Falcon Rules for Six cylinder cars 1960-1965

 

Phil Barber

61 Advisor, FCA

Annapolis, MD

 

 

1. Engine Block and cylinder head

 

Visual identification- The 144/170 engines have 3 water jacket freeze plugs which are visible directly below the exhaust manifold. The 200 cubic engine has 5 freeze plugs.

Color of block and head assembly: Gloss Black (Hi-Temp)on all engines. The only exception is as follows: After June 1, 1965 production date 200 C.I. engines (the entire assembly including valve covers and breather) were a medium Ford blue except the 289-it was Gloss black with Gold Valve Covers and air Cleaner(Gloss Black snout).

 

Note: Some exceptions have occurred on cars after the June 1st 1965 date. Such as- an original owner, never touched car with a 170 engine. It came from the factory with Ford medium blue block and cylinder head with red/orange valve cover and breather.

 

Color of Valve Cover and Air breather:

144-Ford medium Blue

170-Red/Orange

200-Red/Orange (after June 1, 1965 production date entire engine Ford Medium Blue)

 

Recommended Paint codes:

Red-Orange, Dupli-Color DE-1605 or Martin Seynour 7892

Ford Medium Blue, Dupli-Color DE-1606 or Martin Seynour 7958

Engine Black, Dupli-Color DE-1613 or Martin Seynour 7882

 

Colors of paint (other than body color) used in the engine compartment. These are all readily available at places like Trak Auto or Auto Zone.

 

Krylon Semi-Gloss Black code#1613 (used anyplace we refer to semi-gloss black or chassis black)

 

Dupli-Color Hi-Temp Engine Black-code# DE 1613 (For Block and Heads)

 

Dupli-Color Red-Orange code#DE-1605 for valve covers and air breathers on 170 & 200 cubic inch.(until June 1st 65) and the 63 260 V8 (sprint has chrome)

 

Dupli-Color Blue code#DE1606 for valve covers and air breathers on all 144 cubic inch, the 64 260 V-8 (sprint has chrome), the 65 170 &200 after June 1st 65, and "ALL" blocks, valve covers, and air breathers 66-70.

 

Note: On paint color for a "White" steering wheel and all the matching knobs- Dupli-Color Truck and Van Paint in 11oz Spray Cans. Code#T-205 (Wimbledon White) is the best match I’ve seen. Plus it is durable.

 

Notes on Air Breathers:

*The 60 Falcon breather had no air horn (snout)

*The 60 & 61 unit used a clamp on the base of the air cleaner housing to clinch it the carburetor. The snout is supposed to point to the roadside of the car(drivers side)It has a long wing-nut style bolt that protrudes to the front to tighten it with.

*62 and up sixes have a bolt attached to the top of the carb that protrudes through the top of the air cleaner with a wing-nut.

 

2. Exhaust Manifolds:

60-62 used a flat gasket between the manifold and exhaust pipe, the later ones (63-65) all used a donut style gasket there. All used the exhaust manifold locks on the manifold to head bolts. Bolts and locks are a "natural finish" The 200 exhaust manifold is thicker (more capacity) in the 3-4 cylinder area and takes longer bolts at that location than the earlier manifolds. They all have same bolt pattern, however the 200 exhaust pipe is a larger diameter, so would not fit an earlier car unless the exhaust pipe was also changed.

Part Numbers:

1960-62……C2GZ9430A

1963-66……C3OZ9430A

1967-70……D3BZ9430A

Note: In 1965 Ford Engineers designed a new type of exhaust manifold bolt which incorporates its own washer. These are called RAMP-LOK and are correct for 66 and up vehicles. If you use choose to use these on earlier engines they do not keep loosening up and you need not use the aforementioned exhaust manifold locks (the ones with the little "ears"). These RAMP-LOK bolts are available in kit form for all model years from Falcon vendors-namely Melvin’s Classic Ford parts or Auto Krafters.

 

3. Intake manifold-This is integral to the cylinder head and is painted the same color as the head.

 

4. Carburetors: The Falcon sixes all used a one-barrel unit. There is probably a couple dozen different applications. The 144, 170, and 200 cubic inch engines all use units which look similar, however they differ in main metering jet sizes and the venturi size. It is possible to interchange them, however you will get the best performance from the carburetor engineered for the engine in question. A synopsis of the two basic types is presented here.

Notes on the Holley Carburetor 1904, 1908, and 1909 models

*The 1904 was used on 1960 Falcons and can be recognized by its glass float bowl (some may be zinc vs. glass). *All 1960 & 1961 Falcons had manual chokes.

*In 1961 the Falcon got the 1908 model

*The 1909 was used on 1962 144/170 falcons. (it is physically tiny compared to the others)

CFM ratings are posted below:

Model 1904, 1960 144,170 are 130/150CFM respectively.

Model 1908, 1961 144,170 are 130/150CFM respectively

Model 1909, 1962 only, 144/170 are 125/150CFM respectively

*At the beginning of the 1963 production year Ford switched to the Autolite 1100 and 1101 series.

Identification-Look for the engineering numbers and list numbers located at the fuel inlet. You may need a magnifying glass, but you need those numbers to get the correct replacement unit.

 

Autolite 1100/1101 1 Barrel:

This was introduced in 1963 and was used on all 144/170 and 200 cubic inch engines. Ford made different venturi sizes for each engine. All carburetor bores are 1 and 7/16 inch. A teflon type insert is placed in the bore to adjust the true venturi size. The 144 used a 1.0 inch, the 170 a 1.10 inch and the 200 a 1.20 inch venturi.

Notes on the autolite series

*All of these were manual choke until the 65 model year.

 

Identification:

*On this model the engineering number is stamped in the base area near the throttle shaft arm. If you can’t find a number use the below rules.

  1. Through 1967 production year- manual trans cars had one diaphram on the side of the float bowl. Auto trans cars had two-the second acting as an anti-stall dashpot.
  2. Locate the area where the spark control valve is. (Passenger side towards rear of carburetor) Presence of spark control valve means 1963-67, no spark control valve means 1968 and 1969 (or 1966-67 California Emissions)
  3. Remove the top and measure the venturi diameter. 1.20" means 200 C.I., 1.10" means 170 C.I. and 1.00" means it’s a 144 unit.

Note: The final authority on Ford carburetors is Pony Carburetors,2001 Delphi Road, New Woodstock, NY 13122. They make an excellent pocket sized guide which lists all the engineering numbers and list numbers. They also rebuild carburetors. Plus if your numbers are not in the book they can find out what it is and whether or not it can be used on your application.

 

5. Fuel Pumps- The 1960-70 Falcon six used four different pumps. They first may be divided into two categories-single action or dual action. The single action: used on cars with electric wipers. The dual action (or sometimes referred to as dual diaphragms). This is used with vacuum wipers. The extra diaphragm is used to keep wipers working when engine (manifold) vacuum is low. The various choices are listed with brief descriptions and part numbers. Listings are for 144, 170,and 200 cubic inch engines only.

1960-62 with vacuum wipers (dual diaphragm) part number 4896-9350. Most of these units will have a glass sediment bowl on the bottom.

1960-62 with electric wipers (single diaphragm) part number 6491-9350

    1. These units have a filter cannister on the bottom. Part number 6837-9350
    1. Part number 6399-9350

 

Note: Fuel pumps are all cast aluminum alloy and are natural in color. The replacement fuel filter cannisters are available in exact reproduction colors-red or white.

 

6. Generators (all 60-65 six cylinders) These units are painted a semi-gloss black. The pulley is a natural steel in color. A generator splash shield is available. This may be installed on any generator-part# C1AB-10170B

 

30 Amp unit-part number C1DZ-10002C

35 Amp Unit-part number C1DZ-10002A

 

7. Voltage Regulators- These have a natural metal color base and a gloss black cover which has a decal with a Ford Oval and other Regulator info. Part numbers are below.

25 Amp unit C3DZ-10505-A

30 Amp unit C3TZ-10505-B

35 Amp unit C2AZ-10505-C

 

Note: Some units from 65-67 have an Autolite decal vs. a Fomoco decal.

 

8. Starter Motors and Solenoids: All 1960-70 six cylinders used the same starter except the 66-70 with manual transmission is unique. All are painted a semi-gloss black. The starter solenoids come basically two ways- the ones that are a brown bakelite with natural metal bracket are for 60-64 models. The black bakelite with natural finish metal brackets are for 65 and up Falcons. Reproductions have been noted with a variety of supposedly accurate markings on the bracket which are visable from above. These markings with colors are described below:

60-64 Fomoco script, FDR-8150-A, and RBM on bracket, brown body

65-66 Fomoco script, 2701966, and RBM on bracket, black body

 

9. Battery Cables: Most of our advertisers carry reproduction battery cable sets which include the solenoid to starter cable. As a general rule a red positive cable with black negative and solenoid to starter cables will suffice. Just ensure they are long enough to be routed correctly/neatly. Photographs displaying these routings are displayed in the appropriate shop manual for each year. Part numbers of these cable sets are as follows:

    1. six cyl w/o a/c C3DZ-14300

1964-65 six cyl C4DZ-14300A

 

 

 

  1. a. Distributors-all have a cast aluminum body and are unpainted. The caps are black in color. The ‘60-’64 144/170 had a ¼ inch allen style hole in the base of the shaft to accept the oil pump drive shaft. Part number C2DF-12127. The 64-67 170/200 had a 5/16 inch allen style hole in the base of the shaft to accept the oil pump drive shaft. Part number C4DF-12127. The 65-70 200 with themactor emissions control and single vacuum used part number C7DF-12127.
  2. b. Coil- Falcons produced before mid ’63 come equipped with what is referred to as the "mustard top" coil. The Ford part number is FAC-12029-A and was rubber-stamped, in pale silver point, with all the technical information pertaining to it on the side. The coils used prior to 1962 used the Ford script within the oval emblem, situated between the lines of info, and all of the paint was contained within a rectangular border. Beginning with the 1962 models, the capitalized and printed AUTOLITE design was used, though some script/oval were used. In fact, a combo of both the autolite and Ford script emblems were sometimes used. (The variances seem to depend on the place of manufacture.) The combination of the two logos are somewhat hard to find and seem to be found on the ‘64-’65 era engines . The name "mustard top" results from the coils dried mustard colored bake-lite top (where the coil wire slips in). Not until mid-1963 were the black bake-lite topped coils introduced, though the mustard top coils were also used until, apparently the stock of the older (and older appearing) "mustard top" coils was depleted. The mounting strap for the coil is black or in a gray metal color. Part number C0AF-12043-A.

     

    c.Wiring:The wires to the spark plugs and coil are also black. Part numbers for the

    wiring are as follows: Spark Plug Wiring Set (black) 60-70 six cylinder C30Z-12259F. Coil to distributor: C30Z-12298-B.

     

  3. Master Cylinders: Originally the 60-64 had a "fruit jar" style domed top in a copper finish. These units occasionally become available when a vendor buys out an old Ford dealership. The ones most commonly found have a bright metal finish on the cap. The main body is a cast iron finish. The part number is M32900 for standard drum brakes. For ‘64-’65 with power brakes the number is M39626. Sometimes the replacement units will have the caps with a "gold" anodized appearance.
  4.  

  5. Radiator/hoses/heater hoses and heater blower motor: The standard radiator is what is referred to as a two-row unit. Heavy duty ones with three rows may be purchased from most vendors. It is painted a gloss black. The overflow hose is black rubber and is press on to fit with no clamp. The radiator hoses are molded to fit black rubber marked in white with FoMoCo script in oval. 60-62 used heavy pinch type wire clamps(which require special "water pump" pliers to remove. 63- early 64. Dual wire type clamps used late 64 and 65. Non-air cars use a four bladed fan in gloss black. Air-conditioned cars use a 6-bladed fan which is gloss black. The six cylinder has no shrouding around the radiator. The radiator caps are a zinc finish, stamped S.M.Co.part# C4AZ-8100Z. The rivet in the center of original ones is brass. Heater hoses: Black with white stripe. 60 –62 used the pinch-type wire clamp. Later models used the pedestal style clamp. Transmission coolant lines: 60-65 pinch type wire clamp or pedastal clamps. The heater blower motor is gloss black and the speed nuts securing it to the firewall should be an unpainted zinc finish.
  6.  

  7. Hood Hinges: 60-65 The hinges and springs where installed are a dark color(dark gray-black) appears to be a heat treated steel. The 60-62 hood support rod(no hinge springs) is semi gloss black. Radiator support bracket has decals to indicate the proper placement of the stowed support rod. One at center top and one over the top of the tip. The latch mechanism(on hood) is a natural finish. Its receptacle on the radiator support is semi-gloss black.
  8.  

  9. Polaraire Conditioner (optional): On six cylinder cars the compressor is mounted in an upright position on the curb-side of the engine. This causes the relocation of the battery to the driver’s side on so equipped cars. The compressor is painted black. After market units, such as Sears & Roebuck sold basically the same compressor, but it was mounted in a reclining position on the drivers side and is a natural aluminum color. In stock form this is a very scarce item on six cylinder cars so details are hard to come by. The 60-63 service manual has several pictures, but not all the details are clear.
  10.  

  11. Battery: Standard would be the Autolite Sta-ful (group 24) 10.25"x 6.75"x 9") 54 plate, 40 Amp-Hr. Optional Heavy duty would be the Autolite Sta-ful (group 27) 12’x 6.75" x 9") 66 Plate, 55 Amp-Hr.
  12.  

  13. Fuel Lines/vacuum line and Gas Filters: The rigid fuel lines are mild steel with a natural finish. On the six these lines to include the vacuum advance to the distributor are routed forward and around the front of the valve cover. The fuel feed line has an in line filter just prior to the carburetor. It is connected with two short rubber(for use with gas) fuel lines. They are clamped with the wire style clamps. The vacuum advance line has an upward rising U shaped loop in front of the air cleaner. Photo simulations in appropriate shop manuals display this routing.
  14.  

  15. Engine Mounts: The engine mounts come new or remanufactured as a natural stamped steel with a gray-flat black appearance with natural black rubber insulators. The various part number choices are listed here:

a. Front Mounts-‘60-’62 Right and left CODD-6038F

‘62-’65 Right Hand C4UZ-6038A

‘62-’65 Left Hand C4UZ-6038B

b. Rear Support choices:

    1. C1DZ-6A061-A Insulator, Engine Rear Support-Lower (with Cantilever Spring Type Rear Support); 61-65 ( CID 144, 170,200)
    2. CODD-6068-D Support Assy., Engine Rear, Used without Cantilever support;60-61 (144,170)
    3. C1DZ-6068-A Support Assy., Engine Rear with spring type engine rear support (61-65)

 

  1. Horns: Dual horns were standard. Painted a gloss black. Mounted on diagonal brace which runs from the bottom of the radiator support to the frame horn near the bottom of the shock tower. One has a high tone the other low.
  2.  

  3. General Observations on Engine Compartment:

1960-65 Engine compartment is painted before brake lines, heater blower motor, master cylinder, radiator, horns, or wiring is installed. On the 60-62 the engine compartment is body exterior color. In the case of black cars-the engine compartment is oversprayed again in a semi-gloss black (all 63-65 engine compartments are semi-gloss black). The radiator support assembly is semi-gloss black inside and outside. The underside of the hood is exterior body color. The steering column is painted the same as it is on the inside of the car. Brake lines and attaching hardware are all natural finish. All wiring is connected to the fenderwells with the snap together plastic clips which are simply heated and poked through their associated holes. The bolts which connect the tops of the fenders to the inner fenderwell uni-body are natural finish.

 

Submitted by: Phil Barber, 61 Advisor- FCA Barberpr@Gateway.net

 

 

Note: As one can see a great deal of research was necessary to drag all this together. Please- if you have comments or suggestions to add to or correct any of this –please do so. This is a great forum that David has initiated, so let us make the best of it. Phil

 

 

 

 

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