Ford Service Letters
Note: Ford produced these Service Letters for dealers. They were intended to give fixes to problems found as experience grew in servicing the cars. To avoid copyright problems I have re-worded the original Service Letters.
If anyone has any additional Service Letters, I will add to these, as time allows. There are about 30 (I think ??).
Service Letter Number:- 16
Dated:- 3rd May 1966
All Cortinas (except G.T. and Lotus)
Disk Brake Pad Life
Poor disk brake pad life is being experienced, particularly when driven in mountainous regions.
A brake pad of larger swept area has been introduced to all Cortinas, (except Standard, G.T. and Lotus) in production since about the start of September 1965.
You are advised to fit the newer parts (kit 113E-2K021-B) where problems are occurring with poor brake pad life.
(The "old" pad had a straight edge closest to the axle, while the "new" pad has a semi-circular shaped end closest to the axle).
When fitting the new pads make sure that the brake disk is not damaged or corroded. The recommendation was to "scrape clean with a pen knife or a similar instrument. Do NOT use emery cloth.
Ensure that both calipers are fitted with the same type of pad, otherwise pulling to one side will occur.
Cortina Range:-
Service Letter Number:- 21
Dated:- 4th July 1966
Clutch Adjustment
In production (the Cortina range of cars) the clutch free play setting is now 1/8th inch, and this new setting should be used when new clutch discs are fitted in service. This setting should be maintained for the first 500 miles and then re-set to 1/16th inch at all future services.
NOTE: Also applies to Anglia range.
Service Letter Number:- 22
Dated:- 5th July 1966
Battery Continually Running Down
(Cortina 1500cc in-line engine, Automatic Transmission ONLY)
The battery continually runs down due to inadequate charging, generally because of stop/start work and slow driving in towns.
A smaller generator (dynamo) pulley and a shorter fan belt will be introduced to production models:-
Pulley 118E 10130-A (Metal pulley is spot welded around the hub whereas the 105E-10130-A for domestic use is plastic, and the 105E-10130-B export is metal and riveted around the hub.
Fan belt 118E-8620-A should be paint stencilled on the outside edge of the belt. Original belt 105E-8620-A has no markings.
NOTE: If these parts are fitted to manual transmission cars, especially G.T. cars where high engine speeds are likely to be used continuously, it is possible for the generator (dynamo) to be over-revved.
Service Letter Number:- 23
Dated:- 5th July 1966
Rear Wheel Brake Cylinder (Cortina Lotus)
An improved balance between front and rear wheels can be obtained by fitting 0.70 inch (17.8mm) diameter rear wheel brake cylinder in place of the 0.75 inch (19.1mm) diameter cylinder.
A new cylinder of 0.70 inch has been used in production since the 1st week in April (1966). The "old" brake cylinder was 0.75 inch.
Part number 2920E-2261-C 0.70 inch cylinder is identified by two ridges on the cylinder body and a cast "7" on the body near the bleed valve, so that it can be seen from outside the brake assembly back-plate.
It is permissible to fit 0.70 or 0.75 inch IN PAIRS to any one car. It is NOT permissible to fit one of each size to opposite wheels on one car.
NOTE: This also applies to the Corsair car.
Service Letter Number:- 25
Dated:- 7th October 1966
Spark Plug Gaps
In production on 1200cc and 1500cc engines (not G.T.) engines the spark plug gap is set to 20 to 24 thou to facilitate cold starting.
When servicing spark plugs for the above engines the gap between the electrodes should be set between 20 and 24 thou. Also ensure that the central electrode is flat, if necessary use a suitable file.
New spark plugs for the above engines part numbers C4PF-12405-AF type AG32A will be supplied set to the original gap, 23 to 27 thou. If necessary re-set the gap to the revised setting.
No change has been made to the gap settings for the G.T. engines.
NOTE: This also applies to Anglia and Corsair ranges of vehicles.
Service Letter Number:- 27
Dated:- 29th November 1966
Fitting a Flywheel ring gear - Cortina Range
Revised fitting instructions were issued.
When fitting a new ring gear it must be heated evenly to a temperature not exceeding 600° F (316°C) otherwise the ring gear's wear-resistant properties will be destroyed. If the ring gear is to be heated on a naked flame, place the ring gear on a bed of fire-bricks and then play the flame in a circular motion onto the bricks about 1/4 inch to 1/2 inch from the inside of the gear until it reaches the required temperature.
DO NOT PLAY THE FLAME DIRECTLY ONTO THE RING GEAR !
The correct temperature can be detected by using either:
Fit the ring gear with the un-chamfered side (the thrust face) of the gear teeth on the left side when viewing from the front of the engine. Allow the ring gear to cool naturally. DO NOT QUENCH !
This information also applies to
(I would think this applies to all Cortinas, Capri/Classics, and Anglia too -- Tommy).
Click here to return to the Welcome Page
Page last updated:- 19 May, 2006 14:49