ECU FORD CAPRI 1974 Owner's Manual

) Chapter 4 Ignition system 89
2,4A ncmovllI\J the ' 010' rum (28 hire enuino) 2413 The engine speed tllnnel 011 tho ,oto. :lIm (2_8 litre ename) 26 Secul;nn lhe dl surUlllor cap wilh Ihe sp.;ng clops (2.8 "lie engme) A Swing C fail/lillY COIlf.lCt n MQving CQII/act
27 ChcckUl!J Ihe HT tcad le.min;!ls on the (hSlllhutOf 1:.111 2 .8 11I"iliol1 COlt and WlIlIl!! 4 .2 Remov,ng I he COlllaCI h.eilke. low lenS 'OIl le,lds
7 W"H) o;iean the HT Itlad,; llm! check Ihc'" 10' (;onll'[IOI1 Pull the 1(';'Ids homlh!) dl~l&#34;h&#34;10f Cilll one;H <IlOilO ;)IId 'Hake SUIC th"III O wmcr IlilS 10llnd 115 w.1y 11110 the so~k CI tI.!II'Hrl"ls . Clo1l1l <lny I:I>IIOSiOIl "W,IY . Ien .eln the IC!1ds (I)hoto). 8 Glc,," Ihu '!jll'l,on cOIl lowe. ;md check the HT le,,(1 ;IS p.eYiously . ,scJllled (photo)
Check .1nd Mljus( (h£! cont<1c t brc<1ker dwell "flyle (3.0 fi/re
engillt!) !l Ruler to S<lClion 3
Check arid adjllst Ihe ignilion timing 10 Rcler to SectIon 9 .
Reflew /lit.' conl,1CI breaker points 11 Reier to Secuon 4 .
3 CO I1\aet ureaker points (3.0 litr e er>gine) -adjustment
1 Remove thO dis touutor cap and ro tor afln (Sect ion 2) 2 Gentlv I)rrse Ihe contact ureaker points open and e~an\ine the conditIon of Iherr faces. II they are .ough. pined o. dlfty II WIll ue IlCCeSSi\'y 101 new paIn IS to be fined. 3 If Ihe pOInts ale sallSfaclory. Or have been ,enewed. measu.e the gap Uel ..... een the points with feele . gauges. by turning Ihe Clankshaft unlll I',e heel 01 Ihe ureake. arm is on a high poinl of Ihe C<lI11 . Consult the Specd,cnl;ons al Ihe uon;nning 01 th is Chapter 101 ttm correc t sOll;ng
I If Ihe gal) IS IIlcorrCCl, slacken Ihe contact plale SOCuflllg screw(s). , le n "lserl a soewd"ve. ;nlO the sial p.ovided al Ihe edge of Ihe COntaCI ptalH and move the plate unlli lhe gap is corrcc\.
5 Tlghlen Ihe sClew(s) and .echeck Ih e gap.
6 Rein the .010. ;"1IU1 ensurIng th,lt II IS cOflectly located In the sial at
I he lOp 01 the carn Relltlho d'SI"lJuIO' CilP and .elain III IIOS;llon wnh Ihe Iwo clIps . 7 On 1110de.n el1gll'os a mo.e ,1CCu'ale mel hod 01 seHIIlg Ihe I>o;nts Hal) .s by means o f a dwell me lel . NOI only docs 111110 l11elhod give a
IHL'Cisc 1)0 .. 115 gap I)UIII also evens oul ally v,llta llons 111 Un,) cnused by wear "' I he dlst"'lUtor sh ah 01 uushes 0' dlHCf()nce s HI any 01 the heIgh ts 01 Ihe Cil'" peilks 8 The dwell allU1c IS Ihe numt)C. 01 deglee s th, ounh winch Ihe
dIstributor cam lUI liS dUring the IlCrlod betweell Ihe ",S\ilIlIS 01 closu<e and oJlcnmu of Ihe conI act b.e,lker ponlls It Cilll only be r.hech~d wllh
a dwell mele' connecled III aCcor d,lnce wllh lh. } maker's II'Slfl.r.;I'OIlS 9 II Iho angle IS nOI as gIven 111 the Spe<:.hcatl ons. ildluS t the po",ts u~p If the dwell annie's 100 ,,,'ge ,ncrease Ihc IJO'''15 9,111. II th e dwell [lI1gle ;s too small . 'educe Ihe points Uap
4 Conlilct hre[l ke r points (J.O litre engine) -removal and refitting
Remove the d'SlflbutOi C"P and 'OlOr arm (Secl;on 2) . 2 Slacken th e self·tappiu\J sc.ew which secllres the condense. illld low lension lead s 10 the conl,lel ureake. ilssembly ilnd slide oul lhe fo.ked cable telfllll,al;OnS (phOIO). 3 Undo and .emovc Ihe Iwo screws whIch secu.e the contact b.eake' uase pll'Ie 10 thO d'SlflbulOr ilfld hit off the cUlltact b.eaker assembly
(phOIO) .
4 Befo.e IClilling the conlact b.eake. assemhly. smear Iho dlstrluu to . cam wllh a trace 01 g.ease 5 FIt I he conlaC I 1)I(,ake' and its cl,Jlnping sr.;.ew~. but do nOI fully I;ghten the sc.ews \lnlll Iho contilC I b.eake. !I,111 h;IS u een adlusled as descflbed In Sec tion 3
6 R ell l th e rotor "fin and d.stflhuw. cal ). &#34;&#34;&#39;1I&#34;&#39;~1 tI,e IWO clops 10 secure lhe cap.
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procarmanuals.com

90 ) Chapter 4 Ignition sys tem
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<1 3 Contact hlcnkc. mOUIlJrrlO ~CH)WS (,lrrowcd) 63 Dlsconncclinu the V<lClJlHll .1dvllllcC p'pe G.4 OlsconneClill\) Ihe eallh lend
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65 Pull tile wires 10 rhSCOlll1CCl the mull"I)I.,\) COlll1eClor 6.6 flOIO. arm al;\jncd with the slOI on t he d,strlhutor hrnly rim (allowed) 6 .7 C'ilnkshall polley nOlch and Imling covel gr,1(lahOn (28 hIre cn!l'ne)
5 Condenser (3.0 l itrf~ rnllJillo) -testing. removal (lnd rcf ittinu
The PU'I'OSI) 01 tilt) ccmd"",.er (sorllclull(!S know .15 .1 capacItor) IS ensure lh.1I wli,m II", ',()IIi."; ( I!UJakcr POUllS open thew IS no ~po1&#39;~&#34;&#34;1 a~Hl&#34;S ilWlll whIch would C,llIlie ,ap,d weill 011hcu r .. ees ilnd
'!I'Il' ",slue 2 The CUIHIUIlSt" .s hUed !II I>luallel wnh the conlJCI h,e;)kc. points. II '1 becomes r""lly, ,1 w,lI C;II,,'" 'IJ'''IIOI' fa,lure ,15 the conlilCl hreaker 1'011115 1'0',11 he pH)VI!fIl,:ti hom cOllcclly 1Il1elfurlcmu che low ccnsion qrCIIIL 3 II Ihe en!)'lIe becomes very dlHlcul1 co SWrl 01 begins to I11ISS afrer
severill null'S of I lInl1l11\l . and che I)lcilker poinls show signs 01 e l\ceSSlve blllllllll/. Chen chI) condlu o n of Ihe condenser muSI be suspecI One f".ther !C:.t can II" milde hy sepa,ahl1U che points by hilnd wilh the ,umtlon 5WIICtl(:(1 on IItl"5 IS ilCCOoul),,"Il1led by a mighl trash. II IS ,ndu;:allve Ih .... 1 the comlcuscr has I0111cd <I Wiltrout special teSI C<IUlI)lIlc"t the only safe Wily to dl .... Unose condenser 1I0ulJle.s 10 • ..,pll .C" .... suspect 111111 wuh a new one .... nd noCe II Ihe,e is ,my II"p,ovem..,,\I 5 To remove the conden:.cr from Ihe dlSlllbulor take off the (1ISllll)ulo, Cl(1) 1IIld 1010r ;um 6 Slilcken Ihe sel f 'larmll1!) S(:ICw holding Ille condense, IC,ld and low !ension ICild 10 Ihe COIIWo.llul!l,kel I)OU1IS. Shde oullhe forked lerminal on Ihe en(1 of Ihe COf1(lense . lel1d Undo and remove the condense, .el11l1linU screw ;md remove II,e condenser f.om Ihe breaker plille. 7 To rehtlhe condense" s1Illply ,everse the orde, of removaL
6 D istributor (illi en\)ines) -rcmoval and relittin\)
1 k ,1pphcablo II.HlH>VU the 1111 ele,me" ilS descllbed in Chapler 3
2 Remove Ihl! dl ~l&#34;bulo&#39; C;Ij> only (SeClion 2) 3 D,sconlle\:t Ill.., V<oCU\1I1I .. lIvi'lllce pipe (pholO).
4 Whelu l1ppllcnblu dl:;col1l1ecl Ihe eilrlll 1t.!.1(1 hOIll Ihe lerl11ll1nl 011 the d1SI"h11101 budy (pholo) 5 D'scol1l1eCllh(l (h$lrrlJulO, lllulll·plul) COUllcctO'. To dlsconneCllhe plu!!. the w .. ('s IllUSI ho hold and pulled, nOI Ihe plu\) Ilself (pholo). G 'Turn Ihe un\)ine unlrllhe rotor n.m IS poinlrno 10 Ihe No 1 cyhnder SCIJlllun l In the d'SI"hUlor cap. On lalCr models Ihls IS 111so IndiCilied by [I slol on Ihe (I,sl"I)(O(o' hody rml (phOIO) 1 Check also Ihilllho nOlc h m Ihe Cr;lI1kshah polley is III hoe wllh Ihe com,c( '''[llk on Ihe tilllin\) cover (photo) On (llu 30 ht.e eng me Ihe Illinks arc III 2" Inte.v.l ls. hUI on Ihe 28 Ilire enU"le Ihey are on 3' tIllelVals Sec Ihe Speclhcallons fo. the correCI SClllng. Milrk Ihe IIOS'llon of Ihe d'SI"uutor body .n ,el[llion 10 Ihe cyhnder head 8 Bemove Ihe Single holl ill Ihe baso of Ihe d'StrIUUIOI ilnd slowly hI! out Ihe d'SlllhulOf wlthoul IUlilillg its body As lhe dislllbulO' ,s removo.'{llhe skew geM will turn the rOIO, arm clockWIse. Ml1,k Ihe new IlOSlllon of Ihe rOlO' aim on the , .. n Illhe.e IS nOI illreildy a mink Ihe.e (pholos) 9 To reilithe dlstlluutor ensu,e thaI the liming milrks ilre Slill ahgned ilS deta,led rrllJarag'ilph 7 of Ihls Sec lion. Hold the diSlrib Ulor ove' the cylrndc. hel1d so Ihal the hody 10 Ihe cyllnde. head milrks are in alrgnmenl 10 POSlllon the 'Olor arm towiI,ds Ihe mluk on Ihe d,S trrbulol body ilnd slide Ihe assembly inlO l)Osition on tha engine As Ihe geJrs mesh. the ro lor WllllUtI1 ilnd align wllh No 1 segmenl in Iha dlSlrrbulor cap.
1 1 Relit the securing bolt 10 the bnse of Iha dlSlrrbulor bUI do nOt fully Ilghlen ;IllhlS Slage. 12 Check 11I11t on Ihe 3.0 hlr a engme the dlstrlbulo, VJcuum unil is lilcing fo,wilrds. parilliellO the centrO line of Ihe el1\)ine. or on Ihe 2.8 lil,e engine Ihe VilCUIIIll unil is lacing in Ihe duection shown in F ig. 4 .4 . 13 Reconnect Ihe IllUlli·plu\) conneClor. The manlJf~Clurers recom· mend Illill Ihe Illulli·plu!) is 'illed wilh il lilhium hased grease. 14 fleconneCllllu earlh lead (it applicable) and t he vJCUUm advance pipe. 15 Reier 10 Section 9 and se l Ihe 'gnition IlmlllO. 16 Refll Ihe all cleane. (if applicable).
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Chapte r 4 Ig nitio n sys te m
6,SA Unsc rew the clamp bolt, 680 ... and remove the (tistJlbu to. 68C Rotor nnn alignmen t ;]lter re movnl Irorn engine
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F ig . 4.3 IU "i\iol1 timinu ma,ks o n the 3,0 lit.e e:1Uine (Sec 6)
Allow ;//(lic<1leS din'cliu" 0' !(JIM;oll
7 Distributor (3.0 litre engine) -overhaul
W,th the diMJlhuto. removed from the entl,ne. 'emove the rotor arm and the cont.1CI breaker assembly . 2 Prose Ihe small Clfclll} I'om the v"cuum u,,,t p,vo l IXJSt. 3 flemove th e two sc,ews wh,ch sucure the hfllaker pl,lI!! to Ihe d,slJlbu tor body and hit the ,}I'rte orl.
" Slacken Ihe self'lappmg SCfew which SC<:UlCS the condense, and low tenSion leads 10 Ihe contact l .. eaker a ssembly and shde OUI Ihe lo.ked ca ble terminations, 5 Undo imd remove Ihe condenser rCI.1,nlfl!.l screw and remove the condense •. 6 Remove the c" chp. lIiJt washer and wavy wash er from the pivot post. Se parat e the two plates by h,ingmu the holding down se,ew Ihrough Ihe keyhole sial in Ihe lowe. 1)late , Ta ke care not 10 lose the e.Jrt h spring on the prvo t flOst. 7 Remove the two se,ews seeu"n\) Ihe vilCuum un,t to the d IS t"lHIIO' hotly .Jntl remove the vacuum uni t. S To d,snl.JllIle Ihe vacuum unll, remove the plug I.om the end 01 the
unit (md withdraw the spring. vacuum stOp and shims 9 Oelo,e disll1<1ntling th e centJllugal .Jtlvance mech.Jnism. note thM th e tw O spri ngs arc d.lle.ent and ma,k them so th.Jtlh ey .Jre ref'tled in th ei r OJlgHlall}lilces . Remove the sp. ings. pJlse all the circ lil)S securong the cenlJlluga i weights. nl.J.k the weight s 10 'dent'fy their o"ginal positions and then remove them ,
1 0 M3<k which 0 1 th e end slo ts on th e n'cchan,c.J1 .Jdvanctl pl;]le
lages w llh the s tol) m Ihl! ;]C hOn I)I"le II II" s IS not dono. II rs ~ s, llle to h.Jve th e ,oto, ,'Jln 180' from 'I S COf/,-ct pOSition. 11 Remove the lelt pad 1 10m t h e centre 01 the C.JIll. e~pand the circhp
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Fig . 4.4 Distrihutor lilting position on the 2.8litrc e ngine (Sec 6)
XX Re.1r "U;,.' of ellgmc yy V,1CI/(JIII flllil Mas Z = 0 '10 11/'
A Triggcr (lffll U Slillor l!fII!
whICh'S Ihen exposed Ilntl ,emove ,I L,lt all Ihe Ci"n and 1l(IV3ncc plJle ;Issemul y,
12 Do nOI .cmove t he d,stJluutor Sl)indle unless II 's necess.l'y to "1 a new ge.n. 0' S I)iJldle To remove Ihe uear . usc <1 IlUnch Ilnt! hJmmer t o dJlve outlhc lock P'" and Ihon pull tl)() !.Ic", frO'11 Ihe sprndle T"ke cn,e
1 0 rOIil'" ilny slums, 0' wllshe,s wh,ch fll.Jy be In led . W,t h the ueJ' lell'Ov\:(\. the sl)lIldle .Jsscmbly can be withd,awn hom the d ,s'Jlhu tor 13 Belore reassembhng. ca,elully clc.J1l the body 01 th e d,s lnbulOr and "II a s CO'llpo llent p"'ts. II th e sp,n(!ie has been .emoved. lulmenlC II w'lh e'lu",e oil h efor e ,ellssemhly. 14 Reassenlbly.s <1 SUa'ghtIOrw<1Jd ,eve'SilI 01 d,sman tling bUI t he,e Inc several pointS which shoold be noted.
15 Lut)JJc;]te th e ce Jltlil ugnl weights and otho. p3rtS ol the cenlrifugal
advnnce mechanism. the diSlrrbutor shah a nd Ihe pa'l 01 the spindle wh,eh c.l"'es Ihe cam assembly. using engine all. Do not orl excess,vely. 16 " Ih e dr'veshnlt hilS heen .emoved. firSt re fi t th e thru st wash ers below tho action plnte. bolore "'se,ting the S h .l h into thc disl. ih llto,
hody . FII the w3vy washer .Jnd IhrUSI washcr to the lowe! end 01 the shah and then relilthe ge.Jr. secuJlnU it with a new spring p in. II a now gear. or a ne w u"ves hnfL h,15 been fllt ed . a n\lW hole should be d"lIed .1t 90' 1 0 Ihe e~is&#39;U1g hole 17 Alte • .Jssemhhng the centJll ug.J 1 weIgh ts .Jnd sprrngs. check that Ihl!Y movo hccly. w,thout I)inding, 18 8clOle assemblmg Ihe breaker pla tcs . make sure thill the three nylon bearing slUds a.e located "1 tht) h oles ,n the uPllC' uearinU plale and Ih3tthe e.Jrth,ng sprrng ,s foiled to the p,vOt post 19 On complet'on of assemlJly. adlust the conlnCl b'eake , gilp to the spc cified selling
procarmanuals.com

94 Chapter 4 Ignition system
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. --8 2A Removill{J the IllnSlre dust COve, (28 hl'c Cllume)
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J 2C W'''I1!j connector i'Uld seCUJlIlg screw (lHOwS)
9 Ignitio n timing -adjustment
Wnh the (.lIs\"OuIO' III!Cd ilS dcscllbed OIl SectIon 6, check Ihilt 1Ill! COHCCt llllllng m;l!ks "'0 ;1119110d. 2 To check the ;1111,,11 (5 t;1I,e) setting, .emovc the (I'51"lIu I0' c;lll [11l\( check IhJllhc rOl0' ;lIm IS PO"1I1119 to the No 1 cylmdc. scgmon!.n the Cill) rndlcmed by the sial on the 11m. 3 On the 3.0 lUre engIne the cont,le l poullS ll\u~1 he ,ust SCI)ilril\U'!J Tho e~ilCt Instant C,1" he checked by connect"'u il 12 vol1 lest lamp between the contilC, brcilke r low tenSIon Iemur),,1 iUl(t O,"lh, W,th the iUnilion Oil, tho d is trlbuto. ShOllld be turn ed nrl\,·clockwisc unlol lho bulb luSlligh(s. " On (he 28 li(re enuule the ("gger arms and stator ;HIllS must bc aligned It not. (um I he (hst"bulOr as necessary . !:i Tighten the (hSI"buto. clamp boll and .ehl the cap 6 Set In thIS way the lUlling WIll be alll)'Olmalely co<rC(:t but a morc ilccurate rne thod IS by using a stroboscopIc tu"ing hghl. 1 HIghlIght the spcclilcd lIming marks on the trrllll1U cover an" cronkshalt pulley WIth wh,le pamt or chalk 8 Connect a timing liijtH to Ihe No 1 spar k pluij le;l d, 9 Disconnect the vacuum mlvance pIpe at tlHl carhure1l0r or au bo~ juel injection) and plug the pipe then .un the engine unt" nOlln,11 ope.ating telllpera tur(!s a.e .eached.
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8 2B UtJlle. vIew 01 the l.imJer Mrn .lrld Call (28 lIt Ie enU"Wj
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8 20 Vacuum un.1 sC(:u"ng screw WIth e')Hh lead termmal
10 W,lh Ihe enij1l1e I(lIrng pornt thc \fmlng hgh( at the cr",lksholl1 pulley The wh,le 1),1mte<l mar ks WIll ;lIme", sliltlonary ,111d If thO tlmlno IS COller. 1 (hey WIll be III ahgnment. 11 To adjust the tllnm9. stop (he engine. sla ck en Ihe cl;'lmp bolt iln(1 turn the (I ,st"l)uto. slIghtly_ TIghten the clamp bolt. star t the engrne ;md .Ct;heck the (umng Repeat tillS 11IocedUie unlll Ihe rIlilrks ,)re In
hne
12 To check the mechanrcat adv.1nce. Increase the engIne speed and note whelher the wh,te malk on the pulley moves away Irom the mark on th e pOInter . 11 It docs the mechanical advance is lunctioning 13 W,th the enOlile Idlmu the vnCU\ Jm advance can be checked by suc kIng the oldv~ncu pIpe that W.1S removed from the carburellOI o r air box ThIS should also c.Juse the while rnark on the pulley to move away horn the mar k on the pointer 14 On completIon remove Ihe timlllU hght and rC(:onnec lthe v.1CUUIll pIpe
10 Ignition illlllllifier module (2.8 l i tre enuine) -removal and rClittinu
Thc Iunitlon illl\J}l lflcr module is locmed on Ihe left· hand SIde of the engIne COnlpar tment. tUSI behind Ihe hOnt suspenSIon strut upper mounting.
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,6 Chapter 4 Ignition system
9 The spark plug gaf} is 01 conside rable impor1~e. as. if it is too lilrge or too small. the size of the spark ilnd its efficiency will be seriously impilired. The spilrk plug should be set to the ligure given in thl} Specifications ill the beginning of this Chapter; IOTa sel it, measure the gilp with a/cere, gauge. and then bend open. or close. the outer plug electrode untillhe correct gap is achieved. The centre electrode should never be benl as this may crack the insulation ilnd cause plug fAilure if nothing worse. 11 Relit the plugs, and re/ilthe leads from the distr ibu tor in the correct I"ing order. which is given in the Specifications. Screw the plugs in by hilnd initiilily then tighten them to the specified torque using the plug spilnnel.
12 Fault diagnosis -ignition system
By lar (he nlo1jori (y 01 brCJkdown and running troubles ilre caused by InUits In the igrlOlron system er(her in (he low (enSlon or high tens ion circuns There <ire two mnin symptoms Indlca(lI1g Igni(ion IJults. flthel (he "ngine WIll not Start or lire. or the engine is dIffIcult to SWr( and misfiles If it is a regulnr misflte the fault IS almost sure to he in the Icondary or hIgh tenSion cirCUlI. !f the misfir'"g is intermittenL the "HI lt ~oliid be ;n either the high ur low tension circuits. If (he car stops suddenly. or WIll not stilr( ilt ,111, I( is likely thm the lault is in the low ten sion cncwt. loss of power ,1nd overheating, tlpar t from f,lUlly c,lrl>LJratlon or fuel Injec tion Setlln(Js, ilre normally tllle to faults in the d,strrllulOr Or 10 Incorrect I(Jrlltion tlllllrl!J .
Engine fails 10 staft 1 If the engine falls to StM( and t he cal was IIJnning norll1t1l1y when.t wns IJst used, first check ther e is fuel in the petrol wnk. If (he engille tums ovel normally on (he starter 1I10tor and the bilHery is evidently well chmged. then the lault mny be in either the high or low tension circuits. Firs( check Ihe HT circuit. Note: If lire hal/cry is known 10 hI! {(Illy ch,}lged, Ihe ignilion liglll cOllies on, ,1I)d Ihe s/arler 1II010r {,lils /() tum IIIe ongine check the tightness o f the le'lds on the biltlely terillinilis ,1I)d <1Iso (lte seCUIIHWSS oflhe e,l,th leold (0 irs cOllllec/ion 10 tire body It is qui(e common for tlie le,1(ls /0 Ii,}ve wOlked loose. l.'vc'1I If Ihey look ,1n(/ lecl seclI,e. /I one 01 the boll/my ((:{minM {Josts [11.'1.1' vC'IV liot wi".." (Iyiny (0 wOlk Ihe s/mler 1II0tOl (his is ;/ sUie IIId'C,7/IUI/ 0/ ;/ I;wlty COllllel;('On 1(1 1h.11Ie"lIillal. 2 One of tile commonest rOilsons lor bad stmtln!J IS wet or d;UllP sp,uk plug lead~ and dlstribu(or. Hemove (he distllblltor cap. H "JOdenSil(Ion is v iSIble IIlte!llillly dry the CJp With il rag and also wIpe ;lCf the leads nelu the cap_ 3 If (he enUiue sull fmls 1 0 St.l.t. check that cunent IS reachlllg (he JUS, by dlscounectln!1 ench plug le,l<1 in turn ilt the sp1Hk plllU end, .. ,ld holdlllg Ihe end olthe callie about 5 mm (0.2 Ill) aWilY from the cylillder block. Spin the enu'ne all the sta rter motor. 1 Spa,klllg between the end of the cable ilnd Ihe block should he fa"ly strong With J strong leuulm blue spark_ (Hold (he lead WI(h wbber to ilvold elec(IIc shocks) If Clluelll is reilching (he plugs. then rel110Ve them and clean and reg,lp them. Tho engine should now SWrt 5 If there is no spilrk ilt the plug leilds. wke of! the HT lead from the cenlre of the d'sltibutor C<lP and hold i( (0 the block i1S belore. Spin the engine on Ihe SWrter once more . A Inpid succession of blue sparks hetween the end of the loau and the block ind'cate thilt (he coil is In order and that the distributor cap.s cracked, the rOlOr mm faulty, 01 the carbon brush in the tOp 01 the distributor Ctlp or rotor Mm spr ing is nOt making good contact Poss,bly, (he POintS me in had condition (mechanical contaCI hrOilker) . Renew them ns doscribed in Ih is ChnJ)ter, Sec tion 4_
6 If Ihere me no spmks Irom the end of the lend 110m the coil check the connections atlhe coil end of the lead. If il is in order 5(31 1 checking (he low tension circuit. 7 Use iI 12V voltmeler or a 12V bulb ilnd two leng(hs of w ire. On conventional distributors switch on the ignilion i1nd ensure tha t the points arc open. On breakerless dlstlibulOlS ensure thilt Ihe segments on the rOlor are nOt adJilcenl to (he triggel coil. Make a tes t between the low tension wire to the COil ( + ) terminal nnd eilrth. A leading of 7 (0 8 'lollS should be obtained. N o reJding indiCiites a break in the supply from the ignition swilCh or il f,1UIl in the ballast resiswnce wire. A correct rending indicn(es a faulty cojl or condensel, or n blok en lend between the coil ilnd the distrIbutor. On breokedess ignition systems the (rigger coil and ilmplificr module are suspect . H~ve (hem checked by a Ford dealer. . 8 Take the condenser wire off the points assembly Jnd with the points open test between the moving point ilnd eMth. If there is now a leildrng then the tault is in (he condenser. Fit a new one as dcsclibed in this Chapter, Section 5 9 W,th no reilding from the moving point to eilrth, wke ,1 reildrng between eil/th ,1nd the ell or negiltive ( - ) teminal ot (he COIl. A rendm(J here shows a broken wire which will need to be renewed hetween (he COil ilnd dis(rihutor. No retlding confirms thil1the coil hilS failed ilnd must be renewed, afler which the eno"te wdl run once more Rcmtmher (0 rel,t tho condenser wire 10 the pomt$ ilssemhly.
Engine misfires 10 If the enOlnr. mlsfues re!Julariy. run It ilt a f~st irllrng speed. Pull off eilch 01 the plu(! C,lpS III hUll nnd hsten t o (he note 01 the engrne. Hold the phl(J cnp In il dry cloth or with a rubber g love <IS addition,of protection au"inst il shock frOll1 the HT supply_ 11 No d,ifercnce in eng me running will he noticed when the leild 110m the defective plug is removed. Removing th e lead from one at the good cylinders will accentuilte (h e misfire. 12 Remove the plugleild from the end o f the defective plug ilnd hold il tlbmlt 5 i'lli'll (0.2 in) nwny from the hlock_ SWrt (he enoine. If the sPJ'king is fairly strong and regul"r the I""'t must lie in the spnrk plug 13 Tho plu~J mily be loose, the Insulation mav be crtlcked. or the points may have burnt away g,ving 100 wide tI unp lor the spark to juml). Worse stoll, one of the points may hnve broken off. 11 II there IS no spilrk ilt the end of the plu\J lend, or ,f It is weak ilnd IIlIermiHent, check the Ignition leild from (he distrdwtor to the plug. If the IIlsulJtlon IS cracke( 1 or pCIIshed, renew the lead_ Check the COrlilections Jt the distllbutor CilP_ 15 If (here is s(111 no spark, eX,lmllle the dlstlil)utor CilP cillefully fa, (r"dIllU. ThiS Cilll be recoor1,sed by a very thm black line running between two or more electrodes. 01 between "n elec lrode and some
other Pollt of the dlstllhu(or. These lilles J,e p,lths which now conduct electllcit y Jcross the CJp lhus lewng it run to e,,'th. Tile only answer IS a new distllbutor CilP_ 16 APilit frorn the Ignition tll1l1ng being Incorrect. other Ciluses of rlllsl,,,ng hilve already been denl( w l(h under Ihe section dealrng with the f,lriUre of Ihe enuine to star I. To reCi!p - these 0110 Ih,lt:
(,J) The cOllm.lV be {,lufly giving ,111 iniNmil/elll mislile (b) Thele limy he ,1 (/iJmiJged wile or loose cOrlflee/ioll in till! low (eflsion circuil (c) The condensel /II,lY I;e shOll circuiling (i{ filled) (d) There nwy be a meehanic,lllolUI! IiI Ihe dis/flbll/or (bfOken dliving spindle or eOlllac/bleaker spring. if filled)
17 If the ignition (iming is too far reto1lded, it should be noted thallhe engine will tend to overheat. and there will he a quite no(iceable drop in powel. If the engine is overheating and Ihe power is down, and Ihe ,oni(ion tim in!) is correct. then Ihe carburenor or fuel injection should be checked, i1S ,I is likely that this is where the Iilult lies.
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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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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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~10 Chap ter 6 Manual gearbo)( an d automatic transm iss io n
operlltlon. looseness between the inner ;mel oulC. ';)ces. imd 10f genera' wear. NOfIll.llly they should be .enewed on a gearbox lh<11 IS being .ebuil l. 8 II Clther 0' the synchrOnise. unllS ;nc WOUl II w Ill be ncccssmy 10 buy" complete assembly as the Pill ts ,lIC not sold individually. Also check the sliding keys 10' we;'!. 9 Examine tho ends 0' IhO scl(!C I(ll' lor ks where they rub "g.1In51 the channels in the peJiphery of the synchrOntSfl f units_If I)()Ss,ble cOIllp.."e the sclecw. lorks with new Units to hell) dC1Crminc the weill lh,,1 h,IS occtJUcd Renew thelll " worn. 10 If the bCilring bUSh ,n Ihe CXI(mSlon is b;uliy worn II,s OOS110 [<Ike the extension 1 0 yow IOCill For(t gMilgC 10 hilVC the hc;nin!J pulled oul lind a new one fmc d N oto: Tills 1$ 1I01ll!<I/lV dOllfJ willi tile 1!!,11ll.~l!.lfl ,lsscmbiv slillloCMcd ill Ille extellsion/wl/sillY 11 The 011 seals In tile extension hOl/sin!) and I1laln drllle (Jear hcarlllU relainer should he IClleWO(jas a "lillwr of COWSC Dillie Ollt the (Jld sCill wIth the ,lI(1 01 il d,,1t or brond screwdllller. 11 WIll he 1olll)[llha t the senl comes 0111 qU ite enslly . 12 W,th a p,ec t' 01 wood or sllltnhlr, ~Ized l"hl! !O spread the Inad ellenly, c;Hellllly Wp il new sent 11110 pl;lce enSlIIII'!I that It em",s Ih ... )OIC S(llIalely
J Ge1Hbox (4·speed) -reassembly
When any hOlt screws "110 a throuUh hor". JOllll11\!J COlllpnulI/t Should hc nj)lllted to I he lhwads 011l11! holl helorc It ," InS/&#34;h~1 2 Fit Ihe /cve.so Idle. He"r WIlli Ihc It,oolle on the !le;1I tuw;IId,. Ih,' lenr.lnsel! Ihe .dle, s h ah nnll dlllle 11111 with .1 pla~t.c·IIIl:IIIt].1 h;""""" unllllhc OOltOnl ollhe Slel) on the end ollhe shalt.s IIIIsh WIth lhl! ,,11.1 0 1 the gCJloox. Thc mIlled "<liS Should !.Ic l)folld 01 the \Illa/hox la. :e and should be Jli{lned wllh I ho l;lysh;lIt bUfe. 3 Fit the large th,ust wJshel t o the l;lyshalt horfJ at the hOllt 01 thf) ge'Hoox and Ihe smJII IhluS I wilshm 10 lhe layshilh bale ill the ruar 01 Ihe bo~. Thc tabs on the wilshers should be towards t he Cilse illld th" washcrs Should be greased 10 /e tJOIl them III place. /) Check that the needle rollels atld end wilshe/s 01 the layshilh !lear ale In plnee. then lowCI Ihe ueill cluster Into the CilSC Cilrdully. rllaklll\l su,e Ikll Ihe thrust waShCrS arc not dlspl,.ce(1 5 Push tho IIllwt ~h;)/1. tonethcl WIth liS h'llI t}{!:lIIl1IJ. 11110 tlw I,onl of the 1Jf,,1Iho~ until the Cllehp IIlIJI1(llhe heiUlll~llw:irs "(J""15t thu Il(lI1t of the \le~&#34;)OX cas!! 6 Fltlhe drlllfJ hU;)II"\J 'Ul;lInur. lISIII\J (l nr)w W,sk!)!. II1;lkll1\1 SlUl! Ih;It
t he OIl lellHn horo 01 Ihe Ui ls k e l ,1nd tW:illnlJ IfJlilinur .lte ah\jl1fJd as III
FlU. 6 13 Apply 101ll1lng compoullll to the threilds 0 1 Ihe bolts. lIl~e<l ,hem nnd II\Jhtcll to the tOrquo wH)I1ch seltll1!J tl'lIell U1 tl,e
SpecIIIC(ltIOns .
0,1
the new IIlput sh,ll! ncedle rollel heilrlllg ilnd push I t 11)10 tllC oJorc 01 the input sha ft Slide the lOP gC(lr synchroniser baulk IInu on to the cone olthe IIlJ)u I sha h 8 FIt the extension houSll19 gnske!. lhen InSerl the ,1s~&#34;,hlcd mainsha/t into Ihe rca. 01 the box anll (frille II III untIl the nose 01 Ihe Illalnsh~h is fully engaucd in I he II1PUI shilh necdle l>c,l11nU 9 Carefully lu.n the ge;ubox upSIde down. so thilt the layshalt \}e,lr elusler dIOI)S mto engJgelllenl with the malnshillt Jnd IIlpIII shalt Check thilt the gear and the two lluust wilshe.s il.e III line and then c,l.elully push in the layshalt from thc leal. If necessary till) Ihe S h ,ll! In with the p lasuc·headed IHI/llmer. bllt take grC;lI CJre not to dlslodUe Ihe thruSI washels or needle .olle.s . When fully home. the h Ollom of Ihe slep on the .dlel shalt shOuld be In hnc with Ihe face 01 the box and Ihe mIlled flats should be in IIno wllh the Idler shalt oo.e. 10 Turn the geilrbo~ the lighl w;ly UI) Jnd align the hole in the 1>.111 bemll1g SUpj)Orl WIth the dowcl on Ihc cxtcnsion housing. Fit the eXlenSlon housing. Apply jOlllllnu coml)ound to the ttlle<1ds of Ihe bolts. InSClt them and tightcn 10 thO torQuc wrench seHlng gillen In the SpeCll l
C3tions . 11 1/ a new cxtension bush has been fllle(1. check Ih~t the notch 01 011 groolle III II ilhgns wllh lhe o ll,elurn grOOlle In thoJ extension housing. If thc now exlension housinU 011 senl hilS not illready been filled. slide It Ollel the extension Shill t and enrelully tap it in wilh n h~nllller and n
b lock 01 wood.
1 2 FIt J ncw O ·ring to the spcedomeler pll110n assembly. relit the ~Sembly and f it the C llcli l) to socure i1. ,3 Inser t the r(,lIerse gear interlock plungel. ball and spring. Fllihe boll with aloek plate and lIl$crl tI,c l.Iol t. TIghten the boll and bend Ihe lock plilles to seCure ,to
Fig. 6.1 3 Posilionin g of Iront hearin\} .e lainer oil return \}Ioove (Sec 9)
=-*.------t---.---- ---
FiU . 6.14 R olitting the Inyshaft (Sec 9 )
A hlSC//ing /,1vs/!I!f/ B ClJflec / lIi1:qlll!!efl/ of /,J)'$/I,III illld 'fJve.se IdlfJf sl!,lfl
1/1 Insert ~II Ihrce selecto, 10l~s Into Ihcn I)ositlons 111 lhe gearl)o~ 15 Shllc 1~1/2n(1 \le,1r selector ,,111 through Ihe r,ghl-hilll(1 bo.e mille
I:ilse. Ihell tluead ,t through the 1 S I/2nd gCM selector lo.k Align Ihe holes 111 tile lo.k and r~11 ,111(/ t<1l) in the 101l1)ln. Insert the plunUe/ into thc c,lse 16 FIt Ihe pltlllgc/ '1110 Iho 3rd /lOI) ge,ll selecto. lad. inscrt lhe 'illl
t h .ough Ihe ccnHe hore III the C,lse ;lnd Ihread the raIl Ihrough Ihe 3rd 101) gea. sel()(: tor lo.k. Fit the clfchp to Ihe groolle ;n the se lecta' lilll Ahon Ihe holcS III the selectol 100k and ,;lil. insert the loll pIn and lal) .t home. 17 PUSh lellerSC gc,'1 seleelo, r;llt Ih/ough Ihe lelt·hand bore in the hou$"'g. and then thread 11 through the rellerse gear seleclol fork. Align Ihe holes III Iho IOrk and 101.1. inserl a roll pin and tap it home. 18 FIt Ihe interlock plungC/< apply sealing compound to the plug and dfille In Ihe plug 19 Inse!! ICllerSe ueJI ,clay lever and secu/c it wilh a roll pin. 20 Inse't thO sCleCtOr shalt ItHough the selcctol housing COllel and fit the co~er using a new gaskel Insert the COlier rewining bolts and screw them in Iingel lIghl. 21 FII the sel/lCIO' sh:lh b'lIcket 22 Shdo lhe S(lIOClOr flnge. onto the selec tol shalt. Eng~gc the strew III the ,ece~~ in th O shaft ~nd tIghten the sc rew. 23 0101) lhe Ihloo dctent ba lls 1I1tO thcir bores in t he casc. g1Case the thleo sprinus alld Ilise rt thcm Into the recesses 01 tile yeJ.1>ox COllel. FII
a new COlier gasket and positIon Ihe COllcr onto II Insert the COllel holtS and tlghtcn Ihem to tho 10Ique wrench suiting (Jillen III lhO SpeClf,callons
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