"MOTOR TRADER" Service Data I No: 2 9 5

FORD CONSUL AND ZEPHYR

MARK II Manufacturers : Ford Motor Co., Ltd., Dagenham Essex

All rights reserved. This Service Data

Sheet is compiled by the technical staff of
MOTOR TRADER and BRITISH AUTOMOBILES
OVERSEAS, and is checked by the vehicle
rianufacturers. It is the copyright of these
journals, and may not be reproduced, in
whole, or in pare, without permission.
..... ...........................................
F
,

OLLOWING th.- well-known Ford

policy of car production, the new
range of Consul and Zephyr models
was introduced in the summer of 1956,
five years after the original Mark I cars
were made. From a service angle, cur­
rent models retain orthodox features of DISTINGUISHING FEATURES. Each of the models of the range is readily
unit consuuction and design which makes identified by the different radiator grille types. Shown above is the Zephyr, Consul
for conformity with other British designs. cars have closer square pattern grille, and Zodiac cars have horizontal slats. Front
Mechanically, the engine units of the two and rear screens are of the wrap-around type and the headlamps are now hooded.
models have been so designed that there
are the maximum number of parts and Tools which are considered most essential tor hoses and lift out radiator core (two
components common to each. The four­ are listed in these pages and many of setscrews each side). Disconnect all
cylindered Consul is now of some 1,703 them will be seen to have alternative pipes, wires and controls, and remove all
c.c. capacity and the six-cylindered Zephyr application to other vehicles in the range. auxiliaries, including combined fuel and
and Zodiac units of 2,553 c.c. swept All threads and hexagons, except those vacuum pump, oil filter, dynamo, car­
volume capacity. Power output has been on a few proprietary components, are of burettor and fan. Take weight of engine
raised as a result of the increase in internal the Unified thread series. on slings round mounting brackets, re­
engine size, and this is transmitted to the move mounting nuts, setscrews round
rear road wheels through the media of a
single dry plate clutch, three-speed syn­ ENGINE bell-housing flange and lower cover from
front of bell-housing, with clutch operat­
chromesh gearbox and three-quarter Mounting ing cylinder. Draw engine fo.nva;:d clear
floating hypoid bevel drive rear axle. As of clutch spigot, and lift out, swinging
is now the case with most production cars, At front brackets bolted on either side
of engine block rest on rubber blocks round to clear body.
there are several options for varying forms
of transmission; overdrive is available as bonded to studs and bolted to front sus­ Manifolds and Cyl, Heads
is also automatic transmission on the pension cross-member.
At rear extension casing bolted to sand­ Ported exhaust pipe, blanked off at rear
six-cylindered cars. These are, as end, clamped directly to ports in cylinder
are ail other components used in the wich rubber block type. Mounting on
cross-member. Tighten all bolts fully. head. Inlet manifold, flange-bolted to
manufacture of Ford cars, of particular head with gaskets, also clamps exhaust
application to the Ford range, but the Removal
pipe. Assemble exhaust pipe to head
basic principles of design shown in Lift out engine, leaving gearbox in (rear clamp welded to pipe) and insert
Trader Service Supplement sheets Nos. place. Detach bonnet, disconnect radia- clamp setcrews finger-tight. Assemble
258/Cl8, 260/Cl9 and 272/CZS will be
found to apply in most cases of service
adjustment or in overhaul.
Cars are numbered in serial and are
prefixed by the letters 204E Consul, 206E
Zephyr and Zodiac. These numbers and
letters are to be found stamped on top
of the offside front suspension support
member under the bonnet. Engines are
stamped with the same prefix and serial
number on the top face of the offside
engine mounting pad when the engines
are installed.
Names of makers of proprietary com­
ponents are not mentioned to avoid con­
fusion. Most of them are well known,
but in many cases the components are
modified to suit Ford requirements and
cannot be serviced with standard replace­
ment parts. For this reason, the Ford
Motor Co. insist that all components
should be serviced through their own INSTRUMENTS, CONTROU, GEAR POSITIONS AND BONNET LOCK.
organization. 1. Direction warning H1ht. (L/H) 9. Screen washer button. 17. Screen wiper control.
Special tools for repair work are made 2. Fuel tank contents cauce. 10. Bonnet releue. 18. Panel licht switch.
3. •�meter 11. Acceleralor. 19. Ignition switch (twist for
and marketed by Messrs, V. L. Churchill 4. Otl pressure waminc ll1ht. 12. Brake pedal. starter).
& Co., Ltd., Great South West .Road, 5. Main beam warninc licht. 13. Clutch pedal. 20. Choke control.
Bedfont, nr. Feltham, Middx., and car­ a. lfnition warninf, licht. 14. Dipper switch. 21. Direction Indicator switch.
7. Water tempera ura gau,,. 15. Handbrake lever. 22. Gear lever.
ried by all Ford dealers. They are de­ 1. Direction warninc light (R/H). 18. Ll&htinc switch. 23. Horn ring.
signed to speed up certain jobs, and in lnnt upper lelt shows position of controls on steerlnc wheel boss and operative positions of cear I•-· Loww
many cases save costly dismantling. left shows exterior bonnet cakh.
 60=: =
ii FORD CONSUL AND ZEPHYR MARK II Supplement to "Motor Trader," 26 March 1958

.,,
Parts of the four-cylindered engine showing both
fixed and moving components. Lower portion
shows in more detail, assembly of crankshaft and
camshaft components, together with valves and
rocker gear.

..
 Supplement to "Motor Trader," 26 March 1958 FORD CONSUL AND ZEPHYR MARK II iii

Timing sprocket (flat face with timing

SPECIAL TOOLS mark to front) and built-up fan pulley ENGINE DATA
Part Nr. (with rubber bushed torsional vibration General
ENGINE Typi ... ... ... o.h.v.

I
damper on Zephyr) keyed on front end
Cylinder haad locating studs P6015
Crankshaft i:ear remover P6039
of shaft with single Woodruff key and
Consul Zephyr
Cranksha!t gear replace, P6032 retained by setscrew and large washer in
Pulley remover .. . .. . ... CP6041 end of shaft (no provision for hand start­ No. of cylinders ... 4
Main bearing liner remover and re- Bore x stroke: mm ... 82.5 X 79.5
8
placer .. ... ... ... P6035 in . .. 3.25 X 3.13
ing). Pulley hub passes through lipped
Valve sprinf compressor P6062 oil seal in timing cover. Capadity: c.c. ... 1703 2653
Valve guide bore reamers P6056 Rear main bearing cap fits in square CU in ... 103.9 155.8
R.A.C. reted h.p. ... 16.8 25.4
CLUTCH AND GEARBOX Max. b.h.p. al r.p.m.
recess in crankcase with rubber seals in
Oil seal remov,ir (main tool) ... 7657 side grooves (assemble with cap) and split 59 � 4200 86 � 4200
Transmiuion mainshall oil seal L.C. 55 4200 80 4200
H.C. ... ...
composition seal in groove fitting round
adaptor .. ... ...
Transmission extension bearing re-
P7657-3 shaft. Sump flange gasket is in four sec­ Max. torque
(lb ft.)
at
r.p.m:
mover and replacer ... P7040 tions, dovetailed together. H.C. ... .. 92 � 2300 138 � 2000
L.C. 87 2300 128 2000
.
To remove sump on Zephyr, discon­ ...
placer ... ... ... . .. P7064 Compression �aiio
Transmission mainshaf� oil seal re-
Main drive gear bearing remover and H.C. 7.8 : 1
nect anti-roll bar U-bolts, and pull bar ... ...
replace, .. P4000·22 down to clear front of sump. L.C. ... 6.9 : 1
Dummy layshaft .. . ... ... P7048
...
Shifter shaft and overdrive control Connecting Rods
shaft oil seal teplacer P7056
Big ends thin wall, steel-backed, white. CRANKSHAFT AND CON. RODS
FRONl' SUSPENSION
Main Bearings Crankpins
metal lined shells located by tabs. No
Upeer guide seal wrench adaptor P5017-1
Spring clips . . .•. ... P5009
hand fitting permissible. Big end bolts I
Unit mounting sleeve ... ... P5012 have self locking nuts (see "Nut Tighten­ Diameter .. . 2.3760-2.3765in 2.1255-2.1260in
Thrust bearine locknut spanner and
un;t locator... . .. .. . ... P5016
ing Torque Data "). --- --- ---
Upper unit assembly and thrust bear­ Gudgeon pins fully floating, retained Front Centre• Rear
in&' remover and rep lacer ... P5013 by circlips in piston bosses. --- --- ---
Unit piston rod upper euide seat Lencth 1.173- 1.354- 1.650- 1.256-1.258in
wrench P5017 1.183 1.356 1.655
______ ,
Pistons In
in in
REAR AXLE Autothermic aluminium alloy, solid
Dill. bearing adJust;ng nut w•ench ... P4007 •zephyr & Zodiac:-
Crown wheel and pinion backlash No. 1 intermediate: 1.350-1.360in
skirt, Invar strut. Pistons have gud­
gauge .. ... ... P4008 geon pin hole offset nin to off side,
Dill. bearing pre-load gauge ... P4009 stamped " Front" on crown. Cylinder No. 2 intermediate: 1.354-1.356in
D!ff. bea!ing cone replacer .. . P4012
Drive pinion bearing cups remover P4015 Runninc clearance:
bores correspondingly offset to crank­
D.rive pinion pre--load gauge CP4030 shaft centreline. main beairncs ... ... .001-.0025in
Dill. bearing cone remover ... CP4000 Lower compression ring recessed on big ends ... ... .0005-.002in
Rear axle housing oil soaJ rep lacer P4035 End float: main bearinp ... .004-.012in
Drive pinion bearing space, com- big ends ... .006-.01 Oin
lower face. All rings marked "bottom."
parator P4029·1 Big ends will pass through cylinder Undersizes (thous. ol an inch) 2, 10, 20, 30, 40
(gauge block) P4029-2 bores, but pistons will not pass crank Con. rod centres ... ... 5.312in
No. .o! teelh on starter ring gear/
p1n1on 105/9
throw. Remove and assemble through ... ... ...
top.
•consul only
inlet manifold, and tighten all sttscrews Camshaft
evenly.
Duplex roller endless chain drive (same
PISTONS AND RINGS
Cylinder head gasket can be assembled
upside down. See that water transfer chain as for Anglia and Prefect). Cam­
ports are at rear. shaft sprocket spigoted on end of shaft, Clearance (skirt) ... .0002-,000Bin
located by one dowel and retained by Oversizes (thous. o! an···inch) 2½, 5, 15, 30,
Gudceon pin:
two setscrews with locking plate. Remove 4S, 60
Crankshaft both sprockets with chain. diameter ... ... ... .8745-.878in
4
Three main bearings on Consul, four Camshaft runs in three (Consul) or flt in piston ... ... push flt
on Zephyr. Thin wall, 5teel-backed, four (Zephyr) white-metal lined steel fit in con. rod ... ... floating
Compression Oil Control
white-metal lined shells located by tabs. bushes pressed into crankcase. When
End float controlled by split thrust renewing bushes see that oil holes are in
washers on either side of centre bearing No. ol rings 1
Gap ... .OO!h014in .010-.020in
line. No hand fitting needed. End float 2

Side clearance
(Consul) or No. 3 bearing (Zephyr), controlled by bronze fork in groove at
located by tabs in cap. Fit with oil front end. in grooves
grooves towards shaft. Washers art: avail­ Top ... .002-.0035in
Lower ... .002-.003in .001-.0025in
Valve timing marks on sprockets should
Width of
able .0025, .005, . 0075 and OlOin over­ be together and in line with centres. No
size on thickness. All undersize bearings fine adjustment for timing. rings ... .0775-.0780in ,1860-.1865in
are available either standard or .015in
oversize on outside diameter. Valves
Main bearings and thrust washers can
CAMSHAFT
Overhead. Not interchangeable, inlet
be removed with shaft in place. No hand larger than exhaust. Split cone cotter fix­
Bearing
fitting permissible. ing, single springs with close coils to
Flywheel, with shrunk-on starter ring journal:
diameter: 1.7655-1.7870in
head.

�1�1�1�
gear, spigoted on rear flange of crank­ Umbrella oil seal fits around valve
shaft, located by one dowel and retained stem.
by four setscrews with locking plate. Oil
length ... 1.06in .82in
Valve guides plain, integral with head.
impregnated bronze clutch spigot bush Provision for reaming out .003, .015 and 1 ��
Bearinc
pressed into flywheel with stepped side .030in oversize for service.
towards flywheel. clearance .001-.002in
End float .002-.007in
Tappets and Rockers ...
Mushroom tappets working directly in
crankcase. Remove camshaft to extract.
T'ming chain: pitch
no. of links
•zephyr & Zod•ac only
...
I .3751n
52
Rockers are unbushed, all interchange­
able, working on hollow shaft supported VALVES
in four (Consul) or six (Zephyr) pillars. Inlet Exhaust
Shaft located in No. 3 pillar (Consul) or
Head diameter ... ... 1.432- 1.182-
1.4421n 1.1921n
No. 4 pillar (Zephyr) by end of oil feed
pipe, which is held by collar on pillar Stem diameter ... ... .3097- .3088-
stud, with rubber seal below. Rockers .3109in .3100in
Face-ancle ... 45° 45•

�w...
assembled on either side of each pillar, ...
Cylinder head stud tightening dia­ with separating springs between cylin­ Sp•ing length: . .. 2.091n
gram. See also table of " Nut Tight­
ening Torque Data."
ders. Longer spring between Nos. 2 and
3 cylinders on Consul, between Nos. 2 at load
...
... I 1.270in
102-112.251b
 iv FoRD CoNSUL AND ZEPHYR MARK II Supplement to "Motor Trader," 26 March 1958

and 3 and 4 and 5, on Zephyr. End Running adjustment on operating cyl­ speedo drive pinion housing, and take out
rockers retained by split pin with two inder push rod, by nut and locknut to rear extension cover setscrews. Push
plain washers and flat spring washer be­ give hin free movement of release lever. synchro sleeve forward as far as it will
tween. Split pins must be vertical be­ Unhook return spring before adjusting. go without engaging cop gear, and pull
fore oil feed pipe will locate in hole in Clevis pins on pedals are eccentric for extension cover, with mainshaft assembly,
shaft. Feed pipe slides into union at levelling adjustment. back clear of spigot bearing, then lift
lower end, inside tappet cover, on early Access to clutch for service after re­ front end over layshaft and extract
type engines. On current engines, oil moval of gearbox. Clutch backplate and through rear opening.

Ii
seal is located on pipe which is push fit pressure plate serviced only as assembly. Drive out layshaft spindle to rear, using
in block. copper drift to start, and following up
All except end push rods can be re­ Gearbox with dummy layshaft (St/;in long x
moved singly, but usually easier to re­ Three-speed. Synchromesh (inertia 43 /64in dia.), allowing cluster to drop.
move rocker assembly. lock type) on second and top gears. Heli­ Detach front bearing cover and drift out
Lubrication cal gears throughout, including reverse. primary shaft with ball bearing. Take
Steering column control, with "cross­ out reverse idler spindle locking setscrew
Gear pump in sump, spigoted by integ­ change" on column and separate links and draw out spindle (hin x 24 T.P.I.
ral drive housing and flange-bolted to for top/2nd and lst/reverse gears. Pro­ drawhole). Lift out layshaft cluster with
bottom face of crankcase. Remove with peller shaft yoke end slides on splined needle roller bearings, and bushed reverse
skew drive gear. rear end of extended mainshaft, and idler, through rear opening.
Non-adjustable spring-loaded plunger slides in bronze bush in rear extension To dismantle mainshaft and rear ex­
relief valve in pump cover, retained by cover. tension cover assembly, pick off top gear
split pin and thimble. Valve set to blow To remove gearbox, disconnect rear baulk ring (if it has not stayed on top
off at S0-60lb, but normal running pres­ gear cone), extract spring ring from front
sure (no gauge fitted) may be less. end of propeller shaft, and slide front
end out of gearbox. Support rear end of end of mainshaft and slide off synchro
Cooling engine. Disconnect speedo drive, gear assembly, 2nd gear baulk ring, bushed
change linkage and handbrake relay lever 2nd gear and sliding 1st gear. Extract
Pump and fan, pressurized. Thermo­ spring ring retaining ball bearing in
stat in cylinder head, retained by outlet (equalizer clevis and pivot pins, leaving
lever hanging on front cable end) and extension cover, and press out shaft with
union. Pump has spring-loaded carbon bearing. Extract spring ring on shaft
and rubber unit seal. take off nuts holding gearbox support
cross-member to body floor. Detach behind speedo drive gear and draw off
Adjust fan belt by swinging dynamo gear (Woodruff key). Press shaft out of
until there is ½in slack either way on cover over lower front of bell-housing,
with clutch operating cylinder, and take bearing.
longest run of belt. To reassemble gearbox, reverse dis­
out bell-housing flange setscrews. Detach
TRANSMISSION clutch operating cylinder and leave hang­ mantling procedure, noting following
on pipe. · Gearbox and cross-member can points:-
Clutch then be drawn back and lowered out. Oil Spring rings on front bearing outer
Single dry plate, sealed ball thrust trapped in rear extension will drain out race, retaining front bearing on primary
release bearing. Hydraulic operation of of shaft hole when box is tilted. shaft, rear bearing in housing, and speedo
release lever, pivoted on ball-ended stud To dismantle gearbox, remove bell­ drive gear on mainshaft are available in
in bell-housing, replaces normal linkage. housing and selector housing. Unscrew three or four selective thicknesses. Rings
should never be used twice, and new
rings must be selected to fit snugly in

C _zo:

® �
1..
@. e'�'====== 10 (
�-@
@�@�
'
t:,
0

�rJ�
Parts of t�e gearbo_x and clutch, showing assembly of components, gear trains and
their respective shafts, together with selector mechanism and gearcase.
Supplement to "Motor Trader," 26 March 1958 FORD CONSUL AND ZEPHYR MARK lI v

CHASSIS DATA
groove when component is pressed right ing flange nut. Flange hub passes through
home. When assembling front bearing lipped oil seal in housing.
CLUTCH
on primary shaft, note chip shield behind. Bearings adjusted to give 12_-15 lb/in --
Type ... ...
If split bronze bush in rear end of preload with oil seal fitted, by selective ... ... s.d.p.
extension cover is renewed, new bush distance-pieces, available in 10 lengths
must be pressed in with split at top. in .002in steps from 2.004/2.005 to Consul Ze)hyr
Sprinp: no. . .. 6
When assembling mainshaft gears after 2.022/2.023.
colour yellow Brown
... 6
building mainshaft into rear extension Pinion mesh adjustment by shim be­
free lengiti 1.90in 1.92in
...
...
Centre sprin&s: no
cover, slide on 1st gear with fork groove tween pinion and inner race of rear bear­
...
colour Mauve Green
to rear, 2nd gear and baulk ring (two ing. Shims available in ten thicknesses 6 6
...
baulk rings are identical, but should not in .006in steps from 0.1510 to 0.1600in. Unincs: thickness ... .155- .155-
.165in .165in
dia. ext. 8.0in 8.5in
be interchanged after use). Slide synchro Crown wheel spigoted on one-piece
...
sleeve on to hub same way round as differential cage and retained by eight dia. int. ... 5.25in 5.75in
GEARBOX
found, so that longer boss of hub is to self-locking setscrews. Differential side
front, and insert three detents in slots in bevel gears have flat thrust washers I
hub. Insert decent springs under detents, behind, planet bevel pinions have spheri­ Type • ... ... synchromesh
so- that one end of each spring locates in cal thrust washers. No. ol forward speeds ... 3
Final •alias: Consul Zephyr
same detent. Slide assembly on to shaft Differential assembly carried in taper
and secure with spring ring. roller bearings in split housings, with
1st ... ... ... 11.67: 1 11.08 , 1
2nd
Spigot bearing in primary shaft has _13
6.75 : 1 6.40 : 1
ring-nuts for bearing and mesh adjust­
... ... ...
3rd 4.11 : 1 3.90: 1
needle rollers. If unworn, they should ment. Bearing caps have hollow dowels. ... ... ...
lock in place when last roller is added. Tighten ring-nuts to spread bearing Rev . ... 15.86 : 1 15.06 : 1
Stick in place with thick grease, and housings .005-.007in overall (special fix­ Overdriv8. ;ati, : : : ... - 0.7 : 1
PROPELLER SHAFT
screw on top gear baulk ring before ture advisable for checking spread), then
inserting mainshaft. turn both ring-nuts equally to adjust
Make Enfo

I
... ...
Type needle roller bear-
Layshaft cluster has 20 needle rollers mesh for .005-.007in backlash. ...
in each end, with distance-piece be­ ... ... ...
ing U.J.
tween and locating rings outside. Large
thrust washer at front of layshaft is steel­ CHASSIS
backed bronze, tab locating in slot in box. Brakes FINAL DRIVE

Type ¾•floating hypoid

Two smaller thrust washers at rear. , Hydraulic. Two leading shoe front
Steel-backed bronze washer is tabbed to
cluster, and bronze face is towards steel
brakes with separate wheel cylinder for
each shoe. Snail cam adjustment for Consul Zephyr
......
Crownwheel/bevel pinion
washer, which is tabbed to box. Test front brakes. Tighten each adjuster until
teeth ... .. . 37/9 39/10
assembly for end float (.005-.018in). shoe is binding, then back off until free.
Before assembling selector housing, Rear brakes have square ended adjusters
--
BRAKES
test that interlock sleeve, which carries and snail cam on leading shoe, tighten
selector locating balls and spring, effec­ square ended adjuster and back off four
tively prevents two gears engaging at clicks, releasing snail cam until free. Type... ... ... ... Hydraulic
Drum diameter ... . .. 9in
Linin&: length 8.65in
once. Selector sectors are slightly eccen­ Adjustment completed by retightening
width ::: froni" 2.5in
tric, so that either one can move only wedge adjusters and slacking off until
when other is-in neutral, owing to inter­ shoes are just clear of drum. Car must rear 1.75in
thickness ... ... .188-.203in
Total linin& area 147 sq in
ference of interlock sleeve. Sleeves avail­ be jacked up for each wheel to be
able in six lengths. If external levers are adjusted. ... ...
detached, note that front lever (top/2nd) Handbrake operates on rear wheels SPRINGS

Front Rear
is slightly twisted. When assembling through cable in conduit to relay lever
selector housing place forks on gears, and below rear of gearbox, thence through
offer up housing, making sure that forks equalizer and cables to small relay levers Length (eye centres, laden) - 41.94-
42.06in
Width (or mean dia. ol
enter levers. Selector housing is located at each spring anchorage, and from then
by two dowels. on through rods and bell-cranks to coils) ... ... . .• 4.3in 2in
Speedo drive gear and pinion ratios No. of leaves (or coils) ... 10.44 6
Free camber (len&th, coil) 16.Tln 5.898in
expanders.
Loaded camber (length,
are: Consul 24/6, Zephyr Six 29/8.
9.24in (ciJ
Rear Springs
coil) al load ... ... .058in
When gearbox has been reassembled in
698-7221b•
car and filled with oil, it should be topped Semi-elliptic. Loose rubber shackle
bushes, bonded rubber anchorage bushes.
• Zephyr and Zodiac 777-803 lb
up after running, as oil runs into rear Tighten all bolts fully with car in static
extension housing and does not drain
SHOCK ABSORBERS
back. laden position.
Rubber inserts in tips of three main
Type ··· Hydraulic double act-
in& twin cylinder
leaves. Latest Consul models have zinc
1
Propeller Shaft
Service ... ..• Top-up
Needle roller bearing universal joints. interleaves.
STEERING BOX
Nipples for lubrication of joints. No Front Suspension
external sliding joint, as front yoke end Independent, coil springs. Telescopic
slides in gearbox. Type ... ... ... Worm and ball peg•
Adjustments:
shock absorbers form structural part of
column end float shims
suspension units, being located at top in ...
cross shaft end float shims
Rear Axle
double taper roller thrust bearings ...
mesh . .. grubscrew and nut
Hypoid ·bevel drive, ¾-floating shafts. anchored in rubber to top of wheel ... ...
Rear cover welded to banjo casing. Final
• Latest type: recirculatinc ball.
drive assembly detachable. arches, and at bottom in ball joints at
outer ends of lower links. Anti-roll bar,
FRONT-END SERVICE DATA
Complete axle assembly can be passed joined to outer ends of lower links by
out sideways through springs. (Dis­
Caster ... . .. -t•0to+t•
rubber bushes, gives fore-and-aft location
Camber ... ... ..•
connect brake rods at relay levers and
pull out through bell-crank eyes.)
Half-shafts (interchangeable) upset at
and takes brake reaction stresses.
Suspension compares with that em­ �C:.�t• in linalio
� �- _ :::
3½ 0 -4½ 0
H -2t
n-iin
0

No. of turns lock lo lock ...

ployed on Mk. I cars, and readers are
Adjustments: castor ... nil
outer end to form flange on which hub referred to Service Data No. 184 for full
nil
bearing housing, carrying wheel studs,
toe-in .. . screwed track rod
details of assembly and overhaul pro­ camber .. .
registers. Inner ends splined in differen­
ends
tial side bevel gears. cedure.
Hubs run on ball bearings pressed into Steering Gear
housings, with lipped oil seals (lip to Cam and lever, with ball bearing peg, Lever peg carried in ball thrust bearing
bearing) behind. Bearings retained on later type recirculatory ball. with eight loose balls running directly in
axle tube ends by ring-nuts and tab­ Cam runs in cup-and-cone ball bear­ lever and retained by spring ring. End
washers. ing with 14 loose balls at each end of play of lever shaft restrained .by spring­
Bevel pinion shaft runs in taper roller cam, adjusted by shims under lower loaded plunger in screwed sleeve in top
bearings, outer races pressed into final cover. Upper end of column supported cover, with locknut, which governs mesh
drive housing. Distance-piece between in tallow impregnated split felt bush, of peg in cam. Lever shaft runs directly
inner races, which are nipped up by driv- renewable with column in place. in casing.

j
Vi FORD CONSUL AND ZEPHYR MARK II Supplement to "Motor Trader," 26 March 1958

Parts of the front and rear suspension assemblies, with below rear axle components and hub assembly and above left, steering box
unit and linkages.
Supplement to "Motor Trader," 26 March, 1958 FORD CONSUL AND ZEPHYR MARK II vi

--·-------------------------,
TUNE-UP DATA ELECTRICAL TEST DATA

BATTERY
Firinr ordtr (Consul) •.. 1-2-4-3 Plup: make ... Champion Type .. . lead acid
(Zephyr) ••• ... 1- 5-3-6-2-4 NB Voltage ... 12
Tappet clearance: (cold): ,nlel .014in size .. . 14mm
type
exhaust .014in gap ... .032in Consul Zephyr
Valve liming (no clearance): Carburetter: make Enfo
l�l:l :r:a��
exhaust opens...
:: ::...
17° BTDC
51° ABDC
49° BBDC
type downd,aught
single venturi
No. of plates
Capacity 45 ah
9
57 ah
9

exhaust closes ... 19° ATDC Consul Zephyr ,pec. gravity: charged 1.27-1.285
Standard ignition timing 8° BTDC-H/C d'scharge:I 1.110
4° BTDC-L/C ltllin&t: Choke ... 26 31 72 amp/hr
Location ol timing mark ... Pulley & pointer Main Jet .. . 115 145• DYNAMO
Distri&ulor: type and service No. Enlo Power Jet ... 65 107t Type ... ... ... shunt wound
Advance range (dist. de&.): Idling jet ... 45 50 Service No. ... ...
centrif. ... .•. 10°-12° at 4,000 Progression jet 2x80 2x80 Rotation ;comm. end) ... clockw'se
r.p.m. Accelerator pump Jets ... 70 70 Cut-in volts al r.p.m. ... 13@ 964
4° -6° at 4,000 High speed bleed ... 70 100• Max. output .. . .. 228 walls
r.p.m.
vacuum
Max. 1-everse current ... 5 amps@ 12
HC 4-cyl. Needle seating ... 2mm volts
Advance starts (crank r.p.m.) ... 600-800 Float level ... 16mm lrom lace Field resistance 6.1 ohms
Max. advance (crank r.p.m.) ... 4,200 of float chamber Brush tension 22-25 oz
4,000-7,8 Air cleaner: make ... Enio
4,000 Consul H/C type (home) oil wet CONTROL BOX
& L/C (export) .. . oil bath Service No. ... ... EOTA 10505-D
Cam angle (percentage dwell) ... 64-69 consul Fuel pump: make ... Enlo Cut-out: cut-in voltage ... 12.7-13.3 volts
55-60 Zephyr typo ... mechanical Regulator voltage: 10°C (50° F) 15.7-16.1
Contact spring tension 18-22 oz pressure .. . 1 l·2½1b/sq in 2a'C (68"F) 15.6-16.0
Contact set No. (Consul) EOTA-12162/C 30'C (86° F) 15.5-15.9
(Zephyr) EOTA-12162/8 40°C (104° FI 15.4-15.8
Contact breaker gap .. . .014-.016in *Prior to Nov. 1956
Condenser: capacity ... .18-.22 mid. Alter: Main 155 Power 110 High speed bleed 70 STARTER
Service No. ... ... EOTA-11001·3
Rotation (comm. end) ... clockwiH:
Lock torque (lb/It amps) 9.6/380
Brush tension ... ... 30-40 oz
COIL
Type ... •.. ... ... oil filled, 12v
Service No. ... ... ... 100E-12024
Primary resistance (Lucas type) 3.2•3.4 ohms•
Primary resistance (Delco-Remy
.. 4.15-4.55 ohms•
Secondary re•istance (Lucas
lypt) ... . ..
type) ... ... ... · · · 4700-4800 ohms•
SecondarJ res'stance (De!c o• 1
SLACK. Remy type) ... · ·· 5500-7100 ohms•
RED
lRACER *Al 68° F,

YELLOW. ADDITIONAL ELECTRICAL DATA

WHITE -------
Tfl.ACEP. -- - - ·
M _ d_ e l __s_ erv
_ o _ i_ ce .
BLUE . - _ __1 _ _No
_ __
YELLOW 1,
TRACER Hoadlamps ... ... All 204E-13005·B
Side lamps . ... Consul 204E-13200-B
RED• Zephyr 10/57 ... Zodiac 206E-13200-A
Flasher Zephyr 12/56/ 10/57 206E-13200·C
Slop/tail lamps ··· Consul E111•NC-2
WHITE

1 Zephyr 206E•13407-A
TRACER

YELLOW­ Flasher ... Zodiac 208E·13407-B

BLACK Reversing lamp ... All 204E-15500
lRACER
Number plate lamp All 204E-13550-A
Starter solenoid switch All EOTTA-11450
Lighlinr switch ... All lOOE-11654-B
Ignition switch . .. All 204E•11572-A
GREEN -l++t-ht+t+t-i Fog lamp switch ... All EOTTA-15224
Trafficator switch ... 206E-13341-B
Flasher unit .. . .. . All 100E•13350-B
YELLOW. Screenwiper ... ... All 204E-17500-A
RED
I RACER Fuse box . ... 2E-14.S25
Horns: high note ... All 204E-13802
RED­ EOA-13802-B
YELLOW low note ... All 204E-13801 }
lRACER EOA-13801-E
Horn relay ... ... All EOTTA-13842-A
BLACK·
8lUE
lRACER

BROWN.
TR.ACEP.
BULBS
WHITE

1
Volt•
I
MOWN
tage . Waltage
I -- Cap
Headlamps: dip left ... 12 42/36 Prelocus
dip right 12 42/36 Prefocus
vertical
dip 12 42/38 Pre!ocus
Side lamps: standa,'d 12 6/21 SBC
flasher 12 6/21 SBC
S!op/tail lamps:
Standard ... ... 12 21/6 SBC
Flasher 12 21 sec
Number plate'iamp · ..· ' 6 MCC
Ignition ... ... 12 3

TRACER--�::::_-: ====r=====�=������E���g�����
12
Oil warning lamp ... 12 3
MES
Panel lamps ... 12 3 t2 off)
RED-WHllE
MES

Interior lamp 12 Fosloon

MES
Beam and flasher
warning lamps 12 '
:i ----
FUSES
3 MES

FLASHER Accessories ... ... ... II 2 x 35 amp

viii FORD CONSUL AND ZEPHYR MARK II Supplement to "Motor Trader," 26 March 1958

10

12

KEY TO MAINTENANCE DIAGRAM FILL-UP DATA

DAILY EVERY 5,000 MILES Pints Litres
1. Radlator 15. Enll,ine sump -drain, flush and refill.
2. Engine sump } check and top up •Engine sump, Consul . .. 6 3.41
16. Engine oil filter-renew.
Zephyr ...

�==;�«:c�e
l
7 3.91
EVERY 1,000 MILES 17 Gearbox
dram, flush and reflU. Gearbox ... ... 2½ 1.42
18: Rear axle }
!:5. Steerlnll, gear check 19. Front wheel l,u:,s -remove and repack with
Rear axle : : : ...
Coolln1 system: Consul ...
Zephyr ...
2½
18
22
1.42
11.11
12.49
and bearing grease.
6. Battery top up Fual tank ... ... 10½ &all. 47.73
7. Brake and clutch fluid reservoir 20. Air cleaner (oil wet)-wash in petrol and Ty,e pressun,s: · ··
8. Steering ball Joints (6) re-oil. front and rear (Consul) 24-28 lb/ 1.68-1.97
9. Relay arm pivot (2) 21. Air cleaner (oil bath)-wash element in sq in leg/cm•
JO. Gear change levers on steerinll, grease petrol, refill with engine oil. (Zephyr) 24 lb/sq In 1.6 8
column (1) gun lc&/cm•
11. Handbrake cables (2) }
22. Generator-a few drops of engine oil to oil
12. Propeller shaft universal joints (2)--oil hole In rear bearing boss. • 1½ pints for dry oil filte,.
gun (S.A.E.140). 23. Rear road sprinll,s--sprny with penetrating
13. Distributor---0il shaft bearing, auto advance oil
and cootact breaker pivot, smear cam with 24. Front suspension units top up with shock
petroleum jelly. 2o. Rear shock absorbers } al>sorl>er fluid
14. Fuel pump-dean filter and sediment bowl. GENERAL DATA
Wheelbase (Consul) ... ... 8ft 8½in
(Zephyr) ... ... 8ft 11in
DRAINING POINTS Track:
Front and rear (Con,ul)
Front and rear (Zephyr) ...
... 411 4.Sin

......
4ft Sin
Turninc circle (Consul) 3511 0in
!Zephyr) 3611 0in
Ground clearance:
!Consul ind Zephyr) •.•
(Zodiac) ... ... ...
... &Jin
6 in
Tyre size:
Left : Shows radia­
tor matrix drain Front and rear (Consul)
Front and rear (Zephyr and
... 5.90-13 .•
tap situated in base Zodiac) •.• ... . .. 6.40-13
plate, access from Overall len!llh (without over-
riders \Consul) . .. . .. 14lt 4¾in

....
beneath. Right : Overall .enEth (without over-
Cylinder block drain riders) (Zep r) .. . . .. 14ft 10tln
tap at nearside rear Overall width (,ephyr and Zodiac) 5ft 91n
Overall width (Consul) ...
of engine adjacent Overall height i ... lilt 8¾in

.........
lilt 2in•
to starter motor. Weicht (kerb) iionsuli"' 2,5041D
(Zephyr) 2,6911b
(Zodiac) 2,7381b
•Unladen.

RECOMMENDED LUBRICANTS
I
Duckhams Wakefield Esso Shell Mobil Vlitzol B.P.
Enll,ine: Summer and NOL 20 Castrolite Extra Motor X-100 20/20W Mobiloil Arctic New D.20 Energ:ol
winter Oil 20W/30 SAE 20W
Gearbox, steering box ·NOL EP 80 Cast-rol Hypoy Expee Spirax 80 EP Mobilube Byex 80 Ener�ol
(not automatic trans- Transi.mission Light Compound 80 GX 80 EP SAE 80
mission) Oil
Rear axle NOL Ca.strol BYJ)Oy Expee Spirax 90 EP l\lobilul.>e Vitapoid 90 Encrgol
Bypoid 90 Gear Oil Compound 90 GX 90 EP SAE 90

Approved lubricants ofshnilar grades and S.A.E. ratings are also supplied by the following: BRITISH OIL & TURPENTINE CORPN., FINA
PETROLEUM PRODUCTS LTD., GERM LUBRICANTS LTD., EDWARD JOY & SONS LTD., MANCHESTER OIL REFINERY (SALES)
LTD., MORRIS & CO. (SHREWSBURY) LTD., REGENT OIL CO. LTD., STERNOL LTD.

Printed in Eni:land by Cornwall Press Lid., Paris Garden, London, S.E.l.