Ford Mustang Second Generation (1974-1978) Workshop Manual

Complete Technical Guide

1. Introduction to Mustang II

• Historical context (oil crisis design constraints)
• Model variants: Hardtop, Hatchback, Ghia, Cobra II, King Cobra
• Production changes by year (1974 base vs 1978 final edition)

2. Vehicle Identification & Decoding

• VIN Breakdown (17-digit):
  • Example: 1FABU12A123456789
    • 1F = Ford Motor Company, USA
    • A = Mustang line
    • B = Body type (A=Hardtop, B=Hatchback)
    • U = Engine code (U=2.8L V6, S=2.3L I4, F=302 V8)
    • 12 = Assembly plant code
• Warranty Tag Decoding:
  • Body: 65A = Hatchback
  • Color: 2T = Bright Yellow
  • Trim: BA = Black Vinyl
  • Date: 06B = February 6th production
• Engine Stamp Locations:
  • 2.3L: Right side of block near fuel pump
  • 302 V8: Front of block below head

3. Engine Systems

2. 2.3L OHC Lima Inline-4

• Valve Adjustment:
  • Cold setting: 0.013-0.015″ (intake), 0.023-0.025″ (exhaust)
  • Shim-and-bucket system (Ford tool T74P-6500-A)
• Timing Belt Replacement:
  • Remove crankshaft damper (85-105 ft-lbs torque)
  • Align marks: Cam sprocket notch at 12 o’clock
  • Tensioner spring force: 4.4-6.6 lbs
• Carburetor Rebuild (Holley 5200):
  • Float level: 15/32″ (dry measurement)
  • Idle mixture: 1.5 turns out from seated

1. 302 Windsor V8 (1975-1978)

• Camshaft Replacement:
  • Bearing journal diameters: 2.000-2.0015″
  • Break-in procedure: 2,000 RPM for 20 minutes
• DuraSpark II Ignition:
  • Module test: 0.4-0.9Ω (stator winding)
  • Pickup coil air gap: 0.008-0.016″

4. Transmission & Drivetrain

1. Toyota T-4 Manual Transmission

• Shift Rod Adjustment:
  • Neutral position
  • 5/16″ clearance between shift lever and housing
• Synchro Service:
  • 1st gear brass synchro thickness: 0.118″ minimum

1. C3 Automatic Transmission

• Band Adjustments:
  • Low/reverse band: 10 ft-lbs + 3.5 turns
  • Intermediate band: 10 ft-lbs + 2.5 turns
• Governor Service:
  • Clean with solvent (no abrasives)
  • Weights must move freely

5. Suspension & Steering

1. Front MacPherson Strut Rebuild

1. Remove strut assembly (150 ft-lbs spindle nut)
2. Spring rate verification: 450 lb/in (V8: 500 lb/in)
3. Upper bearing preload: 18-22 in-lbs

1. Rear Leaf Spring Service

• Center pin replacement (Grade 8 bolt required)
• Shackle angle: 45° ±5° under load

1. Steering Gearbox

• Worm bearing preload: 4-6 in-lbs
• Sector shaft lash: 0.003-0.005″

6. Brake Systems

1. Disc Brake Service

• Caliper slide pin torque: 22-26 ft-lbs
• Rotor runout limit: 0.003″

1. Parking Brake Adjustment

1. Raise rear wheels
2. Adjust star wheel until slight drag
3. Verify 7-9 clicks at lever

7. Electrical Systems

1. Charging System

• Alternator Test (1976+):
  • Load test: 13.5-14.8V at 2,000 RPM
  • Diode trio resistance: 0.3-0.9Ω

1. Fusible Links

• Main link (red 14ga): 30A capacity
• Replace with Ford P/N D2AZ-14526-A

8. Body & Corrosion Repair

1. Rust Treatment

• Common Areas:
  • Strut towers (apply 3M 08307 seam sealer)
  • Trunk floor (0.8mm galvanized steel patch)
• Paint Code Reference:
  • 9F = Medium Yellow
  • 6L = Bright Red

1. T-Top Maintenance (King Cobra)

• Drain tube cleaning (5/16″ OD tubing)
• Seal replacement (CRL T-174 kit)

9. Performance Upgrades

1. 302 V8 Modifications

• Camshaft selection: <0.450″ lift (stock valve spring limit)
• Exhaust header install (Hooker 6911HKR)

1. Handling Improvements

• Sway bar upgrade: 1.125″ front (stock: 0.875″)
• Polyurethane bushings (Energy Suspension 4.3154G)

10. Troubleshooting Matrix

11. Torque Specifications

12. Fluid Specifications

13. Special Tools List

• Valve spring compressor (OTC 4576)
• Crankshaft balancer puller (OTC 6667)
• U-joint service kit (OTC 7249)

14. Safety & Compliance

• Asbestos warning (brake components)
• EPA guidelines for fuel system service
• California emissions exceptions

15. Appendices

• A1: Metric/SAE conversion chart
• A2: Wiring color codes (1974-1978)
• A3: Factory service bulletin index

16. Advanced Engine Repairs

2.3L Lima I4 Overhaul

Piston Ring Gap Specification:

Camshaft Bearing Clearance:

• Journal Diameter: 1.868-1.869″
• Bearing ID: 1.871-1.872″
• Oil Clearance: 0.0015-0.0030″

Critical Tools:

• Ford Rotunda 014-00006 (Timing belt tension gauge)
• Lisle 15000 (Valve spring compressor)

17. Transmission Deep Dive

C3 Automatic Rebuild

Clutch Pack Clearances:

Valve Body Test:

1. Apply 30 PSI air to cooler line port
2. Verify servo piston movement within 0.5 sec

18. Fuel System Special Procedures

Tank Replacement (1974-1976)

1. Drain fuel (14.5-gallon capacity)
2. Disconnect filler neck clamp (3/8″ hose)
3. Remove 6 body-mounted straps (9/16″ bolts)
4. Inspentorque savers (Dorman 904-303)

Vapor Lock Prevention:

• Install phenolic carb spacer (1″ height max)
• Wrap fuel lines with DEI 010408 heat shield

19. Climate Control System

A/C R12 to R134a Conversion

1. Flush system with AC-Renew II
2. Replace receiver-drier (Four Seasons 33455)
3. Charge: 80% of original R12 quantity
4. Oil: PAG 46 (5 oz total capacity)

Heater Core Replacement:

• Dash removal time: 3.8 hrs (certified tech)
• Evaporator drain tube check: 5/16″ ID clear tubing

20. Exhaust System

Catalytic Converter Service

• 1975-1978 Federal models only
• Backpressure test: <1.5 PSI at 2,500 RPM
• Replacement: Walker 52264 (2.25″ inlet/outlet)

Header Installation Tips:

• Use Stage 8 locking fasteners (M10x1.5)
• Re-torque after 3 heat cycles (35 ft-lbs)

21. Wiring Harness Repair

Connector Types:

• 56-series (Fuel pump)
• 80-series (DuraSpark module)

Splice Protocol:

1. Strip 3/8″ insulation
2. Apply 3M 3851 adhesive-lined heat shrink
3. Seal with Tesa 51036 tape

Ground Points:

• Battery to body: G100 (RH shock tower)
• Engine to frame: G201 (Bellhousing bolt)

22. Trim & Molding Restoration

Cobra II Decal Application:

1. Surface prep: 3M 08984 cleaner
2. Positioning: 2″ from wheel arch
3. Squeegee angle: 45° with firm pressure

Opera Window Sealant:

• 3M 08611 Urethane (1/4″ bead)
• Cure time: 72 hrs before washing

23. Factory Recall Compliance

Critical Campaigns:

1. 74C06: Fuel filler neck corrosion
   • Repair: Install plastic shield (F1ZZ-9C065-A)
2. 77B12: Seatback latch failure
   • Replacement kit: D7ZZ-6361348-B

24. Diagnostic Flowcharts

No-Start Condition:

1. Verify fuel (pump relay click)
2. Check spark (HEI test light method)
3. Test compression (120 PSI minimum)
4. Inspect timing belt alignment

Vibration at Speed:

1. Tire balance (static/dynamic)
2. U-joint inspection (0.010″ play max)
3. Driveshaft runout (0.030″ limit)

25. Metric Conversion Data

26. Lubrication Guide

Chassis Points (Every 12k mi):

• King pins: NLGI #2 lithium (4 pumps)
• U-joints: Ford C1AZ-19578-B grease

Door Hinges:

• White lithium spray (3M 08946)
• Cycle 5x after application

27. Shop Safety Protocol

Asbestos Handling:

1. Wet components before removal
2. Use NIOSH-approved respirator
3. Dispose in sealed OSHA-compliant bags

Spill Control:

• Oil: Tarball TL-718 absorbent
• Gasoline: Chemtron 2C8 neutralizer

28. Factory Recommended Tools

29. Technical Service Bulletins

TSB 77-12-09:

• Issue: Cold start hesitation
• Fix: Replace thermactor spacer gasket

TSB 78-04-15:

• Issue: Speedometer fluctuation
• Fix: Reprogram cable drive gear

30. Restoration Case Study

1976 Cobra II Resurrection:

1. Disassembly: 85 hrs (tag all fasteners)
2. Metalwork: 40% floor pan replacement
3. Paint: Basecoat/clearcoat (3-stage)
4. Reassembly: 250 hrs (using factory AIM)