FORD CAPRI 1974 Workshop Manual

"00 Chapter 5 Clutch
53 Locmlll\J the (flCllon disc on the
f lywheel 5 .6 Cent,.,l ising the friction disc 5.7 TI\)htIJnlll!) 111" ,: 1,,[, h cover holls
6.4 The plilSllC wlls which .cWin the fclcJSC hcnrinl] in the lever (""owed) G 5 nt:lcas(l levor IOC,11;01) 011 the 1"1101 stud
5 The f&#34;~lI()n rt.!;c must now be Cclltrilloscd SO Ihill when the (IllUme imd !Jci&#34;loo~ .1<0 milled Ihe input shall splmes Will pass 1I110uUll the splines III Ihe )HCIIO!) diSC Id(!,lIly a wlille.s;,' dUh;h (;C!l!r<lIiS IIl\J loul or ;m old !I&#39;~;&#34;I>()&#34; Inpul ~h&#34;fl shuuld be u~cd. hlJt ,rlh.'IIHI(,vcly a woodull 'lIilnd,!:i G,II1 h.., Ill.1<ic to IIIe d,mtJnS lons shown In FlU 53 G InSUlt Ihe ccnlr<ll'SIIl(J 1001 Ih,ulIUh the (fiction diSC <lnd 11110 lhe ·"\jot Ill',"""\! (phOIO). nOlillC tho 1001 or movc II Side tu Side until lhe .etlon d,sc 'S "ccwnlCly centm(l 7 P,oy,ess,vely u\Jhlen two OPPOSl1e cover holts unt,1 the ftict,on F I, fnmly held ") posl1ion. then l'Uhten all the holts proy'esslvely ,d 111 (I,,,yo,,,, 1 sellu,mce (phOIO). 8 flemove Ihe cenH<1r,sin\J 1001. 9 Wipe dowllthe \)e,llilox IIlput shJlt ,md "pply a littic molybdenum Iwscd \Jrease to the sptones an(i spioot b(&#39;~&#34;ng slillacc_ 10 flcf,t the ue.1fbux Wilh ref!!lence to Ch"pwr 6.
6 Clutch release bcnring removal 1Hl(1 rcfitting
Remove thc gcarbox "s dcscflbed in Chaptcr 6. Alternal,vely. illhe cngi ne is to bc removed for repairs. acccss 10 the rclcilse bcminy ,s possible leaving lhe gearbox in position. 2 loosen and back oil the cable adjustmcnl milS. 3 Whcre npplicable. plisc lhe ciulCh cnble fuhhel gaitcr flOm the bell housing nnd unhook thc cahle end lotting from the release fevel. <1 Puilihe release I)ealing hom the \Juide tube. Whcre necessary use a scrcwdrlver to pflse the f)Caring flom the Icvcr and lelease the pfas\lC
tabs (photo).
5 Pull t he rclease IiNCI sldcways to d,sengage it from t he pivot retaining stud (photo). thcn withdraw ,t ovcr thc IJuide tube ,1nd input shah
6 The rele ase beann\) is supplied completc w ith lhe huh (photo). If fC(luired. thc two componenlS can be scparated usinU a VICC and soh metal drill.
)Before relltllng (hc releasc bcariny. apply a lillie molybdcnum "."ase 10 the \llude tubc and contact laces of the release lever 8 flefl!1lng is a ((,versal of remov~l. butllnally chcck the clutch pedal and cable ndlUsllllenl JS descflbed in Seclion 2_
7 Clutch c;lllic -Icnewnl
Apply tlol) Io.",dl!<"k" llien lilCk "I' lilt: j'onl of 11"1 Gil o1l1d suppor( on ax il! ~!and~ 2 PIIS" th" dUlch callie whlJel (jilll'" horn lh" h&#39;·lIhou~u&#39;(j. lousel! the ati,US111l'JllI nul(s). ;IIHI unhook the c;,I,I" ,·nrl IlIllllB hOIll lhe release h,v,,, Pull off the !Jalter (phOlUS) 3 Ikmuv" ti,,) c,lhle frorn lhe hole II) lh., 1,,·lIh&#34;u~&#34;l\J. nUlo)\) lhe posltlun of lhe slccve (phOIO) <1 WOlkln\l illS Ide (hC Cilf. remove the luw,,, I,,,",,, pallel lor <ICCCSS 10 the CIUlCh pedal 5 O'SCOlllH!C ! the cablc from lhe cllllLh !JO'ri.11 t,y puslun\J lhe P'" thf<.)u\Jh the cilhle eye.
, '. ,
j'., ;. . , , , .;{
'-,
7.2A Prisc all the rubber Ualtef
.. ~
d
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Chapter 5 Clutch
7 2B .. and unhuok Ih" Illller C<lhlr:
6 Wu,k,n\) rn 1111] <:n\)1I1O Gornp"'ln",nl pull Ihe ,;alJle Ihouu!)h Ihe
h,Jlkhea d ,n
1l1 Icmuve II trom Ihe Gil' 7 Fit the new cahle 1I;;lnu " levels,, 1 of Ihe lemoval p,ucr.:du,e. Ihen adlust the ped<ll free unvcl <IS descllhed III SectIon 2 .
8 Clutc h pedal-remova l <lno refittin\J
Wo,kmg insId e Ihe car. fCf1,OVC Ihe lower Inc,," p,mel helow Ihe
stcerinu colunlfl 2 Bemove the h:lt hand sp"n\J clip <lnd liS W<lsirer 110m the ped<ll
p,vot shalt. 3 U nhook Ih " dulCh ped;,1 ,"IUln ~1)l1Il\J 1 Pus h lire I'c<lal ~h,,11 10 Ilro! "<Jlrl until II IS clca, o f lire pr.:,sal and
'c"'ovr.: IIr" I",d,d 5 I'ush Iht) I'"' oul 01 th " "yu '" Ihe end ul Ihe clutch cahle 10
d'SCOIHleCi Ihr.: cal,l"
B"!1luvlJ ti,,, <:Iuld, pell,,1 plvull"'Sh. E~;,,&#34;&#34;&#39;e Ih" 1',,(1;,1 ,Hld hush lu' w,-,ar ,!Ild r! necess<I'y rcnew Ihe", 8 11e1ll1!1lU IS" I"v ",sal of fCII'OV"1. hUlluhrrc;rw Ihe p1VOI bush w Ith a tie \J,e,l;;e ,11,,1 IHI,'lIy ,ullust Ihe p ed,,1 I,ee trllvcl <IS (Icscrlbed In
~Ct;tlon 2
!) Fault dia\)llusis -clutch
Sympto m
Juddcr when laklnu up drive
ClulCh slq)S
Noise when dep,cs$UI\J clutch ped,,1
)
NOIse when ",I"as"'u clutch ped,,1
7 3 R~llII)Vln~J the ~ ,&#39;hh, IrOIll Ihc h&#34;tlhllu ~.n\J
FiU . 5. 4 Removinn lir e "hnch pe{!;!1 (Sec 8)
l1easun(s)
L,u,,,,, '" wr:r,n ""\1"'" &#34;&#34;JUnt&#39;n~l$ (l"ld, d, sc ,;ool,I",,,,. \I'·d w,th 0'1. or 10" ··gs WOlll
Ciu1t: h c"I,l u ~1,~k&#34;&#34;J ()I tr"ytd I'"ul ly ple~,>ure pl,He .1,>~e&#34;,IJI\&#39;
Clu tc h d,sc stIC~&#34;&#39;\J Oil "'put slr,,1t spl ,o':>
Clul, ·" cirl,I"
I!&#39;o~,,&#34; F<H,lly p.essurc pi,l\" .1s~{)onb&#39;\&#34; Clul Ch ped,,1 and c"hl" &#34;dJ&#34;~I&#34;&#34;&#39;nt ,,,I.{, ···ct
ClulCh ped,,1 nlld c"I,I" ,1dl\lS;,,,,,III (lif.V··:CI Clutdl d,~r: COIII<ll\,,,,,, \·,d v.'lil ",I '" 1 " ·'us worn
Fill,lty I&#34;u~~uru pl"I" &#34;,.~&#34;&#34;,!)I{
WOIII or (lly rul~as,) &#34;~&#39;&#39;&#39;&#39;&#34;U F<lu lly pru~sure pl,He J~,>,,,&#34;lJly VVOIII dut<..1r d ,sc U ' ,oput Sh,1!t &#34;pl,,!,,~
Fau lly Il,u s,>ure pl.lle n,>,>uonbly H,oku", clulCh (j'St; Cl,,>",O,,,og ~PllIlU~
101
,
! '
. , .,
, , I
,
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)
Chapter 6
Manual gearbox and automatic transmission
Contonts
oIrt 1: Mamml gCMhox
It d'''unosis - m,Ulllal ijc(l.box .!l)()x -'emav,1I ;lIld ,efluing . Gc;ubo. (II-speed) -d'smamlln{J GC:UhOK (II -speed) -cxarninallon and renovatIon GCiui)o x (<I-speed) -rcasscllltJly Go,ulla. (5-speed) (hscngn(jcmcm of 51h gear.
Gc;'ubox (5-speed) -(hsmnnthng GC;lrho. (S-speed) -cxnrnin;l1iOIl <lnd renovatIon Gambol( (S·speed) -rcnssemhly ..... _ ........ . GCilrchangc lever (4-speed) -mo(hhcations .. Gene.al desoiption .. Input shah (<I·speed) -dIsmantling .. nd reassembly ............ _. Input shah (5-speed) -dismantling ;Inc! 'Cilsscmbly . LaYllcar (4-speed) -dlsrnall1ling imd rCilsscmbly
Specifications
Plut 1." Manual gearbox
Type ...
R ntios
Four·speed gcarbOI( : 151. ')n(! jrd 4th .... __ ........ .
Reyerse ....... _ ....... . 17
3 ,
8
9
16 11
" 15 10 1 6
13
7
Mil"'shah (4·spccd) Millnsh;'!!! (5,sJ>Ci.Idl nOut,nc Ill"mlcn;",ec
d,smamhng and reassembly _ Ihsm<lnlhng and rCllS5embly
Part 2 : Au(oll/otic (mn$mission I\lIlOrllill lC triln snHSSlon -removill ilnd re titt ing
OownsllIll cillJle removal. reflUing ilnd adlusunelll F.~ttlns,on hous"lg all seill -lenewal
Fault dlilgnOSIS ilutomilllC transmIssion ................................... . General dCSCflPilon ............... . Rouline milinlen;lflCC SeleC10l mechilmsm -MiluslfllCnt ................ . Selector mechilmsm removal. ovcrhaul ond refitling ................. . Stillier Inhllmor/revcrse lamr> switch _ removal and refitting
Four Or "'Ie forw,ud speeds (all synchromesh) and reyerSe
3.16 : 1.94 :
1.41
1 1 3346: 1
5 12 2
20 23 25 26 18
I" 22 21 24
E
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Chapter 6 Manual gearbo x and automatic tran smissio n
F1VO.Sp()od \joiuhox:
'" 2nd 3rd 41h .. 51h f\ovr;,so
Laysh aft cluster gear (f our-speed gearbox )
Elldfio<lt .. Thrusl w,lshm tluckuoss .
lubricatio n
Luh"(.<lnt typo. LuIH'Collll C,IP<lClly F,,,,r·~peed . F&#39;VI~·~pf)ed .
,rquo wrench settings F(}(If.SI!(&#39;,~d !lcar/lO x r fh h01l5,",0 10 HOol,box (. •.• ,(;1> Iw"sIIIIJ to 1'1I1J111H M.1,.\~halt "."
InplIl shafT hoaun» 11,IJIIUlr ExtellSl!lIl hous',,» ... Sf:h,ClOr Shilh IJJil~kel . Sciccto! housinO cove, .... Extension housin\1 cover . GeJlhO x casc cover
Flve·spccdgc,lfbox Guide sloeve Ex lOnsion housing. Geol,hox top cover Seleclor locking mechanism .... FilII), plu(1 51h He,ll cull,H nul 5th <j(:;11 Iud in\) plalf) . GOolr !I,vo,
Pari 2· Automatic transillissio n
Type
Torque converter
if! IWtlO
Transmis s io n ra tios
1 st 2nd. 3'd . Reverse
Lubricant
C~pacily (ilpprOX) . Type :
Early models (blnck dipsl ic k ) Laler Illodels (red dipstic k) ..
T orque wrench settings Torque convcrter 10 dr;veplille .
Do wnshift cable brac ke l
Downshift lever nUl: Duler. Inner.
Inhibito r swilCh
R'ake b;"Uld ~d!usling screw loc knu l .. .
lid l ine .... ... .. ...... ........................... .... . ULI cooler Ime . AU10lllilllC t&#34;,n~lI1ission t o engine. To rque conveilei drJin plug
3.36 : 1 1.81.1 1.26: 1 1 ,
0.825. 3.365 :
0.15100.45 mill (0.006 to 0.018 in)
1 .55 to 1.60 m!11 (0.061100.063 in)
SAE 80 EP oil 10 Ford spociflCatlon SCM 2C 9008 A
20 lit,e (35 pim) 1.9 lilH! (3.3 PUlt)
NIl
39104 8 30 to 37 35 to 4 1 17 10 2 1 54 to 61 71010 161021 9 to 11 17 to 21
9 to 11 4 5 10 49 9 to 11
17 to 19
231027 12010150 21 to 26
2 1 1026
Ford C3
Tnlock (hydrnulic)
222.1
2.47 : 1.4 7 : 1: 1 2 11 : 1
7 .5
htre ( 1 3 2 pUl1)
Ih l It
29 10 35 22 to 27 261030 12 to 15 40 to 4 5 5107 12 10 15
7 to 8 1 2 10 15
7108 331036 7 to 8 13 10 1 4
17 1 0 20 89101 1 1 1610 19
16101 9
ATF to Ford spec,fIC~lion SaM 2C 9007 AA ATF to Ford specification SCM 2C 9010 A
N m Ill f It
361041 27 10 30
16 to 2 4 1
2 to 18
1
010 15 7
to 1 1 41 1054 3010 40
1 6 10 20 12 10 15
4 7
10 61 35 10 45
9 10 1 4 7 10 10
1610
20 12 10 1 5
3010 37 22 1
0 2 7
2 7
10 40 2
0 to 30
, . ,
!
.5 ________________ ........... ........
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104 Chapter 6 Manual g earbox and autom ati c transmission )
PART 1, MANUAL GEARBOX
Gener"l description
The nl<ll1u,,1 \je<lllJo x IS 01 lour or live speed type with one reve rse gear. All fOlwiud geMs Me el1gaged through p,.,ulk rmg synchromesh units . The 1I1"'I1$halt ge<lrs 10t.1te freely on thtfshMt .1nd .1re 111 constnn t mesh with Ihelr cOlJespondlllV gears on the I<lygen- . They nre helic<llly cut to ,1cllleve qUiel runnillIJ
The reverse Ilear all the l.1ynenr has St,nluht·cut sp'" teeth which dllve Ihe 1 st/2"d synchrOlliser huh via the reverse Idler IJeM when I(~velse geiu IS (J1l\Jilge<l
Ge;u$ "re ell!J<oW,d hy" th,ee r<lll se lectOi systCII1 on the fou.-speed Ofi.1r!)ox . ilild a slnUle r.111 selecto. systtml on Ihe f,ve·speed ue.1.box
2 ROlltine Illainten,lIlce
At the "It,,"v<ols sp"c;lfl(:d " I the BOu tllle M,,,ntcn;lIlce sectIon "1 1he .)(l l of the 'll""l1al c,lny alit t l~e follow"llJ pr(Jcedllle
"cc k Yf.'ilfbux oillevul
J.1ck up th,! C;lr amI SUPpO'{ on a xle s!;lIlds. m;lklll\j sure lh"lll 'S levI,1 Alt""l.ltlvely PO~III()n Ihe Cill over .111 "lsfH:r.IIUIl I"l 01 on lamps
) US&#34;&#39;~J ,I s\III, II,le SqLl,lIU key. un~r:&#34;,w IllI< hiler pili" f'O'l1 Ilw Idt h;1I1d ~I(h, of Ih(, oe"rI)Ox (pholo) Not" Ihm Oil Ihc lo"r-sp<:ed 11".101)0 the hll", ph,O IS 101:<otod nlmv" th" d "II1l 1'1110 3 Fo, ;1<:<:Ula{n l"sullS lhe dleck should not Iw Illad.; 1I1lIn"d '''h,ly <llier a 'll".lIu! 1111115 IS 1I1l"vo,dal,le ;illow I,ve 0' t'!llllllllllh,S (or Ih" OIl to seu le
4 Make UP" piece of bent w ire to Ihe d"llells'ons shown III r-'!I G] lhen IIlSCll II ,II1d ,eSl Ihe ho.ilOntal seetlO'l 011 Ihe tllIca(is of the pIli\! hole. Remove the wire and check Ih e all level On all lour-speed
\Jearhoxes . ,11l(1 f,ve·speed ge.1rhoxes m.1nufactlltud ,,(w, M"y 191;1S (!wlld code FIl) the 011 should be level with (]I a milx"num of 5 0 111111 (02 Ill) helow Ihe iJottOIll edne of the ph)~J hole. I: or ('ve-speed !1(;&#34;&#39;IJ()XI!~ m;lIlufactured liP t o Ap,,1 1984 (Iwlld co(ie EG) Ihe 011 "'list I,,, I"v'" W ill, 11,,; bOllom of Ihe plUH hoi" On I,ve· speed Ilca,hox cs "h"nda<:tu,,,,II,(,twe,)Il M"y 198<1 ,IIld 1\.11111 1985 (Iall sulf,x (,n(iIlHI II'
E) the o&#39;(&#34;ltI~1 h" ""'w""" 1 0 0 ""d 150 """ (0 <1 alld 0 G 'n) 1,,;low 110" I)()UDl Il &#34;d~I&#39;! of Ihe I&#39;lu~1 hoi,!
G WI",,,! &#34;&#39;&#34;;&#34;s~.,,y top "I' l h " lev,,! with II", ~1&#39;(!<:I(oed !jI;I(),., 0 1 001 (phulo)
" n,,(ot and "!Ih,,,n Ihn fill", plu!) Ihen lowe, Ihe "II to lloe ~)lolllHf
-;;e.1l'lJox -rmll()val ancl .efiuinu
If the IJ"ilrl,ox IS to he 'emov"d from Ih e Cill wllhcHJI romovlIIU Ihe ""II"l(J, Ih" !1'''"j,UX IS rumov,!d Irom heneallo lloe car Jnd il (,IIUe wound cle.11<mr:e IS 'cqulled 11 all lI,spcu,on luI Or ramps ille not 'IVa,lahle. 1,1ck Ihe Cill.1S hlUh as poss,!>le. support It securely on hlocks 0' stands ,1nll chock the wheels 2 O'SCOIU10Ct the ha tlery
Fig. 6,1 four-spoed \Joarhox (Sec 1)
Fi\J. 6,2 Five-speed !Jcarhox (Sec 1)
I.e , ..
-~
t 25 W II I !
t A • I I I 15 I
7 (11) no I I ~
~-
" I /
~ 10\,
· ... 1--=" ...
Fig. 6 .3 Wire dimensions for IlHlking a geilrhox oil level dipstick (Sec 2)
All dUllet/SIOIIS J/l IIUn A File lIole/n's
:; .
.. ~ .. -,.' . • <
! ,,;
'r '
,j/
' I
live-speed 25 TopP lng'up the gearbox oil 3 ,4 A On the lIve -spee d UOilfhox remove the pack,n g
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) Chnpter 6 Manual gearbox ililel <llltollltltic trnosmission 105
'-
Fin. 6.<1 Usi",! a cranked spalliler to unscrew the goar Inver retainer (Sec 3)
Uus';",,,, 111" !I";)' '"'1''' knOiJ and ",lllOv,! 1he COVlJt <lnd ,,,bl,,,, !' " -.,,, If .1 P&#34;L~&#34;\I&#34; ["'V 0' '-;0:111[(, ""n""I" I~ hlled. thest; 1\,,",,1 I." )VI!d (,,·1,·, tn Ch;'1)I'" 11 d &#39;H;r.,,~sary) 4 Oil II", I"", -'1"",,1 'I,,;,d)()x, 1",,](1 I''''.k ii,,, lock t<lh ilild ullsn"w Ihe 0"," I"".·, '0:1.1111';1 &#34;~&#39;Il!l a ~llllal> ly !:';lIlkud spanner 01 ca",Iloi II~&#34; 01 aha"""", .",,1 dill! On llw j,vC 'SI",,,d (ype. remove tl", 10;"" P<l(;klll0Il,,'" ''''','''"W the Twx s.:wws 1",ld"'!I til<; Iclilillcr l.,f t "111110" geM i<)vo:, Il'h,,\,,·.) 5 On Ih" Imll sp''''d (J<;ad,,)~. pl;",c ,r d'1I' [,ay hencnth Ih" !I",IIt,(lX. remove II", ,h."" 1,llI!! amI. wht:1l tl", ",I h;,s ,I,a liled. rol'llhe l)h'!1 ;"HI lighten II -! I ll"!) ,~ no d&#39;~111 phllJ Oil lhc Ilv,, -speed geillbox 6 Put 1)),11111\1 I))arks Otl lhc (wO I&#34;o:,-,~ 01 Ih" 'U,\[ <lxlu lomt II,III!I" Remove (h e lour holls I,om Ihe !Ca, a~le p'lltOn lI<lnge <llul Ilw IWO bolts !rom Ihe plol'.)lIu. ~hillt cem,e hea,ing suPPO,t <lnd Wllh(haw the p,opclh~, ~h,ill ;)ss"mhly from Ihe eXWIlSlon hOUSing_ Tie a polyll","c bag round Ih!) ,,,,d 01 [he \je<orl)ox eX[r)l\S'()1l [0 keep out dill In 1:,ll( :h
<lny
oil wl"d, Ira" not d'ni"ed,
Fig. 6_5 Gearhox erossltH!lllhcr {Sc. ; 3)
'I 0,,,(I)I)I
:C1 the cl,,[r,h c<ohle ,~,[h ,,,[,,,"I1CO W Chill)h:: 5 . .-mrl wIlel!: ;lpplu,,,(,r., the lucl IIll!!O:llon fll.:1 hne" W,lh ,uf"'e,,ce to Ch.II'I", : 8 Flrlllll'v" (h.: sc,r;w and loekpl.lh: s',cllIlI'H (he Slu;!:do'nl!!e, (I"v" <In,1 (Io"""nn"':t lhe d,we n n",nov", 11le eov"r (,I j'tled) I,om llw ,r,v~lslll!1 hollt "wOldl NOI" whu:h \V,'y t i,e le;-Hls a ,e lolted and llH'11 I"move Ih{IIIl (pho(o) 10 f)"l.lrh 11m c.h;&#39;rI~.1 plpP.S !to'n 11,,1 O:&#39;! hlL!~l Ilhl".r"ld ;lIld IIC IhO:IlI out vi th" way, so lh;rI thc ()IlUIIl~ .Hlo! l,aIlStl"SS lon call he lowclcd 11 SUp!,'''1 Ihtl \)fl",hox 011" I<lC~, or With 1,Ioeks ~&#34;d Icmove the 1>011 st:ClII"'!i lire tr,&#34;&#39;Stl1l~5&#39;()1l to (he "';11 &#34;1\~J&#39;IlC mourI(tll\! <lnd llle fOll! i)(,IIS ""'-11111\\1 the !le,l,I>ox C'OSSIl\('mIH" to lhc floo, (photo). Remove Il,c C'''''',IIII:rniJcr 1 2 l.mV<'1 [he (,nnSIlHss'on a lillie ,Ind II\S(:r[" block 01 wood hctwecll lhe SW"I' ;Ind the II()nt ellUHw mOI" lll\J so lhm 1hc cllOllle rioes not d,op too I;" when Ihu 1r,IIlSIllISSlon IS &#39;~I))()ved 13 [l"mI)V" 1hc bolts secu"l1g the clutch hOIlSlIl!! 10 [Ile en~l&#39;l\e ;)l1d
hn ekpl.,,!! (photos) Pull the ['.lI1SIlHS",OIl ;,sselllhly I() Ihn 'c;" 10
.,..
3.4C <lllli loft OU( the gen' 11.""'1 39 DISCOIHlUC1"1\J the WlllllU frOl1l1hu &#34;~VC&#39;SIflU IIOh( SWitch
[ho) gc"d)ox e,ossmumhe.
).,
{" ; ",
3.13A Two upp.:. cllllCh houSIIlU-lO·engrne boilS (arrowed)
3 13B A lowe, clutch houslflg-lo·hackpl"te I)olt (I,ve'speed (JeJrbox)
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·06 Chapter 6 Manual gearbox and automatic transmiss io n
disengilge the gearbox inpu t Shill! hom ,ho clutch p,Iot bearing ,111(1 clu tc h friction disc. I, is imporlanllhal,hc engine and transmi ssion <'lre kept in lino while this is being done. 14 When the gearbox shaft is cleDr of the clutch, remove th e
tran smissio n assembly from bCn(!illh the car.
15 When refiuing, ensure 1il1 the clut ch pilot h earing in the end althe tfilnksha h is ill plilce Jncl is scrviceDble. Tic the clutch lever 10 the clutch housing, 1 0 pr(!venllhe release le.rertrolll slipping out while the ,Wnsmission assembly is being lined. 16 Smear some molybdenum-based grease OntO the end and splines 0' the gearbox input s!mh lind refit the gearbox by reversing the fcmovili p.ocedure. 17 II is impO.IMll when offering up the {jOMOO)(. th,lt il is e~<Iclly in I me with the cranksh~1t. otherwise the ge,l.bo~ inl)ut shah Will not enter
th e clutch ffiction drsc i1nd the Cfankshnft. Ifthe.e.s d.iilcul1y Inlnatinn th e splrnes 01 the gea.box shillt ,1no the frrctio n oisc. select iI \)em to 'CSlrain the movemcnt of the gc,lrbox shillt nnd turn the gearbox
slightly until the splines enter Do not iluempltO lo.ce the tfilllsmisslOn
ontO thO enlJlnO ThiS Illay (i<lmilgc tho spllllcs <Ind nrilke !rtllng
ImpOSSible
'8 Ahe •• el,uinn has been completed. chuck the 011 level Ifl t he .r<lnsmlSSlon and IOI) UI} ns ncce5sary
Gearbox (4 'S II001l) -dismantling
Romoye the lou. bolts hom the 1011 cove. 01 the t.ansm.sslon c~t()&#34;sion housin!J ilnd f.om the lri&#34;&#39;snHs~ir)Ol eo'S<' Ilcmovflthc \:oye. s.
t.1king c<l.e not to lose the th.ee springs untie. tire lran~mlsslun case cove •. 2 Use n In<lgnet to .emove the th.ee selecto. (fc te nt h,ll1s. 3 Remoy o the bolt 110m Ihe selecto. ImUel .111( wllh(l.;rw the 1'''U e.
from th e seloclOl shalt. 4 Remove tho twO bolts from the selectol sh<llt Ileminu sUPlm.t M{ renlOye it .
5 Remove the Ih.ee bolts from the selector hOUSing COVCI. Remove the cove. with the shaft. then ro tate the selec tor sh<lh slrghtly ,lnd withdulw it hom the selectOf hOUSing cove •. 6 Driye out the '011 pin <It the s.de 01 the elflension hOUSing and remoye the .cve.se ge;" .el<ly leve •. 7 Usmg a Ilin punch <lnd <I h,lmm c •. d.ive out the th.ec roll pins from
th c 15t/2nd. 3!d/top and .cve.se oe,1'5 suiliClently to rele<lse the selector lorks . Hcmove 3.d/top \le;" setecto •• ~d f.llcl rp <lnd th en withd!~w tht) selecto. '<llls tow<lrlis the extllllSIOIl hOllsinu . Note the
plullger ill th o 3.d/top selecto. '<1'1. Remoy e Iho th.ee selecto. lorks. J Remoye the plug hom the side 01 the c<lse and usc II m~lgl1et to ~,t&#39;<lct the plunge. beneath it. Gend back Ihe tabs 01 the w<lshers 0' the two boilS on Ihe e~tension housing. Remoye the bllnJO hOlt, 51)11119 <lnd ball <lnd the ,eyerSlng "ghl switch. spring and plunger . II Use two sc.ewd"ve.s and c<llelully ,)uSh th e speedomete. OUI 01 the eKlCns ion housing 12 It there has been no sig n of le<lking from the eKlension hOUSing 011 seal. tako cafe 110t to damage il. II the senl IS delectlye. leve. it out. t nking cllle not to daillilge its se<llil1g. 13 Remoye tho lou. ~ttachment boilS nnd detach the cxtcnsiOIl hous ing hom tho lIansmission casc o 14 Using n long Ihin d.ift. tilp Ollt th e 1~lyshnft from the front to the
rca •. Allow tho laygeal cluste. to drop into the ho ltom 01 the box. out 0 1 mesh wilh tho lIl<1inshalt gea.s. 15 Withd.aw the mainshalt and elflension assembly from the ge<l&#39;bo~ casing, pushing the 3.d/lop syn chroniser hub lorward slighlly to o lllain the necessary clea.ance. A snlall roller beming Should be on Ihe nose olthe m<Jins halt . but il it is nOlthele il will be found in it s lecess in the inl)ut sh<11t and should be .ellloved . 16 Aen love the lou. boilS securing Iho dliye gear hearing retainer to
tho '.ont 01 the gembox and slide the retainel 011 the input shalt. 17 Remov e the circlip hom the outside 0 1 the fronl bearing and tap the outer raco of the bearing to d.ive the inpu t shillt and bea.ing assembly into the gea rbox. then lilt them out olthe box . 18 Remoye Ihe laysha lt geaf cluste •. Ihe two th.ust washe.s and any I"'o se needle 'OIiOfS.
R emoYo the .eyerse idle , shah by sc.ewing a suitable bolt into Ihe end of Iho shah and then leye.ing the Sh;'lit Out uSing Iw o open ·ended spanne.s. Fi\)
.
6.6 Removing the seleclor 10lk rolillins (Sec 4)
A CIfC/'11
Fin. 6 .7 Revorso gear interlock nnd light swil c h (Sec 11)
A Ravelse liyh, switch 8 Swing C Plf/ngcr
o h!/ellocl< ball E Sc,ew IJlug
Rct.1ininy bolt F
5 M<I;nshaft (4·speed) -dismantling and reassembly
Remoye 3rd/top gear s yn chron ise. hub ci.clip Ense the hub amf
thud gear lotwald lly lel/erinu the,n gently wrth a p<lll o f snipe· no sed phe!s. 2 R emo ye the hub. the synchronisel .ing and 3rd gear from the I.ont o f tho mainsha lt. 3 Mount .he plam pal! 01 the mainshah in a soft jawed vice. unlock
th e mainshah nUl and lemoye it 4 R emove the loc kpli/te . speedometer dfivegem. ilS d.ive ball and Ihen level 011 the reaf bea.ing. complcte With bearing IClaine •. Separate the bea.ing and its lelainel. 5 Remove the 011 scoop ring and lils i gear . 6 Removo 1 sl/2nd gear synchronisc. ci.clip and pull 011 the hub with the bi/ulk .ings and second gear. 7 Check thallhere is a mark to align the selec to. sleeve in .elation to the hub. II no malk can be seen. make one with a dab of paint ~nd then dismantle the synch.oniser hubs. 8 8010/0 sta.ting .eassembly. Clean all parts thoroughly 3nd check
their condition. Smear all Pi/ItS wilh tr3nsmission 011 befo.e fitting .
9 Reassemble the synchroniser sleeve and hub so that the nlafks on thorn align . Inse.t the sliding keys and 1IIIhe shdrn\) key sp"ngs so Ihat Ihei. open ends afe stagge.ed re lat ive 10 each other
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, Mil'" dfivc gear bearing fewincr 2 Gasket 3 Detent balls with springs 4 Transmission case gasket 5 Tfimsmission case cover 6 Speedometer pinion 7 Dowel 8 Extension housing cove! gasket 9 Ex/ension housing lOP cover 10 Selector housing gasket
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Fig. 6.8 Exploded view of four-speed gearbox casing and selector mechanism (Sec 4)
'I Selector housing cover 21 Selector shaft bearing support 29 Seleclor rail wilh 3,d/4th gear selec/or 12 Cap boll wllh lockplale 22 Reverse relay aIm foil pm fork
13 Spring 23 Bcaring sUPPOfl 30 Circlip
14 Delenl ball 24 Extension hOUSing gaSket 31 Plunger
15 Plunge! 25 Se/ecto! fail wllh 1st/2nd gear 32 SelCClor rail with reverse gear selec/or
16 Sprmg selector lork fork 17 Reversing light switch 26 Fiffer plug 33 Selector shaf( 18 Gear {ever assembly 27 Drive gear, bearing relainer 011 seal 34 Selector finger
19
Oil seal 28 Plunger 35 Reverse gear relay lever
20 E~tension housing bush
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Fig . 6.9 Exploded view of four-speed gearbox internal components (Sees 4. 5. 6 and 7)
1 CIfCltp 2 Cllcflp 3 Grooved ball-bearing 4 Input sh<JI/ 5 Needle rollcr beiJring 5 C"cllp 7 3rdl4th gear synchfoniser biJu/k ring 'lcll/oll/sCI 8 3rd/4(h gear s~ hub/sleeve assembly
9 3rd !<C.Jr 15 Circf,p 10 TriJl1SfllISSlon mamsha(l ]6 lSI gear " SpeedomCICf dove lockmg 17 Oil scoop rmg ball 18 InrcrmcdliJle beaTIng support 12 2nd ge." 19 Bcaring 13 ISI '2nd go',,, synchromscr 20 Spacer ClivI/( flflg 21 Speedomercr wormCllve /4 15/ 2nd geal synchrOnise! gear With revelse 22 Lockplale
23 Mainsha/r nul 24 Laysh;1fr /hrust washer 25 Shim 26 Needle folfers (22) 27 Laygear 28 Layshafr (hrus/ wilsher 29 LayshJI( 30 Reverse ,dler gear 31 Idlcr shall
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Chapter 6 M anual gearbo x and autom atic transmission 109
Fig. 6.10 Rcvcrsu [JC>lrill[J '"cill[J fo rwMd s (Scc 5)
10 l'I:IClllhl} syllchlonl~!&#34;!! t,,1nlk "n[J onlO Ihe COl It! 01 second !Je,'. ,1n(1 511110 11 onl0 I he Ill:H(\sili,l t tOIJlHiler wltil h t/2nd lIe,,, wnclHOlliStH iluh. Thn \In", on Ilw huh should Iilcn 100war d. 11 Fit Ihe sync hronise, lJ;oulk WI(I >llld the c"clop ""Iudl holds th n
sV"ch'Olllser hub in ,)I;lCC 12 Slide on hisl Ulli". so th>ltthe sync hronise. conI.' pO"'Oll 10,,5 ins ide the synch'Onlsing .i"U which ha s lust ~en f'IlC(1. 13 Fit thc oil scoop. wilh the all [JIOOVC lilCinU .e;lfwa.ds. 14 Apply !11ulii-pu'l)oSC [Jrf:ilse to thc billl·hciI.il1!J seilt 01 the ilc,,,,"U rctaine •. flellt the lelllinCf with the be>lll"g insCrtll(1 >llId Ihell slldll on lhe sr)acer. 15 Insetlthe d.ive hall 01 rh e speedo meler geM inl0 rhe sh"lt >lnd shue the spcedomete. wo.1lI ueM over i\. 1 6 1: ,1 I h e loc kpl>lte so thm the twO wbs ht II1tO rhe speedolllelC. wOlin \lCi" I(.'C'"SS Soew all t he not alld tl{.lhlen II to the to.que wICnch
SCllln!) !/,vun III the SI)()Clhcallotls. Ihen lock Ihe IIUt hy bendi"" th C
I"IJ w;osh!"!! 11 Fit lhu synchltJIu~r iJ,IlIlk 1II'!110 thll COliC 01 thUd !Jea. ;lIId lit them to Ihu 1,0'11 01 Ihu I&#34;al,,~,h,,1t ,"It the 3.d/wp !W~. sYlldllOliiSC' huh.
With Its Wide ho~s IOWiUd~ Ihe le,u illid (illlil leWII) I( III pl;lce hy IIlllll!)
"'e t.:llchp
11I1)ut shaft (4·slleed) -dism 'Hlllillg and reasscmbly
It IS
not nccessa.y to (los",,,,lIlc Ihe Input sh<llt ullln~5 <lIICW heil'"11J o. a "uw sh<llt IS i)eln!j hllod 2 W,rh <I pJIf 01 cucl lp ploers. eXl'illlrl Jilt! lell10ve the 5111;111 C"CIoI). whlt.:h secules the beill lnUto the Ull'lIl sh<ll1. 3 With iI solt·he<ld ed h'IIllille •. Uently (;;IP 111(1 t)(l.1J1IlU 10.w'If(1unlllII Cilll be "ulled IrOI1l the Shilft 4 When fllllll!J Ihe t)()a'"IU. ensure Ihatlhe {)'oove in lhe I/C.iphe.y 01 the outc. bearmg t.ack IS ,1wo1y hom the geaf. otherWise II Will not he
pOssible to ht the la'!Jc cllch" whldl .etillllS Ihc I/Ca.ing in 1)lilCe III the housinu. 5 Eilhe. SIJnd the UlpUt shalt up.iUhl on a bench and tilt> the be~.ing IntO plncc U5in!J a piece oltllhc 01 suiwble diMlete •. or usc the jilws 01 a vicc to SUllpO I! the be;uill\J ""d wp the rem ollhe i"flut shill! with a soft l.1ccd hammer. 6 When the b earing IS lully home. III tilC cllel'l) which .etains the bearing 011 the shall.
7 lilY!Joa r (4·speed) _ dis milnlling and reassembly
R e
move iI shim Irol11 cilc h end of t he layUMr. ,elllove 22 needle
rolle.s hom each enu of tha \JC<I'. When leassemb hng. I"sell a sh"n 11110 thc bOllorn 01 the borc. Daul.) . ,Ie bOH! wllh general PUfJ)OSC 9,cilSC and inse., t he 22 needle rolie.s .
Wh",n alllh!;! rollers a.e III 1)lilCC. sm ear g.ease ovel thl;!m CO .etain them alld then sccule the sh un ave. Ihe ends ollho rolle.s Wllh y.ease . Due F
ig .
6.1 1 Position o f oil scoop ring with groove facing gcar (Sec 5)
Fi ". 6. 12lDyshDIt and !Je>lr cluste r (Sec 7)
10 Ihe h'!Jh levels of corque lfanSllulled th.ough the gealbo~ " IS ,mllo.tilnt Ih;)t all the needle rolle.s have exac lly Ihe s,1me dlamele. II Ihe n eed le .ollers ,n iI be,ulng have dlffe.ent (liamelc,s. thiS Will cause
t HIeve" IOile! dls urbu!ion which call .e sul t In prelll;)lu.e we<l .. II II IS ncceSSiI'y to renew the needle .olle.s. m<lke sure Ih.1t the lolle.s use(f lu. <Illy olin loC,lIIon nil COllie frOIll the sallie p<lck. II more Ih"'1 (lile Iwck IS (lurch"sed. do 1101 lIIi x the needle .oile,s 1'0111 sep ... «lIe Il<lcks
8 GCiI.box (4·speod) -e xamination and rcnovation
ThO.oughly cleall the inle"Or of the gearbox. and check lor d.oppcd needle . olle.s ilnd spr ing pins.
2 Ca.elully clean ilnd thcn e xamine all the component pa.ts fOf gene,al wea •. d,stOltion, slilckncss of f it . and damage to IlIac hi ned
I"ces and th.ead s. 3 E~alllllle the gea,s for e xccsslve wear and chipping of the teeth. Renew them as necessa.y . <l Examme Ihe laysha /t fa. Signs 01 wear. whele Ihe needle .0Ue.s
beDr. II a small rodge can be felt at eilhe. end 01 Ihe shah il Will be necessa,y to renew it. R ene w the thrU St w ashe.s at eilch end. !i The four synchroniser baulk rings a.e bound to be badly worn and II is lalse economy no! 10 .enew thelll. New rings W ill Imp,ove tile
smOOlhness <lnd spoed of the ge3Jchnnge considerably . 6 The needle .olle. bea.ing and cage, located hetween Ihe nose 0 1 the malnsha/t and lhe annulus In the rear of the IIIpul 5h;,11. IS also "able 10 wear. and should be .enewed as a ",;)un. 01 cOUIse .
7 Exam ine t he condilion o f the twO batl·beDring assemblies. ono on the Inpu l Shaft and one of Ihe mainsha Check Ihem for nOIsy
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