part 17-3 front end, bumpers, and exterior mouldings 1...

PART 17-3 - Front End, Bumpers, And Exterior Mouldings 1 7-43

NG. 41-Cougar Rear Exterior Mouldings

PART 17-4- Windshield, Window Glass, and Window Mechanisms

Section Page ................................. 1 Diagnosis and Testing .17-45

Power Windows ....................................... 17-45 2 In-Vehicle Adjustments and Repairs ................ 17-46

Window Mechanism Lubrication ................. 17-46 Vent Window Adjustments -Falcon,

Fairlane, and Montego- Models 54, 62 and 71 ............................. 17-46

Front Door Window Adjustment - Fairlane and Montego --Models 63, 65, 66 and 76 .................................. 17-46

Front Door Window Adjustment - Falcon, Fairlane, and Montego - Models 54 and 71 .................................. 17-46

Door Window Adjustment - Falcon ............................................. I Model 62 17-48

Door Window Adjustment - Mustang and Cougar ......................................... -17-48

Rear Door Window Adjustment - Falcon .... .,. ......................................... 17-48

Rear Door Window Adjustment - Fairlane and Montego- Mo'del 54 ............................................. 17-48

Rear Door Window Adjustment - ' Fairlane and Montego- Model 7 1 ............................................ .17-5 1

Quarter Window Adjustment - Falcon Model 62 ............................................. 17-51

Quarter Window Adjustment - Fairlane and Montego -Models 63, 65 and 76 ....... 17-52

Quarter Window Adjustment - Mustang and Cougar ............................. 17-52

Tailgate Window Glass Emergency Lowering Procedure ............................... 17-52

3 Removal and Installation .............................. 17-54 Power Window Relay -Falcon,

Fairlane, and Montego ........................... 17-54 Vent Window Glass - Mustang and

................................................ Cougar 17-54 Vent Window Weatherstrip - Falcon ........... 17-54 Vent Window Frame, Weatherstrip, and/or

Division Bar - Manual Windows - Fairlane and Montego ............................ 17-55

Vent Window Frame, Weatherstrip, and/or Division Bar - Power Windows - Fairlane and Montego ............ 17-55

Vent Window Frame - Mustang and Cougar ................................................ 17-55

Front Door Window Glass - Falcon Models 54 and 71 .................................. 17-56

Front Door Window Glass - Montego and Fairlane -Models 54 and 71 ............. 17-56

Front Door Window Glass -Power Windows - Montego and Fairlane -

................................. Models 54 and 7 1 .17-56 Front Door Window Glass -Falcon

Model 62 ....................................... . 1 7 - 5 6 Front Door Window Glass - Fairlane

and Montego - Models 63, 65, 66 and 76 ................................................ .17-57

Front Door Window Glass - Mustang and Cougar ........................................ 17-58

Section Page Front Door Window Regulator - Manual

Windows - Montego, Falcon, Fairlane - Models 54 and 7 1 ............................... 17-58

Front Door Window Regulator and/or Motor - Montego and Fairlane - Models 54 and 7 1 .................................. 17-58

Front Door Window Regulator - Falcon M ode1 62 ........................................ 17-58

Front Door Window Regulator - Manual Windows - Montego and Fairlane - Models 63, 65, 66 and 76 ........................ 17-59

Front Door Window Regulator and/or Motor - Montego and Fairlane - Models 63, 65, 66 and 76 ........................ 17-59

Front Door Window Regulator - Mustang and Cougar ............................. 17-59

Front Door Glass Front Run - Models 54, 62 and 71 ............................. 17-59

Front Door Glass Front Run - Fairlane and Montego -Models 63, 65, 66 and 76 17-59 ' ...................................

Front Door Glass Rear Run - Models 54, 62 and 71 ............................. 17-60

Front Door Glass Rear Run - Fairlane and Montego - Models 63,

........................................ 65, 66 and 76 17-60 Front Door Glass Guide (Front or Rear) - Fairlane and Montego - Models 63, 65, 66 and 76 ................................... 17-60

Front Door Glass Rear Guide - Mustang and Cougar ............................. 17-60

Front Door Glass Rear Weatherstrip - Fairlane and Montego - Models 63, 65 and 76 ....................................... .17-60

Rear Door Window Glass -Falcon Models 54 and 71 .................................. 17-60

Rear Door Window Glass - Fairlane and Montego Model 54 .......................... 17-61

Rear Door Window Glass - Power Windows-Fairlane and Montego Model 71 .......................... 17-61

Rear Door Stationary Window Glass and/or Weatherstrip - Fairlane and Montego Model 71 ................................ 17-62

Rear Door Window Regulator - Falcon ....... 17-62 Rear Door Window Regulator - Fairlane

.......................... and Montego Model 54 17-63 Rear Door Window Regulator and/or

Motor - Fairlane and Montego Model 54 ............................................. 17-63

Rear Door Window Regulator - Fairlane and Montego Model 71 .......................... 17-63

Rear Door Window Regulator and/or Motor - Fairlane and Montego

............................................. Model 71 17-63 Quarter Window Glass -Mustang and '

Cougar ................................................ 17-64 Quarter Window Glass -Model 62 .............. 17-64 Quarter Window Glass - Fairlane and

Montego - Models 63 and 65 .................. 17-65

PART 17-4 - Windshield, Window Glass, And Window Mechanisms 1 7-45

Section Page Section Page Quarter Window Glass - Montego and Windshield -Mustang Models 63, 65 and

Fairlane - Model 76 .............................. 17-64 Cougar.. .............................................. 17-72 Quarter Window Regulator - Mustang Windshield -Mustang Model 76 ................. 17-72

and Cougar .......................................... 17-65 Bonded Rear View Mirror .......................... 17-73 Quarter Window Regulator - Model 62 ........ 17-65 Back Window Glass and/or Weatherstrip - Quarter Window Regulator - Montego Falcon, Fairlane, and Montego -

and Fairlane -Models 63, 65 and 76 ........ 17-66 Models 54, 62 and 65 ............................ .17-74 Quarter Window Front Guide - Back Window Glass - Fairlane and

Mustang and Cougar ............................. 17-66 Montego Model 63 ................................ 17-75 Quarter Window Rear Guide - Back Window Glass -Mustang

Mustang and Cougar ............................. 17-66 Model 63 ............................................ .17-76 Quarter Window Front Run -Model 62 ....... 17-66 Back Window Glass -Mustang and

.................................. Quarter Window Front Run - Fairlane Cougar Model 65 17-77 and Montego -Models 63, 65 and 76 ....... 17-66 Tailgate Window Glass .............................. 17-77

Quarter Window Front Guide - Fairlane Tailgate Window Regulator ........................ 17-77 and Montego -Models 63, 65 and 76 ....... 17-67 Tailgate Power Window Regulator.. ............. 17-78

Quarter Window Rear Guide - Fairlane Single Action Tailgate Switch and Lock and Montego -Models 63, 65 and 76 ....... 17-67 Cylinder - Power Window ...................... 17-79

Stationary Quarter Window Glass and/or Single Manual Window Handle and Weatherstrip - Model 71 ........................ 17-67 Lock Cylinder ....................................... 17-79

Windshield - Montego, Falcon, and Tailgate Manual Window Handle and Fairlane Except Model 76 ....................... 17-69 Lock Cylinder ....................................... 17-79

Windshield - Montego and Fairlane - Dual Action Tailgate Power Window Model 76 ............................................. 17-70 Switch Lock Cylinder ............................. 17-80

1 DIAGNOSIS AND TESTING

DOOR AND QUARTER POWER WINDOWS

Before making any of the following trouble checks, make sure that the battery is fully charged, and turn' the ignition switch to the accessory position.

Refer to Wiring Diagram Manual Form 7795P-68 for locations of wiring harnesses. Schematics are shown in Group 19 of this manual.

ALL WINDOWS DO NOT OPERATE

1. Connect a voltmeter or test light from a ground to the power window relay black wire which is connected to the 20-ampere circuit breaker attached to the battery terminal of the starting motor relay. If no voltage is available, repair or replace the 20-ampere circuit breaker or the connecting black wire.

2. Connect a voltmeter from a ground to the red wire terminal of the power window relay. I f no voltage is available, repair or replace the 20-ampere fuse, the ignition switch, or the wire from the ignition switch through the fuse to the relay.

3. Connect a voltmeter from a ground to the remaining terminal (black-white wire) of the power window relay. I f no voltage is available, replace the power window relay.

4. Check the blue wire at the master ccntrol switch for voltage. I f no voltage is available, repair or replace the black-white wire from the master control switch to the power window relay.

5. ,At this point the trouble caus- ing all windows not to operate should have been found and corrected. The chances of having all of the control switches, ground circuit breakers, switch to mdtor wires, or motor defective at the same time are very remote.

The power window, power seat and convertible top electrical systems are connected through the same 20- ampere circuit breaker. I f failure oc- curs in all the systems at the same time, the 20-ampere circuit breaker is probably defective.

O N E WINDOW DOES NOT OPERATE

1. Activate the switch and listen for the motor running free. I f the motor runs and the window does not move, the rubber coupling or gear teeth have failed.

2. If the motor does not run, dis- connect the wires a t the motor in order to check for voltage at each feed wire while actuating the window switch at the door or from the master switch. I f there is no voltage at the motor feed terminals, check for volt-

age at the switch feed wire. I f there is voltage at the switch, replace the switch.

WINDOW OPERATES IN O N E DIRECTION ONLY

1. Check the operation with the individual and master switches. Re- place a defective switch i f the window operates normally from one and not from the other.

2. If the window will not function correctly from either switch, check for defective wiring between the switch disconnects and the motor. I f the wiring leads are open, replace the wiring.

3. I f the window operates normally in one direction, the motor is not defective.

WlNDOW OPERATES SLUGGISHLY

1. Check the regulator and window runs for binding. Adjust the runs, repair and lubricate the regulator. Lubricate the runs with sili- cone lubricant.

2. Check for frayed insulation where the window wires may partially ground. Check for loose connections which will cause high resis- tance, and make sure that paint is not insulating the ground wires.

GROUP 17 - Body, Doors, And Windows

3. Check motor current draw dur- ma1 operation and should exceed 20 is below 20 amperes at stall, look for ing operation (place an ammeter in amperes at stall. If the current draw poor electrical connections. series with the ground lead of the is above 12 amperes during opera- 4. Motor current draw when dis- battery). Motor current draw should tion of the window, readjust the connected from the regulator plate not exceed 12 amperes during. nor- - glass mechanism. If the stall current should not exceed 5 amperes.

2 IN-VEHICLE ADJUSTMENTS A N D REPAIRS

WINDOW MECHANISM LUBRICATION

The door window mechanism should be well lubricated to provide ease of operation. The window glass mechanism should be lubricated whenever the glass channel or window regulator is removed or excessive effort is required to operate the windows. To lubricate a door window mechanism, apply an even coating of Polyethylene grease (C4AZ- 19584-A) to the window regulator rollers, shafts and the entire length of the roller guides as illustrated by the shaded areas in Fig. I .

VENT WINDOW ADJUSTMENTS- FALCON, FAIRLANE AND MONTEGO-MODELS 54 ,62 , and 71

The vent glass and/or the vent window frame may be adjusted in various ways. With the vent glass in- stalled, the lower pivot spring ten- sion may be adjusted with a socket, extension, and ratchet used through the access hole in the door inner panel. Adjust so that the glass will stay open at highway speeds. The door frame mounting holes are elongated to provide 'a tight fit for the vent window frame in the door frame. The upper pivot mounting holes are slotted to help provide a weather-proof fit of the glass frame within the vent window frame.

FRONT DOOR WINDOW ADJUSTMENT-FAIRLANE AND MONTEGO-MODELS 63,65,66 AND 76 '

The in and out position of the top edge of the door glass and the upper stops of the window mechanism can be adjusted without removing the door trim panel. These adjustments can be performed as follows:

UPPER FRONT STOP

1. Lower the glass to the full down position.

2. Insert a 7/16 inch socket into the glass opening (between the inner and outer panel) and loosen the upper front stop attaching screw (Item AD, Fig. 2).

3. To raise the stop, slide the stop toward the front of the door. To 'lower the stop, slide the stop toward the rear of the door.

4. When the desired stop adjustment is obtained, tighten the stop attaching screw securely.

UPPER REAR STOP

1. Loosen the two upper rear stop attaching screws (Item L, Fig. 2).

2. With the window in the full up position, place the upper rear stop down against the stop on the glass' channel. Then, tighten the two stop attaching screws.

DOOR GLASS TILT

1. Loosen the front and rear run retainer attaching screws (Item N and S, Fig. 2).

2. With the glass up, position the glass inboard or outboard as required to obtain proper engagement of the glass with the roof rail weatherstrip and a flush fit with the quarter window glass. Then, tighten the two retainer attaching screws (Items N and S).

3. Raise and lower the glass to be sure it is free of binds. If any binding is detected, lower the glass and loosen the front run retainer attaching screw. This will correct any misalignment of the front run with the rear run. Tighten the front run retainer attaching screw. "

COMPLETE WINDOW ADJ USTMENT

1. Remove the trim panel and water shield from the door.

2. Loosen the nuts (Items U and C) and screws (Items L, N, S and AE) shown in Fig. 2.

3. Raise the glass to the up position and move, it fore or aft, as required, for alignment with the body opening. Then tighten the nuts (Items U and C) securely.

4. Position the upper front stop down against the stop on the glass channel and tighten the screw (Item AE) securely.

5. Position the upper rear stop down against the stop on the glass channel and tighten the two screws (Item L) securely.

6. Tilt the door glass inboard or outboard as required to obtain proper engagement of the glass with the roof rail weatherstrip, and a flush fit with the quarter glass. This will move the front and rear runs to the correct position. Then, tighten screws (Items S and N) securely.

7. Raise and lower the glass to be sure that the glass travel is free of binds which could result in high operating efforts. If any binding is detected, lower the glass and loosen the front run retainer attaching screw (Item S). This will correct any misalignment of the front run with the rear run. Then tighten the front run retainer attaching screw (Item S)'.

8. Install the water shield and trim panel on the door.

FRONT DOOR WINDOW ADJUSTMENT-FALCON, FAIRLANE, AND MONTEGO MODELS 5 4 and 71

1. Remove the trim panel and watershield from the door.

2. To obtain proper alignment of the rear run to the vent window division bar and frbnt run, loosen the nut and washer assembly (Item C, Fig. 3) and the screw (Item D).

3. Lower the glass until the top edge of the glass is four inches above the belt line. Turn the screw (Item U, Fig. 3) clockwise or counterclock- wise as required to bring the front run into alignment with the rear run. Then, tighten the nut (Item C) and the screw (Item D) to 8-23 ft-lb torque.

4. TO obtain a flush cdnditibn between the top edge of the glass and the belt line when the glass is down, loosen the two lower stop attaching screws (Item F, Fig. 3).

5. Move the glass to a flush position with the belt line. Then, posi-


APPLY AN EVEN COATING OF -POLYETHYLENE GREASE (C4AZ-19584-A) TO ALL WINDOW REGULATOR ROLLERS. SHAFTS AND THE ENTIRE LENGTH OF ROLLER GUIDES A S ILLUS+RATED BY THE WADED AREAS.

FIG. I-Window Mechanism Lubrication Points

1 7-48 GROUP 17 - Body, Doors And Windows

tion the lower stop against the glass channel and tighten the attaching screws (Item F, Fig. 3) to 8-23 ft-lb torque. 6. Install the watershield and

trim panel on the door.

DOOR WINDOW ADJUSTMENT- FALCON MODEL 62

1. Remove the door trim panel and peel back the watershield to provide access. ,Refer to Fig. 4 . f ~ the following adjustments.

2. To obtain proper alignment of the lockside glass run retainer assembly to th'e door window frame and vent window division bar with the retainer, loosen nut and washer assembly D and screw and washer assembly E. Drop the topfedge of the glass and channel assembly to approximately four inches above the door outer panel belt line. Turn screw C 'clockwise or counterclock- wise as required. Tighten items D and E securely.

3. To obtain a flush condition between the top edge of the glass and channel assembly and the belt line when the window is in the down position, the stop assembly is adjusted up or down at screw and washer assemblies U. After adjustment, tighten the screw and washer assemblies securely,

4. Install the watershield and trim panel on the door.

DOOR WINDOW ADJUSTMENT- MUSTANG AND COUGAR

1. Remove the door trim:panel and watershield.

2. Loosen screws A, B, C, D, F, and G (Fig. 5) and lock nuts E, L, and M (Fig. 5). '

3. Raise the window and position the window inboard or outboard for proper alignment with the outside belt weatherstrip. Then, tighten the screw A, Fig. 5.

4. Tilt the window fore or aft to obtain a parallel relationship between the top of the window and the roof rail weatherstrip. Then, tighten the rear guide lock nut (Item E, Fig. 5).

5. Adjust the upper front and rear stops up and down for correct adjustment. Then, tighten the attaching screws (Items F and G, Fig. 5).

6. Position the vent window and division bar run rearward toward the door glass. Then, tilt the vent window fore and aft as necessary to obtain a parallel relationship to the

FIG. 2-Front Door Window Adiustment- Fairlane and Montego-Models 63, 65, 66 and 76

windshield A post. When the parallel clockwise or countercloskwise as re- relationship is obtained, tighten the quired. Tighten nut and washer as- vent window attaching screws (Items sembly C securely (Fig. 6). B and C, Fig. 5). The door glass 3. Install the watershield and door must be free of binding after the trim panel. vent window is adjusted. : I

7. Adjust the inboard or outboard tilt of the vent window and door glass REAR OooR to obtain an air tight interference ADJUSTMENT-FAIRLANE between the windows and thec roof AND MONTEGO-MODEL 54 rail weatherstrip by adjusting the three set screws (Items H, J and K, Fig. 5) in or out as required. When the desired adjustment is obtained, tighten the set screw lock nuts (Items E, L, and M, Fig. 5) and the rear guide adjusting screw (Item D, Fig. 5).


REAR DOOR WINDOW ADJUSTMENT-FALCON

1. Remove the door trim panel and watershield.

2. T-o obtain proper alignment of retainer and division bar assembly- to-door-window frame,. loosen nut and washer assembly (C, Fig. 6). Drop the glass and channel assembly to its" down position and turn screw B

The rear door window glass can be adjusted inboard or outboard in the glass run without removing the trim panel from the door. Loosen the screw and washer assemblies A and B, (Fig. 7) and position the glass as required in the'glass run. Then, tighten the screw and washer assemblies A and B securely.

COMPLETE WINDOW ADJUSTMENT

1. Remove the trim panel and water- 'shield from the door.

2. Loosen thk screw and washer assemblies A, B, C and D (Fig. 7).

3. Raise the window glass to the full up position.

4. Tighten the screw and washer assemblies C and D (Fig. 7).

PART 17-4 - Windshield, Window Glass, And Window Mechanisms 1749

FIG. 3-Front Door Window Mechanism-Models 54 and 71

1 7150 GROUP 17 - Body, Doors And Windows

FIG. 4-Door Window Mechanism-Model 62

FIG. 5-Door Window Glass Adjustment-Mustang and Cougar

PART 17-4 - Windshield, Window Glass, And Window Mechanisms 17-51

GLASS RUN -25766 OUTSIDE BELT WEATHERSTRIP -Z596. 7 5. Lower and raise the window glass.

-.

FIG. 6-Rear Door W i n d o w Mechanism- Falcon

FRONT GUIDE

N 16674

Then, adjust the front and rear giides inboard or outboard as required to align the window glass in the glass run.

6. Tighten the screw and washer assemblies A and B (Fig. 7) securely and check the operation of the window mechanism.


REAR DOOR WINDOW ADJUSTMENT-FAIRLANE AND MONTEGO-MODEL 71

1. Remove the trim panel and watershield from the door.

2. Loosen the screw and washer assemblies A, C, U and R (Fig. 8).

3. Raise the window glass t o the full up position. Tighten the two screw and washer assemblies C (Fig. 8) securely.

4. Lower and raise the window glass. 5. Tighten the screw and washer

assembly A (Fig. 8) securely. 6. Lower the window half way down.

Position the rear run retainer and division bar for proper alignment with the door window frame. Then, tighten screw and washer assemblies U and R (Fig. 8) securely. .7. Install the watershield and

trim panel on the door.

QUARTER WINDOW ADJUST- MENT-FALCON MODEL 62

1. Remove the quarter trim panel and watershield.

2. To obtain proper clearance between the quarter window assembly and the quarter window glass run retainer assembly, operate the window to its full down position, loosen screw and washer assembly D, and adjust the retainer assembly forward. After adjustment, tighten the screw and washer assembly finger tight (Fig. 9).

3. T o obtain proper clearance by- tween the quarter window assembly and the quarter window glass run retainer assembly, operate the window to its full up position. Loosen screw and washer assemblies D and adjust the retainer assembly forward. After adjustment, tighten screw and washer assemblies D securely.

4. Install the watershield and quarter trim panel.

FIG. 7-Rear Door W i n d o w Adjustment-Fairlane a n d Montego Model 54

GROUP 17 - Body; Doors And Windows

REAR RUN RETAINER AND DIVISION BAR

WINDOW REGULATOR

FRONT GUIDE

RETAINER

N 1668

FIG. 8-Rear Door Window ~diustment-~air laie and Montego Model 71

FIG. 9-Quarter Window Mechanism- Falcon-Model 62

be flush with the top of the door glass and also provide a good seal with the roof rail weatherstrip.

4. Manually position the quarter window fore and aft, and inboard or outboard as required for proper alignment with the door window glass. Then, tighten screw and washer assemblies B, C, E, and H (Fig. 10).

5. Push the upper stops (Fig. 10) upward firmly and tighten the screw and washer assemblies M and P.

6. Lower'the window until the top of the glass is flush with the belt line. Then, tighten the lower stop attaching screw N.

7. Check the window operation and fit. Then, install the watershield and quarter trim panel (Group 18).

QUARTER WINDOW ADJUSTMENT-MUSTANG AND COUGAR

1. Remove the rear seat cushion and seat back.

2. Remove the quarter trim panel and watershield.

3.. Loosen the screws (items A, B and C, Fig. I I) before adjusting the quarter window.

4. Adjust the quarter window guide forward or backward and up or down at screws (A, Fig. I I ) to obtain a 0.28 inch parallel dimen- sion between the front edge of the quarter window and the rear edge of the door window, (View AA Fig. I I). After adjustment, .tighten the screws, item A, finger tight. 5. Adjust the top edge of the

quarter window for an interference fit with the roof rail weatherstrip by tilting the guide toward the inside or outside of the body. This can be accomplished by loosening screws, items A and B (Fig. 1 I), and moving the quarter window guide inboard or outboard as necessary. Then, tighten the screws, items A and B.

6. With the quarter window raised to the full up position, turn the regulator handle an additional 118 inch. Then, adjust the window regulator stop (Fig. 1 I) to contact the arm of the regulator and tighten the attaching screw (item C, Fig. I 1).

?. lnstall the quaiter weathersheet and trim panel, and the rear seat back and cushion. TAILGATE WINDOW GLASS

QUARTER WINDOW ADJUSTMENT- 2. Loosen the screw and washer EMERGENCY LOWERING FAIRLANE AND MONTEGO- assemblies B, C, E, H, M, N, and P MODELS 6 3 , 6 5 AND 76 (Fig. 10). If the tailagate window regulator

1. Remove the quarter trim panel 3. Raise the quarter window to . mechanism should fail with the window and watersh~eld (Group 18). the up position. The window should in a partially closed or closed posi-


tion, the following procedure should each side of the tailgate (Fig. 12). washers attaching.. the regulator be used to lower the window. 4. Insert two wire hooks in the arm brackets to the glass channel.

1. Remove the tailgate inside plug button holes and slide the inner Hold the glass and disengage the cover panel attaching screws. panel up and off the tailgate. regulator arm brackets from the

2. Remove the two glass opening 5. Remove the water shield from glass channel and regulator rollers. side gar.nish mouldings. the tailgate. Then; carefully lower the glass into

3. Remove one plug button from 6. Remove the four nuts and the tailgate.

FIG. 10-Quarter Window Adiustrnent Location Points-Fairlane and Montego Models 63,65 and 76

FIG. 1 1-Quarter Window Adiustrnent-Mustang and Cougar

part 17-3 front end, bumpers, and exterior mouldings 1...

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