ABS FORD CAPRI 1974 Workshop Manual

Jacking and towing
Jilckillg poillls To chan!IC ,I WhUt:1 111 ,11 ,-,"W'!ICIICY. usc the t:]ck slIpplled wilh the ve'lIe!!.!. Ensurf! 1hal the Hhldwh,:cl nuIS;OH! ,ciC;lSCd Imlole Ii, cklll\j up thO ca. and make SlUe Ih;u the .lOIn of the 1,1Ck IS luU.,. cnua\Jcd wI,h the body bracket and thatlhe hase allhe Jilek IS st;lIldlt '!J on a 111111 surface. The Jilek supplied w!lh lhe vehIcle IS 1101 $",,;,l)le lor lISC when laislflg the ve!.iclc lor U\;J",l()II;IIlCC or 'Cp,1If up,:r;J110ns. For this walk, use a trol ley. hyd'ilui,c Of screw-Iype tad IOCille(1 und!:. thO f,OIll crOSSlllcmbcr. bodylrame s,(ic-mcmbcls 01 ,ea, il~le cnsing, .1$ ,UuSlr<llcd AlwilyS supplcl11ullt the I.lck wilh axlc-Sl.1llds or blocks t)Cfo,e cfilwhnu bC'H!.11h the em
Usin g the lilling jnck
Fronl IOwin9 pain I S (ll • • owed )
Towing poillls II you/ vehIcle ,s bCIIl9 IOWl;d, m,lke SUfe lhal the lOw rope IS auached to Iho 110111 cmssmembcr or, where Ilued. the towlog eye auachcd 10 Iho 11001 ClOssmember II Ihe vehicle IS equipped wilh atilOma llC Iraosrlllsslon, the d.slanCe lowed rnuSI nOI exceed 15 miles (24 km). 00' Ihe speed 30 mph (48 km/h), olhe.wise sefious damage 10 Ihe Ir<rnsmiSSIOII rnny .estili. If Ihese IlinilS arc likely 10 be exceeded disconneC I and remove Ihe propeller shnh.
I f you me lowrnn another vehicle, minch a lOW rope 10 Ihe lowc. shock absorber mounting brilCkct at thc axlc lube or, If fined, Ihc rCilf
10Wlflg eye.
, 'I I -J ' ,;
~)
'J
: .. ': .... 111"'"' ..... _-.___ •• _...:. __ ... ,
Jacking l)oinl S
Rear towing I)oio \s (arrowe d )
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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
,
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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"00 Chapter 5 Clutch
53 Locmlll\J the (flCllon disc on the
f lywheel 5 .6 Cent,.,l ising the friction disc 5.7 TI\)htIJnlll!) 111" ,: 1,,[, h cover holls
6.4 The plilSllC wlls which .cWin the fclcJSC hcnrinl] in the lever (""owed) G 5 nt:lcas(l levor IOC,11;01) 011 the 1"1101 stud
5 The f&#34;~lI()n rt.!;c must now be Cclltrilloscd SO Ihill when the (IllUme imd !Jci&#34;loo~ .1<0 milled Ihe input shall splmes Will pass 1I110uUll the splines III Ihe )HCIIO!) diSC Id(!,lIly a wlille.s;,' dUh;h (;C!l!r<lIiS IIl\J loul or ;m old !I&#39;~;&#34;I>()&#34; Inpul ~h&#34;fl shuuld be u~cd. hlJt ,rlh.'IIHI(,vcly a woodull 'lIilnd,!:i G,II1 h.., Ill.1<ic to IIIe d,mtJnS lons shown In FlU 53 G InSUlt Ihe ccnlr<ll'SIIl(J 1001 Ih,ulIUh the (fiction diSC <lnd 11110 lhe ·"\jot Ill',"""\! (phOIO). nOlillC tho 1001 or movc II Side tu Side until lhe .etlon d,sc 'S "ccwnlCly centm(l 7 P,oy,ess,vely u\Jhlen two OPPOSl1e cover holts unt,1 the ftict,on F I, fnmly held ") posl1ion. then l'Uhten all the holts proy'esslvely ,d 111 (I,,,yo,,,, 1 sellu,mce (phOIO). 8 flemove Ihe cenH<1r,sin\J 1001. 9 Wipe dowllthe \)e,llilox IIlput shJlt ,md "pply a littic molybdenum Iwscd \Jrease to the sptones an(i spioot b(&#39;~&#34;ng slillacc_ 10 flcf,t the ue.1fbux Wilh ref!!lence to Ch"pwr 6.
6 Clutch release bcnring removal 1Hl(1 rcfitting
Remove thc gcarbox "s dcscflbed in Chaptcr 6. Alternal,vely. illhe cngi ne is to bc removed for repairs. acccss 10 the rclcilse bcminy ,s possible leaving lhe gearbox in position. 2 loosen and back oil the cable adjustmcnl milS. 3 Whcre npplicable. plisc lhe ciulCh cnble fuhhel gaitcr flOm the bell housing nnd unhook thc cahle end lotting from the release fevel. <1 Puilihe release I)ealing hom the \Juide tube. Whcre necessary use a scrcwdrlver to pflse the f)Caring flom the Icvcr and lelease the pfas\lC
tabs (photo).
5 Pull t he rclease IiNCI sldcways to d,sengage it from t he pivot retaining stud (photo). thcn withdraw ,t ovcr thc IJuide tube ,1nd input shah
6 The rele ase beann\) is supplied completc w ith lhe huh (photo). If fC(luired. thc two componenlS can be scparated usinU a VICC and soh metal drill.
)Before relltllng (hc releasc bcariny. apply a lillie molybdcnum "."ase 10 the \llude tubc and contact laces of the release lever 8 flefl!1lng is a ((,versal of remov~l. butllnally chcck the clutch pedal and cable ndlUsllllenl JS descflbed in Seclion 2_
7 Clutch c;lllic -Icnewnl
Apply tlol) Io.",dl!<"k" llien lilCk "I' lilt: j'onl of 11"1 Gil o1l1d suppor( on ax il! ~!and~ 2 PIIS" th" dUlch callie whlJel (jilll'" horn lh" h&#39;·lIhou~u&#39;(j. lousel! the ati,US111l'JllI nul(s). ;IIHI unhook the c;,I,I" ,·nrl IlIllllB hOIll lhe release h,v,,, Pull off the !Jalter (phOlUS) 3 Ikmuv" ti,,) c,lhle frorn lhe hole II) lh., 1,,·lIh&#34;u~&#34;l\J. nUlo)\) lhe posltlun of lhe slccve (phOIO) <1 WOlkln\l illS Ide (hC Cilf. remove the luw,,, I,,,",,, pallel lor <ICCCSS 10 the CIUlCh pedal 5 O'SCOlllH!C ! the cablc from lhe cllllLh !JO'ri.11 t,y puslun\J lhe P'" thf<.)u\Jh the cilhle eye.
, '. ,
j'., ;. . , , , .;{
'-,
7.2A Prisc all the rubber Ualtef
.. ~
d
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·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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~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$"'g. and then thread 11 through the rellerse gear seleclol fork. Align Ihe holes III Iho IOrk and 101.1. inserl a roll pin and tap it home. 18 FIt Ihe interlock plungC/< apply sealing compound to the plug and dfille In Ihe plug 19 Inse!! ICllerSe ueJI ,clay lever and secu/c it wilh a roll pin. 20 Inse't thO sCleCtOr shalt ItHough the selcctol housing COllel and fit the co~er using a new gaskel Insert the COlier rewining bolts and screw them in Iingel lIghl. 21 FII the sel/lCIO' sh:lh b'lIcket 22 Shdo lhe S(lIOClOr flnge. onto the selec tol shalt. Eng~gc the strew III the ,ece~~ in th O shaft ~nd tIghten the sc rew. 23 0101) lhe Ihloo dctent ba lls 1I1tO thcir bores in t he casc. g1Case the thleo sprinus alld Ilise rt thcm Into the recesses 01 tile yeJ.1>ox COllel. FII
a new COlier gasket and positIon Ihe COllcr onto II Insert the COllel holtS and tlghtcn Ihem to tho 10Ique wrench suiting (Jillen III lhO SpeClf,callons
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130 Chapte r 7 Pro pelle r sh aft
14
. 12 ~
"> ., I>
" 10 11
9 a
·6)6f
. -r 3
~I&#34;&#34;)~ 2
Fig. 7 .2 CCllIre bearing and CV joint cOIll I)onenls (Sec 3)
1 FIO,,/ sll,1// 2 Inncr (/(IS/ cJ(cfudm 3 Cemrc bC.1riny 11 Rubber in$u/.l/(J'
5 1f00wl/f/ 6 Du/!)( rlusl cXl;/mh'I 7 AIlYflml'lJ/ shim 8 flull
FiU · 7.3 T ho recess (;ufo\l\lcd) in the <:orllre bearing housing m ust la ce forw(.rd (Soc J)
10 To lI~fll the bearing. first f,lI the 51)<lCO between the bC<I,iny and dust e~clu(tcrs with 11 general purpose urease . Selec t 11 piece of piping or tubing that is just 11 hnclion smaller in (h;lInctcr than the bCilring. place the sphncd p,HI of the shill I upright in a vice, position the bCiI.ing 011 Ihe shaf t and, using a soft hilrlHn cr o n the end of the piece of lubing. drivc\ho bearing firmly and squarely OntO the shalt . 11 Slido lhc con Ire bearing housing and fubber insulalof Ollef the bearing. milking sure lhallhe prelliously nOled recess faces lhe IrOnl 01 lhe shalt. Relil lhe Outef dUSl cxcludCl . 12 loca1O the l1anyc on the splmes of lho frOIll shal l. making SUfe th,l1 tho PfOlliously made marks are aligned . Rel it the cenue bolt and
washOf and tig h10n the boll. 13 Assemble thc two shahs togothCl with lho previously made marks
alrgned. Ihen refit and tighten the constanillclocity joint housing bolts. 14 Refit the propeUef shalt With ,efefcnce to Section 2.
4 U nillorsal joints in sp ectio n
) Weaf in the
needle rollef heafings is Ch,Uoclefi sed by vibfalion in the tfan srnission. 'clonks' on takrng up the drille. and in e~treme cases 01 tack 0 1 lubficat ion. mOlalhc squoaking. and ultimately grating and
shrie king sounds as the bOilflngs breiJk up.
9 Fl.",!!.: /0 C('/IIf<.' 1",11 /1 Cllcllf'S 12 CV /01111 ilssl:mbly
13 Sprillg c.lf' 14 Boll
Fig. 7.4 Using.~ plillor 10 withdraw the centre bClI ring (Sec 3)
Fig. 7.5 Bendi" g the metal tabs to secure the insulator (Sec 3)
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1 Chapter 8 Rear axle 133
Fig. 8 .1 CrOSS-Sl!ction o f cnrlv rCilr ;1xlo (Sec 1)
A Fixed /ellglh SIJ.1C(!f B Pinion slum
2 Routino mnintcnoncc
C Dd1clCII1.11 S/II"'$
At lhe uHerv"ls specIfIed 111 the HOlltmc M.111l1cn;mc c SCCllon III the 110111 0 1 the mnnu;1I c""y oul the following p,uccdw(!.
Check fcar axle oil level 1 Jilek lIlllhc IvaI of the Cil! ;uHf suPPOtl on axle ~I&#34;nds T o C!lSI'''') li1,'l Ihe Cilr is lellel ;,150 I<lo k III) Ih e IrOnl of th e cm Allefll;. \,vcly . OSI110n Ihe en, ovcr ;m IIlSIJO:ction ,)11 or all .;)mps J. Usmg;J 51111<11110 sqll1lrO key, llrlSe.cw the hiler plu\) I.om Ihe 't·h;md Side 01 tho d'lfcruntinl housmu. USIng a 'mger Or., )llceO 01 bent mowl .otl. check Ihat the OlliS level WIth the b0110111 01 tho f ,lIe . 1)lug hole O f il n>i!xnmun ul 100 mill (0 39 Ill) belo w the holo 4 II necessmy top Ull wllh I he euoree! \)I;lde 01 011 ;IS !Jlvcn '" 'Rceommcmlt'd !"brle,',,'s ImrllhUfls' 00 no! ovcllill thc .em ,nle. o th e.wise thc 011 will ove.he;ll ;111(1 he IO~1 Ihl oUll h Ih e b.e;Ith e. vent 5 Rcht ilnd tiuhten thu hUu. plu\1 Ihen lowe. Ihe eM 1 0 the lJ'ound
3 R e<lr <1)(10 - relllov,,1 ,\Il d refilting
Jack up the le,lI olth e cm ;Jnd sUPPOl1 wllh axl a stan ds 0' hl oc ks
posi tioned lIancnlh the sid(Hllemhe.s . Cho ck thc tronl wheels and rcmove the .ear wheelS . 2 Mark thc p.ol>elle. sh;J1! ilnd .eil' <ule drivc ft3!111cs in .elallon .0 ench olhcr. 3 Unscrew the Iou. fI,lIlge boilS while holding the sh M , wilh a mewl
ha. insc<led through the universal 10Ini. o r by applylllg lhe hJ'ldhrake lower the 'eM 01 th e p.opelle. shafl.
4 D is connect the h,mdlllilkc ti.lIle and. whe.e .1pphC;Jblc. tha
t'ansverse ,od from the .ea. (Ide wl,h refalCnce 10 Chal >!el 9
5 CI<lmp Iha fle~lble hr<lke hosa t o the re<lr a~lc then unsc.ew 'he nuts and disconnec t II /.om the IIgid tJ'ilke pipe all(i ;J~le hrnckel. It a ho se clamp is not av allahle. lig hlen a piece of polythene sheel lIenealh the laSle r cyl inde f till> 10 reduce any fl u id loss and also plug the disco nnecte d hose 6 Jack up the ,ca. ilxle a few Inc heS Ihen unsc.ew and rem ove the sh oc k ab so,be, lowe. moun.,n g lIo115. Prise Ihe shock abso,lIers horn lhe b.ack (lIS on Ih e rca. aKle.
COUAPS'8ll -----i--i!~e&#34;&#39;.!i SPACH'
,
Fig. 6 .2 Cross·sc ction of I"ter rear Ilxle (See 1)
Fig. 6.3 Removing the rear ax le fillo r 1)lug (Sec 2)
Fig. 8.4 Flexible brake hose connection to the .ear axle­arrowed (Sec 3 )
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Chapter 9 Braking system
4 Note that in order to m,lintOIll even braking both discs should he renewed ill the sal1 1 e lime
5 T o remove il dl~c. first remove the tHlb as described in Chllpter 10 . 6 Prise lip th(J locklllU I"hs. unscrew the fOlll bolts. and remove the disc from Ihe huh.
7 Clcilll the Illllirnu !ilces of the disc and hub then locale the diSC on the huh and allgel the holt holes.
8 InScrt new holt~. tOI){)ther w rth new locking plates. and tiuhten them to the specrfre(1 torque_ loc k b y bending the tabs. 9 Th e huh Illily now he ref Illed with reference to Chapter 10.
7 ReM hrake shoes -rt)rlewal
Check the front wheels th!:n lilck up the rem of the CM lind support on ,1~le stands. Rel(,a5e Ihe handbr,lke lind femove the reM roadwh~~els
2 Unsr",w th" I"ake drum lewinrnu scrow then t.1p off the ,IIurn \Jsing ;I ~&#34;It f.lced milliet (photos) 3 Barsh away all dust I.orll the brilke shoos, backplate ilnd drum, ",killfl can' ""I /0 11111""., II ;I S 1/ is iHjmiaus to "e,11Ih Del&#34;&#34;~~ ,,;och shoe hold-down sprrng (photo) ,lnt! rOt,lte the sprrn!! ",w"nIlH w.r~I&#34;&#34; th,ou!lh 90" , to rhsengage ,t from the pm sel:rr",d 10 Ihe had' pt. 'I" 1.,11 ,"wily 1Ill! w;'shel and spm}!J
Early moth'ls (iippmxilllawly pm Df!c()tllbcf 1974) 5 Eas,) .. ad} shoe loom ,t~ loc;rllol1 slor III the lixed pivot nrrd tllen detach th,-othe! &#39;~nd 01 ea(.11 shoe f,om the wheel cylind'lr, 6 Note whld, W.1Y fOwul and IIltO which holus in the s hoes tlH~ two retracting sP""Hs Ill. 7 lift ,lway t ho two brake shoes "nd retracting springs. 8 TUf(lthe self- ad lust'ng ratchot wheetum,1 it alJuts the shoulder on t he s lot head bolt.
FiO_ 9.4 Renr brake shoo components Oil e,lrly moclnfs (Sec 7 )
I Pili 'm froft! dowII sWIIIII 2 Buc/."liTlt! J B&#39;,l~&#39;l! shot's <1 II,-IIIrflHiiAe opcra/jllY h-v", 5 lIo/d d"wII slNil/ys
Lawf lII oduls
6 fir"",,:, (/",,1 r:lJvlH 7 IId;III1I1'!IIII.llr!S 8 flNr;Il:IIl'!! .,'I,"IIIIS 9 WI",,:II:yllJldl!l
fJ N Ole the local,on of the shoe 1"lpacl,no sprrll!ls nrld thell unllook tlwm \lSUl!l a s(;lewrh,vef or SUil;!tJle plo~&#34;s. Remuv,) th" lorw,lrd shoe Unhuok tho small pelurn spring loom the reill shoe and then rumuve the shoe lenvinlJ the adJus!Cr in pos,tiol} (ph o tos)_ 10 Tu remove tim adjuster unit. del<J~h the hllluH)p,lke cahte or pod <It the clevis (Jlmer side of backpl.1ll)) <lnd withdp,lW the adJl,stef
'nech<lnism (photos)
7.2A Re<lr t,r<lko shoes With (IrUIll removed (eilr ly models) 7.2B Rear brake shoes with drum removed (Iatc! models) 7.4 Brake shoe hold down sprinO
cylinder (later models) 7.98 Brake shoe attachment to anchor ( later models) 7.10 Halldbr~ ke tra nsverse rod connection to opera ting lever on backp!ilte (Jrlowed)
,
j
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rhapter 10 Suspension and steering
F<lull (haOl1osls suspension ilnd steeling FIonl co,1 spOI"g remOIl,, 1 imd .ehIlOllO . FrOln huu ,el11ova', .chuing and ue,lrIng adruSl!llcnl FrorH hub bC;1II1195 -rencw,,1 .... ....... , .. . F,onl st<llJilis. b,ll -,clllolli,l imd .eliulI19 ..... FIOn! suspcnSIOIl strut -,01ll 01l<11 and .efottlng F.onll.ack comrol arm -.emoll;! 1 <lnd rellUlng F'aln wheel alignment and Mooring angles Genc.al description ...... ,...................... .._ ... . Power steelin\) -bleedmg ......... _ ...... _ .0_''', .. _. __ POWIJ• sleeri llU gear -removal <lnd refining,
Specificatio n s
Front suspension
Rear suspension
, . , enflg gear (manual) Type ................... ....................•................ Steeling whecl turns (lock to lock) .. . LUbrican t type ............. ................. ...... . lUbricant capacity _ ............................. .
" G 3 ,
7 ,
• 20 1 15
"
Powel stCCIlIlg Ilump .. remOllal ,111(1 fcllting RCiU leill SI)II119 . emoval. bush renewal .1nd Iclottlng Flo;"), shock iJbSOfOO' removal ,m(/ felUtlng , ............... , Rein sl<lluhscr bar rcmoval and rcfruing
ROlltlllc m"IIH ennncc .
Steering column -rCmov<ll. ovcrhnul <lnd rctrtllng
Slecrong gear (manual) -overhaul and adJustmcn t .. Steeling ge'lf (manu"l) -removal and relrn ing •...•.•...
Steeling wheel -rCfllov<l1 <lnd rctilling ...
Track rod and baliJoll1l -renewal
Wlleels nlld lyres -uencrill CilfC and maintenance ...................... .
17 10 9
" 2 19 13 12 ,.
" 21
Independent. MacPherson strutS with Integral telescopic shock
ab sorbers <lnd stabiliser bar
Seml·elllpliC leaf springs with flgld <lxlc. t clescopic shock abSOrbers
and stabiliser bar
Rack and
pinion 3.36 SAE 90 EP gea r oil 0.15 IlIre (026 pint)
i
i.
!
I (
!
:~
I:
II
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)8 Chapter 10 Suspension and steering
Power steerin g gear Type .. Steer ing wheel turns (lock to lock) lubrican t Iype, Lubricant capacity . Fluid Iype .
Fluid cilpacily: Sepilrilte reservoir . Integli!1 reservoir .
Front wheel alignment C",nbc, M;lXll11um dlffcrence side \0 side C<lSlor M,.xirnunl dtffcrence side \0 side . Toe·in
-yres SllC . <;JSsu,es Illl/m' (~(Jflclll&#39;). 185170HR13: Up to 3 persons . More than 3 persons. 1 B5170VR13: Up to 3 persons . More \h,1I1 3 persons. 205/60VR 13: Up \0 3 persons . More (h,m 3 persons .
195/50VR15: Up 10 3 pe.sons . Morc th(ln 3 persons.
Torque wrench settings Fran! SIIS{!cl!siotJ Stlut upper 1110untrng . P,ston rod nut Suspen Sion &#39;)~&#34;,{Jont St;rhiliscr birr mount"'lt . Stab iliser h;rr to track control ,)In,
Track cOIHlol ~rrn p,vot
,H'o1( slIspCIlsion od abso,bcr lower mountH'g .ock absorber upper mounting Stabillser bar to axle .. St;rl.lIlIscr har 10 underbody
U ·bol . Sprinu I.ont mount"'g . Spring rear sh;rckle
SINNing Steering gear (m~nual) Track rod end uall,oint Coupling shaft to pinion. Coupling shah t o column . Steering wheel.
Steering column.
Roa(/wiJec/s Wheel nuts/holts: Conicall;rce . FI(lt face.
General description
, -'The flonl suspension is of Independen t MacPherson Strut Iype incorpotating inleglal telescopic shock ~bsorbers and a stabilisel b~r. The ,eal suspens ion is o f semi ellip tic leaf spring·with· 'l ive ' axle Hydrau
l
ic assisted rack tlnd pinion 3.25 SAE 40 oil 0.20 litre (0.35 pint) AulOm<ll ic transmiSSion lIuid to ESWM 2C 33E. SaM 2C 9007 AA. or D2AZ 19 582 A
2.2 litre {3.9 pint} 0.5 lure (0.9 pinl)
1- 0 ' 30' I" O· I l' O' O ' 45' 01070 nun (0 !O 0 28 ",)
185170HR13. 185/70VRI3. 205/60VR13 o. 195f50VR15 Front Rear
23(1.6) 23 (1 6) 28 (20) 28 (20)
2<1 (1 7) 28 (2.0) 28 (20) 32 (22)
28 (20) 28 (2.0) 32 (22) 32 (22)
26 (1 8) 26 (1.8) 32 (2 2)
32 (22)
N'H Ibl It
20 to 2<1 151018 40 to 45
30 to 33 <11 to <18 30 to 35
28 to 33 21 to 211 21 to 61 15 to <15 25 to 30 18 to 22
53 to 63 39 to 11 13 27 to 33 20 to 2<1 40 to 50 301037 35 to 41 26 to 30 25 to 36 181027 35 to <11 26 to 30 11 to 14 8 to 10
20 to 24 15 to 18 24 to 30 18 to 22 16 to 20
12 to 15 231030 17 to 22 27 to 34 20 to 25 17 to 20 13 to 15
85 to 115 63 to 85
115 to 140 85 to 103
type, incorporating telescopic shock absorbers and ;l stabdiser bill. The steering is of rack and pinion type, but may be either m(lnual or power·assisted . The steering wheel incorporates 11 convoluted cam which is designed to collapse rn the event 01 (In accident to prevent
injur y to Ihe driver. It is not reco mmended that the power steering gear is dismantled on Ihis work is best entrusted to a specialist.
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