clutch FORD CAPRI 1974 User Guide

"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.
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7.2A Prisc all the rubber Ualtef
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procarmanuals.com

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
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) Chnpter 6 Manual gearbox ililel <llltollltltic trnosmission 105
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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\('mIH" to lhc floo, (photo). Remove Il,c C'''''',IIII:rniJcr 1 2 l.mV<'1 [he (,nnSIlHss'on a lillie ,Ind II\S(:r[" block 01 wood hctwecll lhe SW"I' ;Ind the II()nt ellUHw mOI" lll\J so lhm 1hc cllOllle rioes not d,op too I;" when Ihu 1r,IIlSIllISSlon IS &#39;~I))()ved 13 [l"mI)V" 1hc bolts secu"l1g the clutch hOIlSlIl!! 10 [Ile en~l&#39;l\e ;)l1d
hn ekpl.,,!! (photos) Pull the ['.lI1SIlHS",OIl ;,sselllhly I() Ihn 'c;" 10
.,..
3.4C <lllli loft OU( the gen' 11.""'1 39 DISCOIHlUC1"1\J the WlllllU frOl1l1hu &#34;~VC&#39;SIflU IIOh( SWitch
[ho) gc"d)ox e,ossmumhe.
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3.13A Two upp.:. cllllCh houSIIlU-lO·engrne boilS (arrowed)
3 13B A lowe, clutch houslflg-lo·hackpl"te I)olt (I,ve'speed (JeJrbox)
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·06 Chapter 6 Manual gearbox and automatic transmiss io n
disengilge the gearbox inpu t Shill! hom ,ho clutch p,Iot bearing ,111(1 clu tc h friction disc. I, is imporlanllhal,hc engine and transmi ssion <'lre kept in lino while this is being done. 14 When the gearbox shaft is cleDr of the clutch, remove th e
tran smissio n assembly from bCn(!illh the car.
15 When refiuing, ensure 1il1 the clut ch pilot h earing in the end althe tfilnksha h is ill plilce Jncl is scrviceDble. Tic the clutch lever 10 the clutch housing, 1 0 pr(!venllhe release le.rertrolll slipping out while the ,Wnsmission assembly is being lined. 16 Smear some molybdenum-based grease OntO the end and splines 0' the gearbox input s!mh lind refit the gearbox by reversing the fcmovili p.ocedure. 17 II is impO.IMll when offering up the {jOMOO)(. th,lt il is e~<Iclly in I me with the cranksh~1t. otherwise the ge,l.bo~ inl)ut shah Will not enter
th e clutch ffiction drsc i1nd the Cfankshnft. Ifthe.e.s d.iilcul1y Inlnatinn th e splrnes 01 the gea.box shillt ,1no the frrctio n oisc. select iI \)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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Chapter 6 Manual gearbox and automatic transmiss ion 111
24 Chec k the plilY between the selector finger and 3.d/top geM selC{;lOr .a,1 (F,O. 6 .1 6) . lh,s d,mens,on shou ld be 0.9 mm (0.035 in). lo m"ke t he chec k. move the selec to. leve. up to the .everse gea. SlOp. Us.ng a lever. push 3.d/top gear selector .all \0 the rear and then
measure th e clea .ance by rnsel1lng leeler gauges betwee n 3rd/top gear selector rild "nd seleClOr finger. If th e cleM,mce 's no t ns specified. it shou ld he conecled by chnnging lhe .everse interlock geM plunger for one whIch will give the ,'PI).opria te clearance. 25 F,t a new gasket 10 the e~lension housing cover. Posilion the
cove •. ,nSOI I the fi~ing bolts nnd lighten Ihem 10 Ihe torque wrench Solt1inlJ g,ven in the Specifications. 26 M,1kc su, e th atthe geMl>o~ dmin plug is I,tted and tigh tened where apphc, 1hlc. then I,ll the uenlbo~ 10 the COffect level with the specl l'ed
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10 Gcnrchnnge lever (4,sjleccl ) - m odificnlions
1 To ,mp,ovelhe \]flnr ch nngc movemcntlJctwecn lh(: Hea.s. , smallm CO".,r levcl Sl)!"'g ,s 1'lIr,<:I. the new 51)/,nU d,amclr'!' bc inU 20 mill (008 aga,nst the orig,n;r l sp.,n!) IIiarllctm 01 2.5 nUll (0 .1 0 inl.
Fig. 6 .15 Cover. d ewnt balls and sprinus (Sec 9)
Fig. 6.1 7 Gearchange lever components (Se c 10)
A Spliny B Rct.1illiny pin C Pf;JSlic C ilP
Dlillcnsion X mUSI be gloater Ilran dimension Y
2 To renew Ihis sp.ing. lir sl remove the gear lever unit from the trnnsmission as given in Section 3. 3 Press or drive out the roll pin and remove the plastic cup (F ig . 6.17 ) ;rnd spring .
4 When reassembhng. check that the pin di('!meter is less thiln the width 01 th e slots (X ,n Fig. 6.17), II necessary grind down the pin and
d e·llUrr the slots by ca.e ful filing . When filled the pin slotS mus t face upwMds. 5 If the gear leve. was loose when in use. an O-ring can be filled in placo o f Ihe retainer sOill as shown in Fig. 6.1 8 .
6 When this flng ,s fmed an(I the gear leve. reIOCalr:!d. screw the retainer cap inlO pos,tlon so th ilt It jus t touches th e O·ring . Mark the relntlve pOSitions of tile cap <lnd selector hou sing. then llghlen the cap " fUll he. 15 mm (06 In).
11 Goarbo~ (5·speod) -disillantling
1 Clean the e~tello. 01 Ihe gearbox w.th paraffin .,nd w.pe d.y. 2 Remove the clutch release beallng and allli lele",ng 10 Chapter 5.
0035;11 10.9 mill}
Fig. 6.16 Plav between selec to r finuer and 3rd/4th geM selector rail (Sec 9)
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A
Fig. 6 .18 Cross· section of gear lever showing 0 ·rin9 (A) location (Sec 10)
i
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Chapter 6 Manual gearbox and automatic transmission
3 Unscr(lw .1ml remove Ihe reversrnu IrUtli SWilch (rhOIO). 4 UnbO lt the clulch bellhousrrl\J f,om the /,onl of the ge~rbox. Removo Iho gaske t 5 Unscrew tllo bolts .111<1 w,thdr<lw the r.lutch releilSe heilring gUIde
sleove 1101(1 tjolskCI from Ihe I,ont 01 the w~nrl)ox (phOIO). 6 Unscrew Ihe holts ilnd lemove the tal) cover lind gaskel (photo).
7 Inve,1 the UflilrllO x <Inc! allow Ihe 0,1 10 d',lrn. then lurn H upright ngain. 8 UnSCfew Ihe holts ,lnd hh Ihc 51h !tcm lockmg platc from the extcnsion hous,ng (photo) 9 hl,nct the 51h neM lockmU sP""1J lind t)'" from the extens,on
housrng (photos) Use il sc,ew to 'elllove the I)'''. 10 WOrk'no tllooulIlI the \le"r lever npr:,w,e. usc ,1 screw(l"ver 0' sm,,11 d,,/t to 1np 0,,1 Ihc exlrlO1s,on hOllSIII!] ,(:.lr covc, (l)hOlO)
I I Select revct~e !Ica, <Inri pull Ihll seler.ln, Sh.lft fuliV 10 the ,e;I' SUPPOfl tile Sh.lh w ith <I pu;ce of wood. th en II"ve out the roll pin <lnd w,t hdrllW th e r ~nn&#34;&#34;Ctor Irom the r";'1r of tll(1 s"l(lctor sho1ft (photos)
, .,-
12 Unholl and removc Iho extension housing Irom the ,ea, of Ihe
!)en,box . t1 nece5snrv lilP tho housing wrth a soft·/aced mallet to releilse ,I t,om 1he dowels. Removo tho gnske ! {photo}.
13 P"se Ihe cove, from th e ex 1ension housing Dnd withcfrnw the speedome1e, d"vc\Jenr (photo). 14 Selec i neut,<ll then. u511lg nn Allen key. unsc,ew the sOIO(:tor 10ck,,,U IIlCCh<lrHSm ptug from thO sille 01 the mnin casrng. EKtrnc\lhe spun!) nnd tock"l!l pm. ,I ne<:essmy USIl1IJ a t)en m<lgnet (photos). 15 O"ve 1he roll llUl hom the soleclor boss Dnd selector shDI!. 16 II nccess,1'V Ihe sclCCIO' shnlt centrnhslng spring nnd 51h gear 10t~krn!1 I;onl.ul ""'V he femoved U sing a small sCfcwdrive •. push out Ihe pili <llll! ph'!1 nu" shde the conllOl hom the selec lor shnft (photos).
1 7 Note tho loc.,t,on of Ihe selec to, components. 1hen w,thd,nw the Scll!CIOr shafl I,om Ihe rellr 01 the Ue<l,bo~ <lnd remove Ihe selecto. boss ,"'11 lock",!! plain, lSI/2nd .1lld 3rd /41h selecto r fOlks. and 5th oe~, Sl,rm:IO , lurk ,UHf sl"eve. NOte 1I11H 1he ,all pm hole 1(' Ihe selector boss ,s InwlI&#39;lI~ Ihe f,ont (photos)
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11.3 Revc,sm!t lilmp switch 1 1.5 Clutch rdense 1.K.'111"'!1 gu,dc sl(:cve 11.6 Tal) cover and tPske
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11 85th \)e;II lockrrlU plilte 1 1.9A 5th eil' lock"' SP""!t 11.9B 51h !)C<ll lock,n u pm

11 1 1 B Ilemovong scle<:tor shaft connector
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procarmanuals.com

) Chapter 6 Manual gearbox and automatic transmissio n
121
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1 5. 17 MC~Sll&#34;nu corchp· 10·SPCI1(lOIllClcr drivcgc,l' dImension 1 5 .1 8 Sc lcCl0f Sholl! t1sscmlJ lcct 1521 FIlling selector sh1lft/boss fall pin
15.23 Speedome ter dJlvcgcn, cove.
IOCkmg cOI1l,ol hy Inserl;"y the 1)111 ;lnd 1>lu9 2 1 Ahgn the holes. then (lillie Ihe roll pin il1lo the sc lcCIOf boss ;111\1 SI~ICC1Of s h<lh (photo) 7.2 tnserllhc ~clCClOr lock lll{J pin lind spnng, npl} !Y sonlcr t o the plug ·'uc.1ds. then insert ,111<1 liUhlcn lllc plug uSlIlg ,Ill Allen k ey.
_ 3 Fit Ihc SPCCdOIllCICI dnV(!IJciII to tho r(!J' ex tenS Ion housing. Apply " ionic scali.., 1 10 Ihe cove. Ihe'l pro ss II 111\0 \he housinU (phOI0) . . nornavc the 1 (!U1llOHUl1y flHed bolts 1'001 Ihe mlCfllIcd.nle housing. •.• en scle<:1 4th {Jom. 25 Slick n new \Jaskot 10 the e~tcnSlO&#34; housing with glC,1se. ,md fot the hOusing 10 Ihe inle,mcd'Jle housi"g T .. ke c", e nOI to (I,ml<lge t he 'e'"
all seal. ,1"d m,1ke sUle th<ll Ihe sclecto, shah cenll<thSlng SWinl] loc .. tcs on the pin (photo).
26 Insert the bolt s .:md tighten them to thespcclflod to'Que In d,agon .. 1 sequence. Befo.e Inserting the Ih.ee bolts which go light through tllo
main c .. sing ... pply se<tl<lnt to their threads 27 Selec t levelse \Je .. r <tnd loc .. te the connector on the re .. r o f the
se leclor rod . Support the rod wi th a piece of wood. then drive in the '011 pin_ Selec t neutral. 28 Press the .eil' cover into the extension housing .
29 Check that the 5th gea. interlock slceve is corrcctly .11ognoo. then 'nscrt thc Sth geil' locking pin and spring.
30 Appl y some scalallt to the 5th geilr locking plate. 10Cilte It on thO extensio n housing. an d inselt nnd t igh ten th e bolts to I h e specIfIed torque. 31 Fit the Ueilrbo~ top covcr. together WIth a new gas\(et. and lighten
the boilS to t he sf1eclf.ed tOfQue in diagonal sequence. 32 F u the clulC h relCilSe bearing guide sleeve (oil slot dow nwllfd s). together with a new gilsket. and lighlen th o boi lS to the specillt~d torque in d;ilgon;11 sequence. Where neceSS;1ry apply seal,.nt to the bolt threads_ 33 Fitthe clutch bell housing to the Iron t 0: the gearhox. together woth new gaske t. Apply sealant to the bolt threads. thcn inse n the boilS .~d tigh ten them to Ihe SIXlcllled 10rQue in diagonal sequence. 34 Inscrt and trgh le n the .ev(usinl.l Ioght switch in Ihe ex tensio n housing
1525 Selec tor sh aft spring pin (arrowed)
35 FIt the clutch reLease l"l'lIIng and a.1Il wuh .efercnce 10 Chnl)\ el 5.
16 G e(lr box (5-spee{l) -d isellg i:lgem enl of 5th gear
I I
is possI ble 'or vducles hu,l t bclo.e NovcmiJer 1983 to have i:l p.oblem WIth 5th ne". Illillplllg Ollt of cnuanClllcn t during normal
(hlv lnu
2 ThiS 1I0uhle Cilll he rcc tl',cd hy suhstitutinu nlod,hc<l 5th ge.1'
componen1S t o Inc lude thO hub. o!\Ulk ""gs .. nd sci(.-ctor 'ork.
3 Rem ove Ihe gearbo_ "s de$("bed in SectIon 3. This wrll nCCCSSlla te lemov ing the ge(l' Icvcr "nd lu"C I cove. whIch is held In ,)OSltlo n by TOOK typc sClews . 4 Removo the clutch Hlleilse bearing and tevcl 110m the bclthousing . 5 Unbolt ami lemovc the lOP covel. 6 C"ory out the opel,1t'0"S dcsc llbed in par "graphs 8 10 1" 01 Seclion
" 7 M"r\( Ihe ex.1Ct IIOS""o n of t he speedometcl wormdrive on the milinshil lt (lnd then draw it off using a pulter .
8 Extr"ct the ci. et,p "nd H)move the 5 th sp(lcd sync hro unil/rom Ihe
mJinsh"lt. 9 Dismanlle the synr.hro "nd reasscmble using the new p" rts, When I Itting t he b"ulk lings. m"ko sure that theil bevelle( 1 side is tOwa.ds the
re,,' o f Iho ge",box. 10 Caffy out the ope,,,,,ons desCfibed in jh"lfilgraphs 16 to 22 and 25 1027 in Section 15. 11 Inser t the 5 th ge<lr locking pin and spring to Ihe extension housing_ 12 SmC<lr the 5th gear 'ocking pla te WIth seal"n t and locate It w ith nuts hand tight. I 3 Adjus t the gearchange mechanism by pressing the gear lever lully
1 0 the light whIle "1 tho} neul'il' mode and then tighten the locking plate nutS to ill o 'que 0125 NIIl (l8tbl It). 14 Fit the top cove. olnd gasket and I he clu tc h release components.
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, 22 Chapter 6 Manual gearbox and automatic tran smissio n
17 Fllult dingllosis -IlH IIlU<l I gCMboll
Symptom
Weak or in effec tive synch romesh
Jumps out of gem
Excessive noise
Exces~ivo difficliity III enonU ing (]0,11
P ART 2: AUTOMATIC TRANSMISS IO N
18 Gen eral description
Thc aulOma llC l,an~nHss&#39;on ,;rkl:~ lhe JlI&#34;Ct~ uf the clutch and Hcmhox. wh,ch ,"c. of cow se . mounte(1 heh,nd lhe enu;ne . The unil has a 1"'{lO nluminl"'" content which helps to .elluc" liS
overall weinhl and 11 IS o f compact dimenSions. All 0,1 coole. 's filled ,IS
Reilson (s )
Sy nchronising cones worn, spilt Of dmnaU ed O~ulk rin g sy nch romes h dogs worn, or dmnagcr!
Broken gcarc h,lnUC fOfk rod spring Selector fo rk rod !IIOOye h.ldly worn
Inen!!cc! 9(,1(10 of oil in gc,llhox 0' 0,1 level 100 low Bu sh or ncc(tie roller hC<lrlng s WOUl or dnlllill)cd
GeM welh exce ssively WOrtl 0' (l;Ullll!Jcd
l;'lync:u 1hru st W;'\ShCfS w or n ililowing excessive cndplilV (folll,spC<ld only)
C lu tc h cilhle .1(tjllsllllcnl in corrcr. l
Sliln da.d .. nd ensules cooler OI)(lI.lI1Qn of the \.,lnSUlISSlon lind!)! l.a>l." lowinU ;lnd sunlla. conrll1i0l15 . A VaClIl,Hll conncctlon 10 lhe IIII~I manifold p,ovldes smoO lh cr anrl morc conSI$1r.1l1 clownstlll,S IIndc. load than IS the case Wilh IIn,lS nOl !IlcOlI)Or.11U1IJ lh,s f,,(:Illly The sysle m cotlllJltses lWO tIl.lin com(lonenrs.
(.1) A /"ree e/c'mcnl "v,/lokinc/ic IOUIIIII I:Ollvcrler cOII/,lmy 1:;'I'.1h1(.' o f /orqu c 1II1I!lIplicii /iorr ;, 1 .1/1 irr"mldv Villl;,hle r.1/1O (h) A /unluC/Sln'cd respOlIsiv~ .md IWdwlllrI:illlv IIIIL'f.1lCr! cp'· qL"fie f/c.1rbox COIIII}liSIilf/ pl.wel.l/V m:.lISII/S /IIovidmy tlllf:C forw.l/d 1.1/ios "llff OIlC Icvcrsc ril/'O
Fig . 6.24 C utllw ay view of th e a utomatic transmission (Sec 18)
1 GovelllUi ,'ssemblv 6 rop/leve/sc clu/e h 10 FlOn/ SCIVO 2 GOVlIIJI OI IIlIb 7 FIOIII blilkc bil/Jd /I Valve botlV 3 Olle ·w/lV cfalclt 8 rorquc convenor 1 2 V/lcuum diaplu/lym 4 IlCill bfiJ~C baml 9 Hvdraufic pump 1 J Re/ll servo 6 Forwlllfl cia/eli
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Chapter 8 Rear axle 141
lings apm! and compress the clutch plntes. The nction is varinble. depending on the power npplied. so tlMt under full power the dIfferential will lock completely nlld full torque will be appl;ed to both
11 Fa ult diagnosis -rear axlo
Symptom
NOIse
"Clonk· Oil nccelera tlon nnd deceh:ontlun
,... Ilenka\Je
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renr wheels . Under coasting or overrun conditions the differential will operate as a normal stnndard unit. The unit incorpora tes four different;nl pinions <IS <lgninst the two pinions lilled to standard units.
Roason(s)
Worn axleshaft bearing Insufficient luhricant
Worn dlfferentinl houSIng bearings Worn crown wheel and pinion Incorrect crown wheel nnd pinion mush
Worn 1I. leshalt splrnes Excessive crownwheel nluJ pinIon bncklnsh
Pm ion oil senl Icnkrng ReM cove r gasket leaklllg 011 seal on <lxlesh<lfl bearing leakIng
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)
rernoy .. ' and refl Uing -69 spcc,'iC<ltions -66 Carpets maimcnancc -1 76 Centre console removal .. nd refluing -189 Choke . au tomatic _ 71 Cigar 'ighter romoval ;lIld . e 'ru in g -225 C lock (console mounted) .emoval ilnd 'clming 223 el,/tef, -97 cl seq Clutch assemhly ",speclion 99 relluing 99 remov;]1 99 calli e renewal 100 dcsc.illllon 97 laul l d'''[jnos.s 10 nMlllIon,wec. foulorU) 98 pcd,,' rCIllOVill ,mel fcllUII1\) 10 1 release bca"ng .emoval ;mll wl,ulIIU 100 Speclflc,uions 9 7 Condenser (3.0 lilre models ) lCSI,nu. 'CIllO"'o1' MId refllli,,!) 90 Connecting rods (3.0 l itre engine) 5 1.52.54 Connectin g rods amI gudgeon pins examina tion ilnd ICnov;'Jlion 37, 52 Connecting rods ;lnd pisto ns refi Hing ~ 42. 54 Contact breaker points (3.0 litre models) i1djuslOlCm -89 remov1)1 nnd refiuing -89 Conversion fac tors -18 Coofing system 57 CI SCII Coo ling systcm nnhl.cew ",ixltlle GO desC.i,l liOn 58
d'ilUlinU 59
(IlIvchells
G3 e~p:mSloll I nnk 6<1 Ian hub l)()nllllH (30 hilI] 1110<1111,;) 64 f~ull (II;)Ul1osl~ 65
flll".U -
60 lIush"'9 59
",nmlen,lncc. roullllC 59
'ild,nlOr
GO speclficn llon5 57 lem,)er;!lurc unuuc Sf:n(Ie. unil -134 IhcrmOSl<11 -61 10Htlle wrench selll ngs 57 VISCOUS drlv\! 11'111 -63 W1)ler IWIllP 61 Crankca se ventiln tion system 2.8 tol'c engine -39 3.0 rillC engine 53 Cranksh1)ft 2.8 li l.e engine examinat ion nnd rcnoviuion -37 refilling -<10
3 .0 til.e cn gine examination lind renOV1'l110n -52 Crankshilft and main bearings (3.0 litr o engino) removal -51 Crankshllft pulley refitting (2.8 hIre engine) -44
removal ( 3 .0 litre engine) -50 Crankshaft r ear oil seal (3.0 litre engine) .efllling - 55 .emova l -51 Cylinder bores ~xaminalion and .enovation -36. 51 Indo r heads 2.8 titre engine dismanll ing .• cnova lion and .eassembl y -35
Index
D
refining - 45
3.0 litre engin e
. eassembly -55 refining -55 .emoval wilh engIne -49
removal wil h engine in car -49
Decarhonising -52 Dimensions. vehicle _ 6 Dim-dip lighting system _ 226 Disc br1lke s scc Front disc brakes Distributor overhaul 2.8 hlle engIne -93 3 a !r1l0 cng,ne -92 rcmoval and r efIlling _ 90 Doors eXle.io. hllndle ,emoval and refilling - 183 lock 1Issernbly removal and .efilling -184 pillar swi lc h -224
priVill e lock ,ernovill and ref'lIing -185 fnllics tracing nnd feCllik al ion -178 remOle conlroi hnndle removal and refilling -180 Hlmoval and rell\1l11g _ 185 Irim j>ilnel removal and ,efi ning _ 182 window Irnm c
moul(II ng nnd door wealhcrSlrips
removal and refining -185 rcmoval and relining -185 wmdow glass removal and retilling - 184 window regulnlor nssembly
r emoval and relilling -183 Drivebelt s .emov,,1 ilnd refil ling -63 Drum brakes sce Renl drum brakes
E
Eloc triclIl.system -198 e/ seq Electrical systcm altell11110, -201 10 203
ilu xiha.y driving "ghl -212 bmlery -200. 201 bulbs -199.21310217 ciga. IighlOf -225
clock -223
d escrip llon -200 dim-dip ligh ling syslem -226 laull diilgnOSIS -19. 233 ""sher unils and rel1lys -225
fuse s -199. 220
headligllls -211 10213 horn -220
inSI.ument clUSler -22 1 inSI.ument vollage .egula lor - 226 Inmp5 -21410217 mninlenance. fOUline w 200 mobite r"dio equIpment - 226
precautions - 200
rildio /casse tte player -226 specif ications - 198
speedomeler cab le -226 Slmte . mOlOr -207 swi tches -223 10 22 5 lailgall) wash er -217 laHgme wipef -217 to.que wrench sell ings -199
w indscree n washer -219 windscreen wiper -21810 220 wi.ing diagrams -235 10 249
25'
Ii
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