Ford Fairlane 1968 Service & Repair Manual

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Basic Information Identification Make: Ford Model: Fairlane Year: 1968 Generation Generation: Fifth Generation (1966-1967) Codes Platform: Ford D-platform Introduction Market Position Market Position: Mid-size family car/personal luxury car, positioned as...

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Description

Basic Information
Identification
Make:	Ford
Model:	Fairlane
Year:	1968
Generation
Generation:	Fifth Generation (1966-1967)
Codes
Platform:	Ford D-platform

Introduction
Market Position
Market Position:	Mid-size family car/personal luxury car, positioned as a more affordable alternative to larger Ford models like the Galaxie, and a more stylish option than compacts of the era.
Competitive Analysis
Competitors:	Chevrolet Chevelle, Plymouth Satellite, Dodge Charger, Pontiac GTO (though often positioned slightly differently).
Key Features
Key Features:	Stylish, modern design for its time, available with a range of powerful V8 engines, comfortable ride, versatile body styles (sedan, hardtop coupe, convertible, station wagon).

Manual Details
Coverage Areas
Coverage Areas:	All mechanical and electrical systems, bodywork, and maintenance procedures for the 1968 Ford Fairlane.
Page Count
Page Count:	Hundreds of pages (exact number not specified, typical for a comprehensive factory service manual).
Manual Type
Manual Type:	Factory Service and Repair Manual
Language
Language:	English
Format
Format:	Digital PDF
Searchability:	Searchable PDF allows for quick access to specific topics.
Print Functionality:	Ability to print specific pages or sections as needed for workshop use.

Manual Coverage
Systems Covered
Engine Systems:	Engine teardown and reassembly, lubrication, cooling system, fuel system (carburetor, fuel pump, lines), ignition system (distributor, coil, spark plugs, wiring), exhaust system, engine tuning, emission control systems (if applicable for the era).
Transmission Systems:	Manual transmission (clutch, gearbox, linkage, fluid), Automatic transmission (C4, C6 - fluid, torque converter, valve body, seal replacement, general operation, troubleshooting).
Drivetrain Systems:	Driveshaft, universal joints, rear axle assembly (differential, axle shafts, bearings, seals), wheel bearings.
Suspension Systems:	Front suspension (ball joints, control arms, springs, shock absorbers, steering linkage), Rear suspension (leaf springs, shock absorbers).
Steering Systems:	Steering gear (manual and power steering components, pump, hoses, linkage), steering column.
Brake Systems:	Drum brakes (front and rear), disc brakes (front on some models), master cylinder, wheel cylinders, brake lines, parking brake system, brake fluid specifications.
Electrical Systems:	12-volt electrical system, battery, alternator/generator, starter motor, ignition switch, lighting system (headlights, taillights, turn signals, interior lights), instrument cluster, wiring diagrams, fuses, relays, horn.
Body And Chassis:	Frame inspection and repair, body panel alignment, doors, windows, locks, interior trim, bumpers, grilles, weatherstripping.
Chassis And Frame:	Inspection, repair, and maintenance of the unibody construction (for most body styles) or body-on-frame (for station wagon). Includes frame straightening and reinforcement procedures.
Procedures Included
Maintenance Procedures:	Oil changes, lubrication points, filter replacements (oil, fuel, air), coolant flushes, spark plug replacement, tune-up procedures, brake adjustments, battery maintenance.
Repair Procedures:	Engine component replacement (carburetor, fuel pump, water pump, alternator, starter), transmission overhaul, differential rebuild, suspension component replacement, brake system repair, electrical component troubleshooting and replacement, body panel repair and replacement.
Troubleshooting Guides:	Systematic diagnosis of common problems, symptom-based troubleshooting, diagnostic charts.
Specifications And Tolerances:	Torque specifications for critical fasteners, engine timing, valve lash adjustments, clearance measurements, fluid capacities.
Engine Rebuild Procedures:	Detailed steps for complete engine disassembly, inspection of engine components (pistons, rings, bearings, crankshaft, camshaft), cylinder head reconditioning, valve replacement, and reassembly with proper clearances and torque values.
Transmission Rebuild Procedures:	Instructions for complete overhaul of both manual and automatic transmissions, including component identification, seal and gasket replacement, valve body servicing (for automatics), and proper assembly techniques.
Technical Depth
Technical Depth:	Comprehensive, covering from basic maintenance to complete engine and transmission overhauls. Includes detailed disassembly, inspection, repair, and reassembly instructions.
Illustrations And Diagrams:	Includes hundreds of illustrations, diagrams, and photographs to visually guide repair and maintenance procedures.
Manual Type
Manual Scope:	Comprehensive factory service manual, not an owner's manual or condensed repair guide.

Manual Specifications
File Format
File Format:	PDF
Print Quality
Print Quality:	Printable pages. (Quality of original illustrations may vary based on scanning of original source material).
Binding Type
Binding Type:	N/A (Digital PDF)
Paper Type
Paper Type:	N/A (Digital PDF)

Engine Specifications
Primary Engine
Base Engine:	200 cubic inch (3.3L) Inline-6
Optional Engines:	289 cubic inch (4.7L) V8, 302 cubic inch (4.9L) V8, 390 cubic inch (6.4L) V8, 428 cubic inch (7.0L) V8 (Cobra Jet).
Performance
Horsepower Range:	120 hp (Inline-6) up to 335 hp (428 Cobra Jet)
Torque Range:	Approx. 190 lb-ft (Inline-6) up to 460 lb-ft (428 Cobra Jet)
Fuel System
Carburetion:	Single-barrel (Inline-6, 289, 302), Two-barrel (302, 390), Four-barrel (390, 428 Cobra Jet).
Ignition System Type:	Conventional breaker point ignition system with distributor, coil, and spark plug wires.

Transmission
Standard
Standard Transmission:	3-speed manual transmission
Optional
Optional Transmission Automatic:	3-speed Cruise-O-Matic (C4, C6)
Features
Transmission Features:	Column shift for automatic transmissions, floor shift optional on some manual and performance models.

Dimensions
Exterior
Wheelbase:	116.5 inches
Overall Length:	Approximately 199.9 inches (varies slightly by body style)
Overall Width:	Approximately 75.0 inches
Overall Height:	Approximately 53.0 - 54.0 inches (varies by body style)
Weights
Curb Weight Range:	Approximately 3,100 lbs to 3,800 lbs (varies by engine and body style)

Safety Features
Ratings
Safety Ratings:	No formal crash test ratings available from modern agencies for vehicles of this era.
Active Features
Active Safety Features:	Brake system (drum or front disc), steering system.
Passive Features
Passive Safety Features:	Lap seat belts (front standard, rear optional), padded dashboard (in later production), safety-glass windshield.

Technology Features
Infotainment
Infotainment System:	AM/FM Radio (optional), AM Radio (standard). Some models may have had dealer-installed options like 8-track tape players.
Driver Assistance
Driver Assistance Features:	Power steering (optional), Power brakes (optional, usually with front discs).
Connectivity
Connectivity Features:	N/A (No electronic connectivity features in the modern sense).

Maintenance
Service Intervals
Oil Change Interval:	Recommended every 3,000 to 5,000 miles or 6 months, depending on driving conditions. (Refer to manual for specific recommendations).
Tune Up Interval:	Typically every 10,000 to 12,000 miles for spark plugs, points, and condenser (if applicable).
Fluid Specifications
Engine Oil Specification:	API Service SE or SF recommended (or equivalent for the era, e.g., MS rating). Viscosity typically 10W-30 or 10W-40, depending on ambient temperature. (Manual will specify exact grade).
Coolant Specification:	Ethylene glycol-based antifreeze. Typically a 50/50 mix with distilled water. (Manual will specify capacity and type).
Transmission Fluid Automatic:	For C4/C6: Type F (Dexron was not yet prevalent). Consult manual for exact specification.
Transmission Fluid Manual:	GL-4 rated gear oil, typically SAE 80 or 90. (Consult manual for specific type and capacity).
Brake Fluid Specification:	DOT 3 or DOT 4 brake fluid.
Rear Axle Fluid:	Hypoid gear oil, typically SAE 90 or 85W-90. Limited-slip differential (if equipped) would require specific additive. (Consult manual for exact spec).
Known Issues
Common Wear Items:	Ball joints, tie rod ends, bushings (suspension and steering), universal joints, water pumps, fuel pumps, starter solenoids, carburetor issues (float adjustment, gaskets).
Electrical Issues:	Aging wiring harnesses, voltage regulator issues (if generator equipped), switch failures (headlight, ignition), brittle insulation on older wiring.
Body Issues:	Rust (especially in lower body panels, wheel wells, frame rails), door seal deterioration, chrome pitting.

Vehicle History
Brand Heritage
Brand Heritage:	Ford Motor Company, a pioneering American automaker with a long history of innovation and mass production dating back to the early 20th century.
Model Evolution
Model Evolution:	The Fairlane was Ford's primary mid-size offering during the 1960s. The 1968 model year saw a significant redesign, moving to a longer, lower, and wider profile, with a coke-bottle styling motif. It continued to offer a wide range of engine and trim options, catering to different market segments from economical transportation to performance-oriented models.
Production
Production Years Fairlane:	1955-1959, 1962-1971
Manufacturing Locations:	Various Ford assembly plants across North America.

Awards & Recognition
Recognitions
Recognitions:	No specific awards for the 1968 model year are widely publicized in the manner of modern vehicles. However, the Fairlane consistently received positive reviews for its styling and performance options in contemporary automotive press.