Ford COUGAR 1968 Shop Manual page 660

PART 15- .3
-
Instrument Cluster, Gauges And Controls
15-45
the battery ground cable.
2. Remove the instrument panel
pad (Refer to Group 18, Part I).
3. Remove the eight screws retain-
ing the cluster to the instrument panel
and position the cluster out. Discon-
nect the speedometer quick disconnect,
by pressing the ribbed sections of the
plastic ring inward to disengage the
catch and pull the cable from the
speedometer head. Unplug the fuel
gauge terminal wires, the multiple
connectors to the printed circuit and
convenience control lights, i f so equip-
ped. Disconnect the heater switch, heat-
er control cables, and the clock, if
so equipped. Remove the cluster.
4. Remove the heater control and
switch knobs. Remove the seven screws
retaining the back of the cluster and
remove the cluster back (Fig. 14,
Part I).
5. Remove the two nuts retaining
the fuel gauge assembly to the instru-
ment cluster and remove the assembly.
6.
Unsnap the ornament from the
center of the gauge assembly.
7. Remove the three screws retain-
ing the gauge finish cover and care-
fully remove the cover.
INSTALLATION
1. Position the finish cover to the
fuel gauge and install the three retain-
ing screws. Be careful not to damage
the hand of the gauge.
2. Snap the ornament into the
center of the gauge.
3. Position the fuel gauge assem-
bly to the cluster, and install the two
retaining nuts.
4. Position the back to the clus-
ter and install the seven retaining
screws. Install the knobs on the heater
controls and switch.
5. Connect the multiple plugs to
the printed circuit, fuel gauge terminal
wires and the convenience control
lights, i f so equipped. Push on the
speedometer cable connector until it
snaps into place. Connect the heater
control cables, heater switch, and the
clock, if so equipped.
Position the cluster to the instru-
ment panel and install the eight retain-
ing screws.
6.
Install the instrument panel pad.
7. Connect the battery ground ca-
ble and check the operation of the fuel
gauge.
FUEL GAUGE AND
TEMPERATURE GAUGE-
COUGAR, COUGAR XR-7
AND MUSTANG
The fuel and temperature gauges
are replaced as a unit.
I . Remove the instrument cluster.
See Instrument Cluster Assembly -
Cougar.
2. Remove the nine rear cluster
housing retaining screws. Remove the
rear cluster housing and gauges.
3. Remove the four nuts retaining
the gauge assembly to the housing
and remove the gauge assembly.
4. Position the gauge assembly in
the cluster rear housing and install
the four gauge retaining nuts.
5. Position the cluster rear hous-
ing assembly to the cluster and in-
stall the nine retaining screws.
6. Install the instrument cluster in
the instrument panel.
FUEL SENDING UNIT
1. Remove the fuel from the fuel
tank.
2. Disconnect the fuel gauge send-
ing unit wire from the sending unit.
3. Loosen the hose clamp and dis-
connect the tank line at the sending
unit.
4. Remove any dirt that has ac-
cumulated 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 re-
moved.
10. Check the fuel gauge opera-
tion and check lor leaks.
IGNITION SWITCH-
ALL MODELS
I. Disconnect the battery ground
cable from the battery.
2. Insert the ignition key in the
switch. Turn the switch to the ac-
cessory position. Insert a wire pin in
the hole on the ignition switch. Slight-
ly depress the pin while turning the key
counterclockwise past the accessory
position. This will release the lock
cylinder from the switch assembly.
Pull out the lock cylinder with the key.
If only the lock cylinder is to be re-
placed, proceed to step 8.
3. Remove the bezel nut with tool
T65L-700-A (Fig. 9).
4. Lower the switch assembly from
the instrument panel and remove the
FIG.
9-Ignition Switch Connector
Removal
accessory wire retaining nut and de-
press the .tabs securing the multiple
connector to the rear of the ignition
switch with a modified tool 18918-A
(Fig. 10). The modification of the tool
consists of grinding the inside of the
tool jaws to allow clearance around
the rear of the switch. Pull the multi-
ple connector from the switch and re-
move the switch.
5. To install the switch, depress
the tabs on the multiple connector and
plug the connector into the switch as-
sembly, being sure that the tabs lock
in place.
6. Position the switch in its re-
tainer and install the bezel nut.
7. Insert the key in the switch
assembly and turn the key to the ac-
cessory 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 cylin-
der operation.
8. Connect the battery ground cable
to the battery and check the operation
of the switch assembly.
INSTRUMENT CLUSTER-
FAIRLANE, FALCON AND
MONTEGO
The removal and installation proce-
dure for the Fairlane, Falcon and
Montego con be found in the printed
circuit removal and installation pro-
cedures. The appropriate printed cir-
cuit procedures are located in Part 5
of this Group.
INSTRUMENT CLUSTER
COUGAR AND COUGAR XR-7
REMOVAL
Instrument cluster components are
accessible by removing the cluster as
an assembly.
1. Disconnect the battery ground
cable from the battery.