How to Rebuild a Carburetor in a 1966 Mustang

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The 1966 Mustang came with four basic engine and carburetor combinations: a 200 HP 6-cylinder engine with a 1-barrel Autolite 1100 carburetor; a 200 HP 289 V-8 with a 2-barrel Autolite 2100 carburetor; a 225 HP 289 V-8 with a 4-barrel Autolite 4100 carburetor; and a 271 HP 289 V-8, HiPO engine with a 4-barrel Autolite 4100 carburetor. It is imperative to identify the carburetor by the engineering number stamped on the carburetor. There are a least four combinations of jets and venturis for the 1966 Autolite 4100. The process of rebuilding involves careful disassembly, cleaning, detailing and reassembly. Please refer to the specific diagram and instructions for each carburetor variation.

Things You'll Need

  • Appropriate carburetor kit
  • Assorted slotted screw drivers
  • Assorted Phillips screw drivers
  • 1-gallon bucket
  • Carburetor cleaner with basket
  • SAE tap & die set
  • Simple Green cleaner
  • Machinist's flat file
  • Complete machinists's drill set
  • Cookie sheet
  • Bench grinder with wire wheel
  • Center punch
  • Drill press
  • Penetrating oil
  • Hanging Hooks
  • Replacement screws as necessary
  • Eastwood's Carb Renew
  • Eastwood Cad paint
  • Eastwood's Underhood black paint
  • Nitrile gloves
  • Mechanic's gloves
  • Safety glasses

Disassembly

  • Set the carburetor on a cookie sheet. Remove all the screws and linkages for the accelerator pump, choke, dashpot or power valve assemblies. Retain any springs or clips.

  • Remove the screws for the air horn. Lift up the air horn. Disconnect any remaining choke linkages. Flip the air horn over and remove the float pin and float. Remove the fuel inlet seat.

  • Remove all distribution plates and venturis from the main body. Watch for presence and placement of check balls in the venturi plate and the accelerator pump passages. Remove the main jets in the bottom of the main body.

  • Coat the choke plate, main and secondary plate screws with penetrating oil and let them set for several hours. Coat for the second time with penetrating oil. Carefully remove the plate screws. These screws are small and will break off commonly. If one breaks off, file off the stub from both sides to remove the shaft. Remove any nuts, pins or clips retaining the plate shafts. Remove the shafts and any accompanying springs. Remove the idle screws and tension springs. Remove any remaining parts.

Cleaning and detailing

  • Place small parts in a basket and into the carburetor cleaner. Put all the larger parts into the carburetor cleaner. Let soak for at least one hour. Remove and drain. Wash all parts with Simple Green cleaner and water. Immediately dry with compressed air and a blower nozzle. Make sure to blow out all passageways.

  • Chase each screw hole threads with an appropriate size tap. Make sure to do the plate shafts. If a shaft screw broke off in disassembly, center-punch the screw and drill out the body on a drill press with the appropriate bit and re-tap the hole with the correct tap. Blow all the passages clear with compressed air.

  • Hang the parts to be painted on hooks. Paint all the main parts with Carb Renew. Paint all the linkages with cad paint or underhood black. Allow the paint to fully cure.

Reassembly

  • Install the plate shafts and accompanying springs, pins, nuts or clips. Install the choke, main and secondary plates on their respective shafts. Replace screws that were broken with new ones. Install the idle screws and tension springs, tighten to lightly seat, then back out 1-1/2 turns.

  • Place check balls back in the correct passages. Install the main jets in the bottom of the main body. Install the fuel inlet seat in the air horn. Install the float and pin. Following the float adjustment directions for the specific carburetor, adjust the float height to specification by bending the tab.

  • Install all distribution plates and venturis with appropriate gaskets. Install the air horn with a new gasket. Route all linkages through the holes. Replace all screws and tighten.

  • Install the accelerator pump, spring and new gasket. Install the choke assembly with a gasket. Replace linkages in correct holes. Install the power valve and new gasket. Install dashpots and brackets. Install any remaining shields.

  • Make sure all parts have been replaced. Perform any other bench adjustments outlined in the specific carburetor directions. Install the carburetor on the car.

References

  • Photo Credit Hemera Technologies/AbleStock.com/Getty Images
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