine it is necessary to in stall a plug in the water outlet at Ihe rear of the right cylinder head and install a water temperature sending unit adapter in the water opening at the rea...

Page 59: ...valve Lash Adjustme nt Typical The cylinders are numbered from front to rear right bank 1 2 3 4 left bank 5 6 7 8 The valves are ar ranged from front to rear on both banks E 1 I E E I I E The sending...

Page 60: ...and hood lower weatherstrip as an as sembly Remove the fan spacer hub and drive belt and the radiator and shroud assembly Remove the cap screw and washer from the end of the crankshaft then remove th...

Page 61: ...ooling system and he crankcase Remove the radiator oil level dip stick and the oil pan Remove the drive belts fan crank j 1341 A FIG 39 Timing Gear Alignment 302 or332 Engine shaft damper and remove t...

Page 62: ...n the camshaft and crankshaft Fig 38 Be surc the timing marks on the sprockets and chain are positioned as shown in Fig 37 There are 12 timing chain link pins between the timing marks on the sprockets...

Page 63: ...ill the crankcase Fill and bleed the cooling system Operate the engine and check for coolant and oil leaks ON 292 MO AND HD 1 8 ENGINfS USE lARGE END ON 302 AND 332 HD 1 8 EN USE SMALL DIAMETER END FI...

Page 64: ...ft bearings Installation 1 Oil the camshaft and carefully slide it through Ihe bearings Install the spacer Be sure the chamfer on the inside of the spacer is to the rear or faces the camshaft when it...

Page 65: ...en and instalilhe hold down clamp Connect the distributor primary ire and the vacuum line Install the istributor cap and connect the spark plug wires and the coil high tension lead 6 Fill and bleed th...

Page 66: ...r cover Install the intake manifold Connect the fuel lines and acceler ator linkage Install the carburetor air cleaner Fill and bleed the cooling system Fill the crankcase 10 Make a preliminary cold v...

Page 67: ...ve the crankshaft gear 2 Make sure all bearing caps m a in a nd connec ting rod are marked so they can be installed in their original locations Remove the connecting rod bearing caps then carefully pu...

Page 68: ...fRONT Oil SUNGER CRANI SHAFT f llONT OIL BEARING INSfRTS c o FIG 56 Cronkshaft and Rela ted Parts 302 or 322 Engine JOURNAL SEAL TO CYllNDER BLOCK BOlT j l RETAINER N JOU NA SEAL TO SEAL RETAINER RET...

Page 69: ...imum limit inspect the thrust bearing faces for scratches burrs nicks or dirt Jf the thrust faces are nol defective or dirty they probably were not aligned properly Install the thrust bearing and alig...

Page 70: ...GROUP 1 ENGINES 1119 FIG 62 Piston Pin Removal connections and gaskets for leaks PISTON AND CONNECTING ROD REMOVAL The pislOn and connecting rod as sembly is shown in Fig 61 1 Drain the cooling system...

Page 71: ...ING ROD DISASSEMBLY Mark the pistons and pins to assure assembly with the same connecting rod and installation in the same cyl inder from which they were removed Remove the piston rings Remove the pis...

Page 72: ...of the engine When installed the rod bearing lock slots In tbe connect ing rod should be toward the outside of the engine 3 Check the clearance of each bearing following the procedure un 7 Start the e...

Page 73: ...tory apply a light coat of engine oil to the journal and bearings then install the bearing cap Tighten the cap bolts to specifications 6 If the rear main bearing is re placed replace the retainer seal...

Page 74: ...p stick Fill the crankcase with the proper amount and grade of lubricant OIL PUMP The oil pump is shown in Fig 69 REMOVAL 1 Disconnect the oil inlet tube at the pump and remove the 0 ring seal Loosen...

Page 75: ...Ihe filter element and all gaskets Wash aU parts in solvent Make sure all the openings in the center bo t are clean 3 Install a new fiber gasket on the center bolt then pl ace the bolt through the fil...

Page 76: ...rque Tighten the U bolt clamp then tighten the muffler and outlet pipe clamps and supports MUFflER REPLACEMENT RAM S HORN TYPE EXHAUST MANIFOLDS Loosen the muffler pipe clamp and slide the clamp away...

Page 77: ...buretor feed Nos 1 2 3 and 4 cylinders and the left barrels feed Nos 5 6 and 8 cylinders The fuel induction system is shown in Fig 3 TABLE l Engine Model Application Patent Piston Plate Engine fix Dis...

Page 78: ...1 74 GROUP 1 ENGINES 1686 FIG 2 Super Duty v a Engine Sectional View...

Page 79: ...PART 1 4 SUPER DUTY v a ENGINES o FIG 3 Fuellndudion System fUEL AIR MIXTURE 1 75 1687 A...

Page 80: ...nd the air brake compressor is mounted on the left side of the block The combustion chambers are lo cated in the cylinder block Fig 5 This reduces the intense combustion temperatures in the head area...

Page 81: ...e front of the oil pan is forced through the pressure lubrication sys tem Fig 7 by a rotor type oil pump The oil pump mounted in the front of the crankcase is driven by the distributor through an inte...

Page 82: ...aft turns the hole in the connecting rod bearing aligns with the hole in the journal causing a direct squirt of oil onto the cylinder wall A passage is drilled from the No I camshaft bearing to lubric...

Page 83: ...PART 1 4 SUPER DUTY v a ENGINES 1 79 80TH THERMOS TS STAGE I 80TH TH OPEN STAGE 2 v STAGE 3 1679 11 FIG_ 10 C Ung Sy tem...

Page 84: ...On a truck with conventional brakes disconnect the vacuum assist brake line at the intake manifold On a truck with power steering disconnect the power steering return line and the pump pressure line a...

Page 85: ...to the pump reservoir and the pres sure line at the pump housing Con nect the return line and pressure line to the bracket on the frame left side member 5 Connect the engine ground strap hand throttle...

Page 86: ...pins in the engine block engage the holes in the fiywheel housing 2 Install two fiywheel housing to engine bolts and remove the guide pins Install the remaini ng bolts then tighten all the bolts to sp...

Page 87: ...The engine rear support is shown in Fig 15 or 16 The procedures PART 1 4 SUPER DUTY V 8 ENGINES BRACKET fj l USED ON C SEJlIES TRUCKS ONLY 1683_A 1 83 FIG 14 Engine Front Support given apply to eithe...

Page 88: ...f the manifold and the higher tem perature thermostat is installed in the front of the manifold Apply sealer to the thermostat bousing gaskets and position them on the intake mani fold Install the int...

Page 89: ...1 Drain the cooling system Re move the air cleaner the intake mani fold assembly and the valve rocker arm covers Disconnect the mumer inlet pipes at the ex haust manifolds 2 Release tbe spring tension...

Page 90: ...ameter pin punch and in stall a plug cup side out in each end of the valve rocker arm shah 3 Install a cotler key in one end of the shaft then install the rocker arms supports and springs in the order...

Page 91: ...in their proper sequence making sure the lower ends are positioned in the tappet socket 4 Position the oil baffle plate and the valve rocker arm shaft assembly on the cylinder head Install but do not...

Page 92: ...the exhaust valves Use a step type feeler gauge go and no go to adjust the valves t Make three chalk marks on the crankshaft damper Fig 27 Space the marks approximately 90 apatt so that with the timi...

Page 93: ...roud and radiator Remove the alternator power steering pump and air compressor drive belts Remove the air compressor idler pulley and disconnect the alternator adjusting arm al the cylinder front cove...

Page 94: ...at the gas ket surface of the cylinder front cover and block and the cover bolt threads with sealer Position a new cylinder ront cover gasket on the block Install the cylinder front cover 3 Install th...

Page 95: ...front oil slinger the cylinder front cover crankshaft damper the water pump the oil pan and the oil level dipstick 3 Install the valve tappets in sequence Install the valve tappet chamber gasket and c...

Page 96: ...s and the intake manifold assembly Perform a preliminary valve lash adjustment Install the dis tributor cap and connect the spark plug wires and the coil high tension lead 4 Fill and bleed the cooling...

Page 97: ...surfaces Remove the rear journal oil seal from the block and rcar main 1S76_A FIG 42 Seol to aearing Cap Installation bearing cap and remove Ihe cap 10 block side seals 6 If new main and or conncctin...

Page 98: ...few drops of oil inlo the parling lines between the bearing cap and the cylinder block from the out side Blow compressed air against the seals from the inside of the block If air bubbles appear in th...

Page 99: ...tor Fill and bleed the cooling system Fill the crankcase with the proper grade and quantity of engine oil Start the engine and adjust the ignition tim ing Operate the engine at fast idle and check for...

Page 100: ...emoved Remove the piston rings Remove the piston pin retainers then drive the pin out of the piston and connecting rod Discard the retainers PISTON AND CONNECTING ROD ASSEMBLY 1 l ubricate all parts w...

Page 101: ...d to the minimum diameter with minimum clearance interfer_ ence may result causing an early fail ure It is not recommended that bearings be fitted to a journal which exceeds the maximum out of round s...

Page 102: ...ankcase Remove the oil level dip stick the oil pan the oil pump and pick up tube assembly and the intermediate drive shaft Re move the cap from the connecting rod to which new bearings are to bt insta...

Page 103: ...nd retaining wire in the pick up tube Position a new gasket and the oil pick up tube on the oil pump and install the retaining bolts INSTALLATION 1 Insert the oil pump drive shaft into the oil pump Po...

Page 104: ...mp then separate the muffler from the inlet pipe and remove the muffler the center bolt into the adapter finger tight Rotate the filter assembly slightly in each direction to make sure the gasket is s...

Page 105: ...a ANO MINT Pront t a r 223 E J I E I E E I E I I E 292 302 and 332 E I I E E I I E 401 477 and 534 E J E J I E I E INOINI IDU I M Manual Shift and Transmatic Transmissions A ll Engines 475 500 Fordoma...

Page 106: ...11INTD DINCI m SttInd rd ChI Intake Exhaust 292 HD 0 0015 0 004 302 332 401 477 and 534 0 002 0 004 VALVE MECHANISM VALVI LASH Cold INTAKE 223 Six and 292 0 019 302 332 401 477 and 534 0 020 EXHAUST 2...

Page 107: ...020 VALVE TA IT DIAMITIIt StClndClrd 223 and 292 0 4986 0 4992 302 332 401 477 and 534 0 8742 O S747 VALVE MECHANISM Cont VALVE TA PIT TO TA n lOll CLiAIANCI 223 and 292 0 oooS O 0024 Wear Limit 0 005...

Page 108: ...CONNECTING ROD PISTON PIN IUSHING 1 0 Standard 401 477 and 534 1 2201 1 2204 All Other Engines 0 9122 0 9125 PISTON PIN IUSHING OUT O ROU ND AND TA IR 401 477 and 534 0 0002 All Other Engines 0 0003...

Page 109: ...it 401 477 and 534 0 001 223 0 0015 0 0029 All Other Engines 0 0008 GI INO CU NCI UM SSIMILlD 223 0 003 0 006 PISTON RINGS O IVIN G TO SH n CLI NCI ItING WIDTH 223 0 001 0 002 Compression Ring 292 0 0...

Page 110: ...OCKII SHAn SUPPO T TO CYLlNOII HIAD 223 45 55 292 12 15 302 and 332 22 25 VALVI 10CKI AIM DJUSTING SCRIW Solf Lockl lI Minimum lo quo 10 0101 223 292 302 and 332 3 VALVI OCKII M ADJUSTING NUT 401 477...