oil level FORD CAPRI 1974 User Guide

Chapter 5
Contents
CIUICh il$scmhty '"SIJoCcl'Qn . Clu\(;11 assembly 'Urn!!ll!) Clutch llsscmhly lemOY," C lutc h cilhle .efluwal._
Clutch
Clutch !Jedal rClllovnl illld ,cflltl"U
Specifictions
Genera l Type ..... Clutch (lise (hamClcr lining tlnckncss Clutch pedal hcc "<lvel
Torque wrench setting Pressure plate (Isscmhly
Gene.al description
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5 3 1 8
All manu:!1 transmission madllis covered by this manual nrc lilted Wilh a singlo dl3phrilgll SpllJlg clutch. The unit COlllt)riscs il steel cover which is dowelled and bolted to the tear lace of the lIywheci ilnd conla i.lS the pressure plnte. diaphragm spring and fulCrum .ings . The clutc h " iClio n disc is
ee to slice along the splineJ gearllox
Inpu t Shillt and is held in posi t,on between the flywheel and the pressure plate by the pressure of the pressure plate spring , Friction linIng materiill is riveled 10 the d,sc and II has a spring cushioned hull to absorb transmission shocks and to help ensure a smoo th take oft. The circular diaphrilUm spring is mounted on shoulder pins ilnd
'Ield in place in the cover b.,. two fulcrum rings . The spring is also held ,0 th e pressure platc by three spling steel clips which are rive ted in
posi tion .
The
clu tC h ,s aCluated b.,. a cable controlled b.,. the clulCh pedal.
Clutch '0Ie,150 bCilfl"U -remova' and wl,u,"g Filult (ioilU"OS'S -clutch Generill descllptlon . noutlilc rn,untenanco .
SlIlgle (Iry plate. dlill)hragm sprong. cilhle ·ope.ated 241,3 rnm (95 Ill) 381 nun (0 15 In) 27.01 40mm (1.OG:i 0 .16,n)
No. Ib l It 16 to 20 12 10 15
G 9 1 2
The clutch release mechanism consists 01 a .elease leve. and a bearing which conwcts the lelease Imgers on the pressure plilte assembl.,.. The eHect of an.,. wear of the friction ma terial in the clutch is adjuSled out b.,. means 01 a cable adjuster at the lowel end 01 the cable where it
passes through the bell housing .
Dep.ess lng the clutch pedal actuates the clutch release leve. b.,. means of the cable . The lelease level pushes the lelease bearing
forward to bear against thO release l ingels so moving the centre of the diaphf()gm sprong within the annular rings which act as fulcrum points.
A s th e centrO of thO spring is pushed in. the outside of the Spling is pushed OUI. so Illoving Ihe pressure plme backward and disengaging the p.essu.e plate flom the /tielion disc . When the Clutch pedJI is Icleased. the diaptllaglll spring torces the plessule plate into contac t w ith the frictIon linings on the d,sc and at the saIne t,me pushes it a flactlon 01 an InCh fOlward on I\S splines . The
disc is now fuml.,. sandwic h ed between the plcsswe plnte Dnd the
flywheel. so the d.ive IS laken up.
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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
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! '
. , .,
, , I
,
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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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·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 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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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)
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) Chapter 6 Manual gearbox and automatic transmission 119
11. 1~) 2nd (Ie", [Inti thrust w,1shcf h.1l1. showioO t .. llloctltinu hole
(&#34;,,()w~d)
20 Slide 3ul \jC,lf 01110 the f,aiH 01 the mninsh<Jll. then Iccme the
syndHOlllscr rill\) 011 the gOilf cone. 2! lUC,ll(llhc 3rd/4lh synchlOniscr unit on the l11.1inshaft spllllcs with the long side 01 the huh f"cinO the front (pholo). Tllp the unit fully hOllle lISIrl\)" melal tube. then fit the ci'clip . Milke sure th aI the sluts in the 3([) geM synchroniser ring (lrc <lligned with till} slidinU keys .. 5 the
synchroniser unit is being fitled.
13 Input sh(lf( (S·speed) -dismantling Dnd reassembly
!'ld!;! to Section 6
11 GCil,ho)l ([i·spced) -C)lamin,lIion [In(1 rcnov[ltioll
Ref or 10501:[ '0 118 hut now the lollowlng pOllltS :
(,1)
111<:,,) ,1fI! five sYllcll,v rillYs (h) /IlL' I"yshlft lI[1s 110 IIIlIIsl w,lsllt"s (e) (lielL',1ro IWO ball-/)cmiIJYs ,lrId olle ,01lcI hCMiny (d) Wile" ,cnewi"y Ihc IIL'cr/lL' ,01lcI /)(1,1/ill[lS ill I!lc I,Jyslml/, (ISO wllels 25 75 111111 (1 OTt! ill) fony. IIlhc Oligin,ll ,ollers W{!lC 33 111/11 (T 299 ill) lony, two exll,l space's will be requi,ed
(Fiy 623)
15 Gcarbox (5'SI}Cc(l) -rC<lssemhly
I Loc~tc the l11il\j 11ellc disc In the uottom 01 the m(!in c~sin\j. 2 Fit the rcvcrsc relDy Icvel 01110 tilc pivot (llld retain with the cllclip_
Fit the \juidc to the leve r 3 Posit ion the reverse idler \Je~r in the m~in cDsill\j with the Ion,) shoulder facing the reill and en{lllued with thc ,eiDy Icver. Slide ill thc Idler shalt lInci t<lP fully horlle WIth a solt·f1lced m1lllet. 4 5me,lr ,)Ieasc Inside Ihe end of the IJyshlllt \Jeill clUSlCr then fit the SflilCerS and needle roller ueilrings -there Me 21 needle rolters. If ilddltional spacers (He being used. place them behind the needle rollers {Fig. 6 23}. Make sure that there is sulficient grease to hold the needle rolters in position whIle the lilyshaft is fltled. Due to the high levels of torque trilnsmitted Ihrough the auov e transmissions, il is important tha t all the needle ,ollers of a countcrshaft needle rolter bearin\J have CXilctly the same diDmctcr. If the needle rollers in a be(! ling have dlfieronl diameters, this w ill CDuse uneven load distribution which can .esull in prOI11,l!urc we<lr. II It is I\cCCSSilry \0 rcnew the counlersh1lft
nee(lIe .ol lers, 1l111ke sure Ih1l1 the rollcrs used for an y onc location all
)me from t he SMne l"JilCk It more than one pDck is purchased, do not ,ni x lho needlc rol lers from sepilrate p~cks. 5 Insert the layshJlI in the gear cluster unlil the front of Ihe shah is flush With the frunt \Ie~r on lhe cluster.
1221 3 r(I/41h syl1chro unit
Fig 6.23 Layshaft necdle roll.)/ he<lring (Sec 14)
11 Lays""'1 o NCf!dlf! follf!IS
G Loc,.tc the lilyshah iln!! gCilr ell/stP' III tho hOllom of the .11il;n
caslnu_ 7 Pos.1I0n ,. n(.'w \Jaskot on the Ill;nll (;;05"'11. Ihen hi the mllinshah ilnt! inlCrll1ed"l\C houslIlg. and IClllpor;I"ly secu.e w,th twO bolts. 8 Fit the mll"t Shilh needte roller heilrrn\J to the end 01 lhe mainshJlt
or In the centle 01 lho input Shilh (photo).
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,
15.8 Input sh<lft needle roller beilrinU
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) 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
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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 6 Manual gearbox and automatic transmission 123
When towing a vehic le wIth automl11ic uansmission it is impoltllllt to observe the precautIons gIven til ,he 'Jading and Towing' se<:,ion at the Iront 01 the manual. Due to the complexity of the au'oma',c tran smission unit. If performance IS not up 10 s tandard, or overhaul is necessary, it IS impera tive that this be left to the locallllain agents who will have the special equipment for fault diagnosis and rectiflcallon. The content of the following sections is thereforc confined to supplying gener", Informl11ion 1'Ind any service information and ins t.uc tion tha i cnn be used by the owner.
19 Routine Illilinte,wno
At the i!lle.vnls SI)CClfiecllll Iho ROllllne Milintennnce seCIlOll in the I.onl 01 th e Illanllal cnllY Oul Ihe follOWIng p'ocp.dwe
Luuricow selector link'1[}() , Applv the h;rrldh.,lke th(:n J,lck \lp the front of Ihc Cill ,'lid Support
,n nxle Slnnds
2 Orlthe Irnkn!JCs at cndl end 01 Ihe genrsh ,h rml on the Icfl·hnnd "le 01 Ihe Iransnll~s,on lowel the cnr \0 Iho wound,
Check /mn.Wllissioll fluid level 4 Elrlll!! the engIne and trnnsnllSSlon to nOllllal ope.IlIUl!IIp.llIperillllfe
and I)alk tho vehlchl on le vel grOllnd 5 Wi,h Ihe engIne idllll(l. move tht: 1.,lnsnllSj"on St:leclt>r lev!]r through ill! pOSlllons 1!lIee lImes. Ihen onuaue '1" ,11111 wall for ;rt lea~t one minute. 6 With ,he engine 51111 idling, wllhd.ilW Ihe lr.1nSnllSSIOll d,psllck.
Wipe it dean, reinsert II, wilhd •• 1W 11 for Ihe second !line nnd read off the levol. 7 Two tv pes 01 automatic transnllssion fluid a.e nvarlilblc (sec SpccifiCiltions 10' tv,>c numbe.s) .1nd It is ImpO,I,ln , Ihilt IheV 'lIe nOI mixed. The colour 01 the dipstick. 10' flUId level checklllg denotes which fluid tvpe to use , 8 If a tlr1nsnllssion requlII"U 1,1ter tvpe fluid IS I'lled 10 " to'<lue COIlVOIlr!r preViously used w<lh oarl.er tVI}e fluid, or vice vr:&#39;.~iI, the compollellt~ shOuld Ire Ilushed 10 ,1IIoi(1 mlxinu o f the two Ill/Ids
COllsult your I'ord dealer rI thIS cond,t ron arIS&#34;~ 9 If III)r.CS~.1rv IOp·up with til'.! spec.rlled orl, thr ough tire drpSlrck tube. 10 tire MAX m, uk, The '1"<rlllrty leqlm ed 10 r,IIS!] tile level !rOllr 'V1IN In MAX IS approxlmatt:lv 0 3 Illre (05 pIIIl)
Adjust Iront brake /)(In(/ '" ApplV Iho handb."ko tholl lack 1'1) th'.! ',ollt 01 the ca. and sUPPO.I axlo stands 11 D,sconnoC t the downshIft ca!)le at Iho t'.1nsmISSlon 12 Slacken Iho brnke band adJusto, sClew locknut and unSClew the
adjus'or screw n lew h,fIlS . 13 Tlghlolllhe adJuslo, sOcw to 14 Nm (10 Ihl II) IISIilU a SUItable lo,que wrcnch From Ih,s poSlllon slaCken the adJusle r screw bv exact Iv I'll \Urns (pre·1983 models) or 2 Iwns ( 1983 and late,
model), Ihen tighten Ihe locknut Wllhoul diSlUrblllg Ihe pOsition of Ihe adjuster sc,ow .
14 R econnec t the downshift cable and lowe' Ihe car 10 Ihe ground.
20 Automalic transmission -removal (HId refining
If l)Osslble, ,aise the car on a hOlsl o. place it over an inspectIon pit. Alternatively, it WIll ho necessary 10 Jack up Ihe car to obtain the Illaximum possible amount of wOlking room undernealh. 2 Place a large d.ain pan benealh the transmiss.on sump (011 pan)
Ihen. working horll the ,car, loosen the a!laching boilS and allow ,he lIuld to drain. nemove all thO bohs excep t tho two I.onl ones to draIn as mIlch fluid as pOSSIble, th on temporarilV .efit Iwo bolls at th e re,1I 10 hold it in place . 3 Remove tho Slilrte. moto. as desc.ibed in Chapter 12 . • jWhero apphcable, rernove the access cover Dnd ad3pto, plale bolts,
Ie the engine untrl the to.qu e converter drain plug is visible, then
unsc.ew Iho plug and d.ain Iho Ihud Into a suit3ble con winer. Refl! and l'Uh ten Iho plug.
Fig. 6 .25 Checkill{J tho au tomatic transmission lIuid lovel (Soc 19)
Fig. 6.2 6 FrQ,1 bn'ko band adjustment (Sec 19)
A Arllf/SICI sc/t'w a Locknut
C Downslu/t Icvel D Downs/u/t c.lblc
Fig. 6.27 Torquo convorter to driveplato boll -arrowod (Sec 20)
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