manual transmission FORD CAPRI 1974 Workshop Manual

" ,
'6 Routine maintenance
)
Every 250 miles (400 lUll) or weekly -whichever comes first
Check the engine 011 level and lOp up " OCCCSSJry (Chapler 1) Check and adlus t lhe IYIC pressures (Chilplcr 10) Clean the windscreen and windows C lean the hcadlamps
Every 6000 miles (10000 km) o r six Illonlhs - whichever comes fir s t
£II[1ille (Clwpter 1) Change engllle 011 and IIher
Cleiln oil flilm c"p Chcck 10 1 ,IllY fluid leaka!)e ,n enUme CO'llp:lnUlCIl1
Cooling syslem (Clwptet 2) Check cool:'lnt level
Fuel syslem (Clmpler 3) Check idh"U mi~lUle (cmiJUiello1 IllUdels onlv) al I"SI se.v,ce ollIe, overhaul C heck idllllg sj)ee d
Ignition sys/Cm (C/I,Wler 4) Clean ,1nd re!)"p Sl)".k plu!)s (.:on!nC ' breilkCl Illudels olllv) Cle an and check d'Shibu\o. C"I). '010'. HT lealls mId co.1 (COllWct
bleaker modcls only) Check elwell angle (cOntact b.e"ke. mo<lel s only) Check i900\OOll hlllillg (COnt:'lC1 break er models only)
Cllltch (e/Mllter 5) Check adjuSlmenl
Bri/king sys/Cm (Ch,1pter 9) Check selva
Che ck hydraulic flu id h,vel
Ch(: ck p"ds :'Illd sho(:s lor wear Check h.ake hllcs and hoses
Suspension .wel stvi'ring (Chi/pICr 10) Check tyres 10' w ear and dam:lge Check steering COmp{lIlCnlS l o r w e:l l "lid d.1nlilue
Bodywork. .111d fittings (Clwptef 11) C lu .. >ek se"t belts fa. we .... damage :lnd secwity
Elvc(ric.11 systcm (Ch,7jJ(ef 12 ) Check Ope.iltoon 01 "Uhts Check wilsher flUId levels Check b.1ltery eleclrolvle lev el
Every 12000 miles (20000 kill) or 12 mOll1hs - whichever comes first
III .1(/(lIlioll 10 Ihe 6000 m/le sciler/Ille
Engine (Ch.1f)ter 1) Check and adlUSI valve clearanc es
r"' .......... ~.~-.... ._ •• -.... __ .... . 3lii1&l •
Cooling system (Chapter 2) Check condition "net tension of 1111011)<1101 dflvehelt
Fllel sys tem (Chapter 3) Tighlcn inlel IIHlnl lold boits/nuts Check vacuum hoses Check e~hiluSI syst em Check ll1r ctonne. temperature cOllllol (,I applicable) Renew fuclllllC ' (fuel injec tion models only)
Ignilion system (Chapler 4) lubricate th e dis'flbulOf (conUlel br eake r models only) Renew the coninCt hu,akcr points (II nppllcJblc) Renew the spMk plugs
Transmission (Chapter 6) Check ool/th"d level Lulmc;ue automatIC 1.,'Insmlss,on IInk:'lue
Rcar axle (C/MplCt 8) Check 011 level
Bli/king system (Chaplet 9) Check v,lcuun' hose
llliJllc:'l1C Ihe handhlake Imk,loe
Suspensioll {//j(J swelill!J (C&#34;.1plt~( 10) Check condItIon and hlllSlon o f POWI.II ~I!&#39;tllllli dllvthtl1 (II .1l1pllcal,
Check MlspenSlon 101 we;" ;111(1 d;1Il1.1!)e
Bodywork ,1I)d fillings (Clwpler 11) Check opera lion of all locks Check secu.ity 01 dOOf check sl.aps
LlIl)fIcalC locks. door c heck S\','P5 :'Ind fuel fdler cap flap
Check underbody pr olCctive coalm!)
Electrical system (Chapter 12) Check Opcra1l0n of all eleC111!:al IIcm5
Evcry 2<1 000 llIiles (40000 kill) or 2 yc;u s -\Nhichever comes firsl
III ,1(/111/'011 10 the 12000 111"'1 $d&#39;~&#39;f/u/e
[nyino (CIWpICf 1) f!ell'!W crankC:l $e e""5510l1 v;llve
Cooling syslofll (Clwptor 2) Renew COO!:1II1
Fllel SYS(CIII (Ch, '/pliJr 3) Renew"" II Ih!r elemenl
TrallsmissiOIl (ClwjJWr 6) AdjUSI aulom;1\IC trall5nll5SIOll h,ake b;'IIld
Every 36000 miles (60000 kill) o r 3 yenrs - whichever comes first
III .1(/{/I('01l 10 Illc JJIl'VlOUS schc(/ulcs (",lIc" JJJIJ"ci,bfc)
Brakillg system (Clwpter 9) Renew hyd,auhc flUId
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7
__ ----------------------------------------------------------17
5 -
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1 J
U
i( 8
2 --I-~.&#39;-&#34;&#39;\r__ / II [!CJ.:=J-~
-.... ,I /
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• •
Recommended lubricants and fluids
Component or system
Engine (1)
Manual gearbo x (2)
Autolllatic transmission (3) Black dipstick Red dipstick
Rear ade (4)
POwer steering (5)
Br<lking system (6)
luhricant type or specification
SAE 20W/4Q o r 20W/50 multigrade engine 011
SAE 80 EP 0.1 to Ford spee,flctlllon saM 2C 9008 A
ATF 10 Fonl speclliCil tion SOM 2C 9007 AA ATF 10 Fonl specillcmion SOM 2C 9010 A
SAE 90 ad to Ford specI fiCatiOn SaM 2C 9002 AA
ATF to Ford specd 'C[lllon ESW M 2e. 33E. SCM 2C 9007 AA or DZAZ 19582 A
Hydraulic fluid to Ford SpeCifICation SAM GC 9103 A
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Chapter 1 Engine 49
----------------~--~----------------= anuill transmiSsIOn models, remove foul clops <lnd remove Ihe 16 On h(11 sing cover . On ilulonHll lC tr&#34;nsmIS~lon models dIsconnect Ch.llCh au lug the 011 cooler hoses. and P It the Irans!1lI$S10n then remove th e l'illlsnllSS lon to-engine 17 Suppa <
bolt~ n automatic 1.,J;lsmission .models. drilm the torque conve!ler ,\Ild 18 Ihe drivep l<lte boilS wllh ,clerence 10 Chnpler 6. UO~~~~ Ihe weight 01 tho engine on thc hoist ilnd then pull tile euuin!} " d \0 separJIC;1 1'0111 the \'<lnSIllISS'OIl. 0 " [lU10111<1(1(; IlilI151"'5' 10' ..... 31 , I
. odelS make s"re Ih,lt the torqlle converter ,em,,!!)s lilly 1f1 1he $lOI1 m transmission . 20 When the engine hilS been SCpM,lICd from 11l(l 11.,11$1111551011, 1,lllh!.! . ,lowly chccklll9 j,equently to see (hMllle CflUllle does not loul " ng,ne . ~nv part of the bo?ywork. 21 W hen the engUle 's cle,lr of the iJody . lower it to the ~lfOun(i. Of
Ir~nsler it to a WOrk lJench
4 $ Engine disill1lotling -generill
Refer \0 Sec t,on 7
46 Engine illlcillilrics -removi\1
..
1,',lh the engine sep,l rated from th" t r;IIl~:nHS~r()&#34; remove Ihe ~.tcrnally mounted componelliS ;l~ lulluw~
C;J//)Ulello, i.lnd fllcl {lump (C"'1!,lt" 3) IlIlel ,wll exhiwsl tII,wi/a/ris (Chaf!/t't 3) Sp,>r/( plugs and drS/fllmlor (Chaplet 4) AllCllwlor (Chaplet /2) F.w ,7I!d policy (CII,71I1C' 2) W.JICf pump ,wd Ihcffllos/.1I (Clmp/t't 2) C, ,1IIkc,lSC vcn/iliilion lubc 011 {,f/CI (Scc/ion 40) Ol/Icvl!! r/rpsllc/o; and {,/lCf C,?!, [II!1int' 1II01tn/ill.ll h,.1r:kvls Ciulell (Ch,7/I/l'l 5) Powl'r S/Cl'l/IIN 1'(11111' (Ch;lll/Vf 10J
<11 Cylind(Jr heads relllowti with engine in car
I
Q,scunnecllhe IJiltlery le,lds ") ~cmove the splilsh slucld. by renuJVIII<j 10\" holts nnd luur chps J II.lee il cOrltilm er 01 10 Irtre (I·' 6 pint) r.ap.lr.lty unde!l1e,Ilh Ihl.! ~&#34;lr.llor. remove the rmll:l\or hallam ho~e and drilill Ihe system Rr:rnove the rad "l\()r lap ilose . !l Rcrl10ve Ihe au Clealler. d'SC(lnner.t lile h,el p'pe fro m the ~MI;;&#34;rllor and Ihe l"e,lIiler hose hom Ihe rocker cover.
, R ernove the servo V,lCUlUl1 hose I<om tile Inlr:1 l11illlllold ~ enlOve Ihe IllIe e bolts and rem!)ve II,e Ihrollie Irnkaqe lI<ilC~l;t .omllic le wo1h Irll kilge '
~ DI~conrlccl Ihe rilll,.llul hose from Ihe ilulomallC choke D,s·
,onneCI the vac\JUnl h"e I<om cariJU!l:1I0r .
• D,sconnect" I I I 10 0 le ea( <orll Ihe lempelnllllc sende< Unit.
co I I~con&#34;ecllhe HT ICilds Irom the spark plugs and IrOlillhe Ign'llon I ,1od remove Jlw L T I I I I .
MId I I If . CiI( 10 lie dlSl1i Julor Reillove aile h Xlng bolt 11 0
' I
a Ihe dlst"I>[1I0r ilSsemlily.
'Sconllect Ihe all II 51 halts' , ' ernillOr Cil) es. ilcken the ailelllntor 1110ul1l11lg un( <emovelh~d b I hi· '" ... live C I. I en remove the fllCrnfilor h XlIlg bolts rernove the ~I&#39; . 12 R " erniltor ')nd liS I,x,ng lIrackel. CIlIOVe Ihe Spa k I cOvers d "p uos. Remove Ihe IIUIS secufII1(.l Ihe rocker 13 R an hll 011 tho covers. emove the I I I . . mlel III f IVC '0 IS sec linn\) the onlet lII,1(l,lold and take 011 lile 14 l an, old complr:te Wllh ca<lIurello, OOson Ihe rock turned a ·d er """ .ldjust"'g nulS ulI\ll Ihe !Ocker arms can be ) hoe Or SI CI(F'(J 1 10) Ihen rCOllOV!.! Ihe pushrods ilild lily them oul Itl PO,ition l~llS I, lill.!1[ finds through a sheel 01 paper 011 which Ihelr III I Ie ("",II,e . I
Pusil rod . C,II1)e "Oled. 11 IS very Imporl<lIlI Ihal the IOtnOVCdS .1<0 r(;f,tted \0 Ihe same villve as Ihat from which they were
"IOC>! "
Fi~,. 1 .10 Turn the rocker (HillS to olle side 10 relllove the pushrods (Sec 47)
15 n,,,,,ove Iwelve lIolts ilnd delilch Ihe exh,lusl I1\,lrlllolds frOI" Ihe cylrrlrtr:f he,lds. 16 Sinckell the cyhmter hend boilS progressively in the revtnSe order to Ih"l shown ill FIll 1.19. IlcrllOVC Ihe bolts nlld hit olt Ihe cylindOf head.
It lile (.Iilsket has stuck and the cylrnder heJd cannot lJe lifted off. wp the cylinder heild wllh n hide·f.1cert. or plnstic·headed hJmmer. 00 nOI try to pri se IlIelil off wllh a screwdrivOf Of rtilillage WIll result.
4 8
Cylinder he,l(ls -rernovfli wilh engine O\lt o f car
Follow Ihe sequence (.I,,·elllll SectIon '17. 51;lItll1g.l1 PillillJl1lph 10. dl$lcoa,d,n!1 leil.!lellCeS to pa'is willch hJve alreildy bcen rcmuved
49 Villve$ _. removal
Rt:rllove the d('POSIlS /'0111 tire corllb\lsl,on chambers ~nd vnlve
h eads by ScrilPIl1!l and W&#34; ~ b'\Ishlll(.l Tilke CJre nOI 10 scratCh the cyllnde, he~d gaskel lilces 2 Lay the CylOl(ier hemt on ,IS sllll) .llld h t the lo,~ed cnd of .1 VJlve spllng compressor ove, the ~plln9 rctiluler ""d ti le head uf the complessor screw in Ihe cenl'e of Ihe v"lve head 3 Compress Ihe sprrng abolll " qUJller 01 an Ulc h 10 Iree Ihl} split colle l hom the top 0 1 the v,llve stelll. If Ihe sPltng ,eliHner "nd collel Slicks. do not screw the co",p,essor down lurlhc< . bec"use IIIIs lII.ly dJr11J\je the valve Slem. bUI lJp the sprong reliluler sha,ply wllh a Ioghl
hammer. 'I When the Iwo halves of Ihe collet h')ve been '(:nloved. onscrew the spllng compressor umrl Ihe spring IS no longe, compressed nnd
remove Ihe compreSSOr . 5 f1Olllove the spltng retnlner. the spflng and the oil seal from Ihe villve Slem. Ihen wrlhdrflw Ihe villve from I he cylinder head. 6 D iscard the valve Slem all senls and plflce Ihe Olher componenls to\jellrCt. identilying them so Ihal they arc refItted III the correC I plnce
III Ihe cylinder head. 7 Remove Ihe sp,11k plugs from Ihe cyhnder hend. II nOI alrendy
removed.
50 Rocker arms -removal
1 Remove the SIIfI nul from Ihe foch" .1'111 Illoullt,n\) stud 2 Lift off the rocker <Hill b')ll seiltin\! and Ihe roc~er Mm and Iny Ihe tl1<ee parIS 10<jethe r II IS ImpOrtilllt Ihat Ihe locke' arm. its hall SCJling and nUl ale refa ted \0 I he snme stud as Ihe one 110m which Ihey were
re moved.
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50 C hapter 1 Engine
51 T llp pcts -removat
Remove the 1<lP11C1S I.om their bores with ,1 1ll1lgnct "nd pl,lee them ,, 11 r,lek in sequence. 2 If (lny <lIe (1I111cull10 remove, .ot.:l1C the crnnkShilh. willch wIll Ciluse the cilrllshilll 10 lurn lind move the IilppclS 10 ,elcilse them hom <Iny
!.111m "' thell bores.
5 2 Crnnksh<llt pulley -remov al
Prel/cntlho CJ,lIlkshilf l hom 'Ot:ll111(J. by lillllmUl!J the flywheel,' the (jl1nin.! 'S 0111 01 the C;1I, o' hy 10ckll1\1 Ihe transmIssion ,I the cnOllle IS 51,11 III the Cill . 2 Rclcilsc the p"lIny boll hy l,oUlU 1l '111\1 511.11111C. ;'Ind rapptl1\J the sp,lnnc. ShiH ply, thon remove Iho holl ;1I\d washer 3 Usc il S I).ockcl pllile. 10 (h"w the pulley olllhe Cfilnkshall. Do not ilUOl1lpl 10 lever II oH, bC(:.lIlSl; the engllle [,onl COV(II IS j,aulle ;111(1 Icvcrn'H ilU1l1l1S1 11 Ill;)y (11510'1. or even InC.11; II.
4 Wilhdraw Ih~ Wood'uH key hom the end of th(! CllInk5hah and pl,lC,(! " w'lh Ihe pulley. til(! holl alld its washer 5 The C&#39;.1nk~h;)h p"lIey m;oy he ICliloved wilh Ihe eno,,,e III Ihe C:\I. hilt ,I 'S IIIsl tU!Ccss;o,y 10 ,emove Ihe ',ld'illO' :lI1d thc rh'vehelts
53 Flyw heel -remov[ll
P,even llhe flywhcel hum 101m",!) by FHlHllln\J Ihe lin!) !lcal ;ollain~1 ;In imp.ovised SIOI). 2 On nlodels willi nl;lnu:ol 1I;o"$""S5'01i. Icmove Ihe Clulch plessure 1)1;lle and disc :os described in Ch:op!Cr 5. 3 Rele.lse Ihe s,~ bolts secu.in!1 Ihe flywheel 10 Ihe CllInksh;oll .lnd lefl\OVC I,ve of Ihenl.
4 Whilc supporling Ihe tJywheel III pl;ll':e .• emove Ihc Sixlh hoi' ,'11d Iolt Ihe lIywheel otl c;o,elully. so 111:01 Ihe m;lllllg su.lilccs of flywheel [lild c.;onksh;oit ;o.e 1101 dllm,'ged
5 4 Sump -removal
W"h lhe '''1(1'''') oul fli the e,". CII~&#34;&#39;C Ihal Ihe sump has 1o('CIl d,amvd ;ond then lilln the engll1C ()VCI so tl1011 Ihe sump's U l)I)ClmOSI F" wOOr1CII bloc"s tn Slll)lmrl tim en!l'ne 'n Ih,s POSIIiOIl . 2 Remove 11m h()IIS seCUlln( J the oil Sump 10 Ihe CI.1nkColSe o1nd rClllOVO Ihe SUll1p_ 11 the sump IS stuck 10 the c r;ollkcasc . II should be reh;lIsctl hy 1"'SII1\1 olle SIde wllh 11 sClcw drover. 3 To !Cn,ovtl .Ile sump wllh Ihc CIIU"HJ Hl tloe eM. 11151 IcnlUVC Ihe
d'l)S llck :ond d'SCOIlII(!Ct Ihe hatlery 4 Remove Ihe luur holts ;ond lou. Ch,)S ;ond dCI.leh Ihe OIl splash
shIeld.
5 Pl;oce a Con'"lIlcr 01 at lellst 6lttre (106 JlIllI) cal,,-.elly heneath Ihe SUml). remove Ihe d,ain pl\l(l ;ond d,aln Iha sump. Reflilhe d.am plull and (11)hlen II 10 Ihe 10lqUO wrench seilIng gtven In the SIXlClflC;JIIons G Del:och the engme fubl)CI mounllngs, by lemovlng the" nuts an(1 w:oshe!s. 7 Romove the ciampinI) bolt hom the tal) ;oml bOIlOI11 endS 01 the Steellll!.) intellnediate sh(lil. rush Ihe lap end 0 1 Ihe shlilt upwollds unlll Ihe lowcr ell(1 Clin be dlsenga\led 8 PI<lCo:o jack undOI Ihe lI;ol15mis5ioo nnd use II to HlIse Ihe engine Slr\lhtly.
9 Remolle I he Inur boilS securing Ihe fronl anlj·roll har to the Slde·membei (lnd the l()ul boilS securing each engHle mounling blllckel to .lIe sidenlCmber. 10 Remove the 011 sump Imlts lind I I the sump hns sluck to the crilnkc;ose .• elellse the sump by press ing 'I sideways wilh a screwdriver.
55 FrOllt cover -removlll
If Ihe engHle IS In the CM. II wllllnSI he necessaly 10 dlsc()nneC lthe l!allefY. drll'" 11m coolll1\) sys tem ;ond lel110lle Iho radiillor. 2 loosen the alternalol mounllrlg bOilS. SWlrlg the aitemalor downwilids .0w:Olds the cyltnder block and lemove Ihe drive belt
3 Remove the bolt Irom the cenlro of Ihe cooling Ian .. nd pull (
Ian and clutch assembly. 4 Remove Ihc boil an d wilsher from Ihe centre of the cran pulley .. nd I hen use ., claw puller 10 drilw Ihe I)ulley ofllhe sha nOI anempllO lelle, Ihe pulley ott. t)Ccause Ihis may .esull in dllm. t he Irani covcr.
5 Rcmove the si~ bolts secuung Ihe sump 1 0 Ihe honl cover an, t he cleven bolts securing Ihe I ront cover 10 the Cylllldcl block . G lIlt Ihe cover ott ;ond remove Ihe g;oskel.
5 6 Tillling gears -relllov;ol
1 Remove the honl cover 10 e xpose Ihe IImlnu ueo1/S 2 Removc Ihe bolt and washer sccu"I1IJ Ihe fat!Je gear I,
cn,nsIl1'll t. IhCIi pull.he geill ol! and Icmovc tho Woodllll! key. 3 Dlllw the ileal hOI11 Ihe cr;onk!;h:oh am! remove Ihe Wood'utl
57 Carllshaft -r erllov;ol
The camsh:olt nwy be rCUlovfld wllh the cll!JlIle 1<1 Ihe car •• lollowlng p!Cpol.aloIY wo,k IS co1med out. 2 0,,,,,. Ihe cootong syStelll nnd .emove Ihe .ad,mOl 3 Dlsconneci the ballery. 1 Remove Iho sp.1lk pili!! IC.1ds 1,om Ihe spalk 11lugs. 5 D,s':Ol
eCI the le;ods I,ull' Ihe :l lt'!11\.110r. remove Ihc allelllalo·
l i S (hivebell. G Undo "nd rem ovC tho screws S()CIIIII1U Ihe .0dcl covers and It Ihe rocke. covels and Iheir ilaskcls 7 Sincken lhe nulS secullnu the rocker ~&#34;ns unlollhe locke' arm, he swung aside . 8 Remove the pushrods. idenlllylllg each one as .. IS lemoved. so 1 Ciln be rell1l ed in Ihe same position 9 Remove the cylmde. heads, <IS doscllbed in Sec l,on 47. then L­magnet 10 tilt out Ihe tappels. PI;oce each t;oPI)Ct WIth Ihe pus which il Oper;oleS, so th<ll Ihey :olso WIll he relliled in t lle;1 0';1 POSlt101l5. 10 Remove the Iiont covel liS descrohed 111 SectIon 55. 11 The cllrllslwh pl:!lc IS secu.ed w,th twO cro5s·hc;od counlel,
screws. These cannOt be removed wI,h an oldm;OlY screwdliver ,lily nllempt 1 0 do so WIll resull OIl Ihe sc,ews bemU d",na\.l<:d. I Impact SCfeW(!IIver is nOI ilva,lnl)lo. the SCIOWS m;o¥ he Icmoved w sui l:oblc key lInd the urace 01 a sockel scI 12 Remove t he c.1m5ho1ll IhllJS I !)lolW 011\(1 the space. hclund II 13 Pull the c;omsh;oll lo.ward to wllhdl,1W 'I. 100f 111\1 Cil!e 10 ~ee&#34; Sh,'lllfl Ime. 50 Ih;ollhe edges ullhe cams do nOl rt,1mnge Ihe cam~ beilllllUs_
58 O il pump -r e m oval
Remove Ihe crill1kc:ose sump as ;olleady dcsc"hed 1 2 Remove Ihe boll aUJchmg the 011 scrcen 10 the Illalll 00111.119 (
/ /

Fig. 1.11 Oil pump o n tho 3.0 f itre efluill(l (Se c 58)
F
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56 Chapter 1 Engine
91 Engine -refilting
Rcf'tlIng the engine is a rCllcrsnl alth e removJI procedure given In Section 44. bUI in addrhon note the following 1)O;I1IS:
(,,) Ugh/I)' 9(0"50 Ihe ycar/)QIC ;npu{ Sh,ll{ (m,lI/v.,1 transmission) (b) Check tlMllhe dlileh fc/c,He .7Im is cOIf(!clly loentcd (m,lllu,)1 (fiJn$miSS;OIl) (e) Adiusl (he clutch cClbfll ,15 (/(!sCllbcri ill Clwp/fN 5 (m,mu,,1 flilMmission) (d) BelOfc COfl/weliny the engine /0 {I!(! ,W{omMIC {MOSl/tllSion check 111M /he /O((/lle con vet/or is fully 01l9,19N/ wilh lite /f,lfI smiSSI()II pump by reh'/(!IICa to CIWp/Of 6 (e) Refll' file ,)II/QIII,llie ("'''lllltHiOIl WillI 1141/11 ,15 dcsCfI/)t'd III Ch,lpWI 6 (/) Ad/usllhe lellsioll 01 the IJowor steeling IIlIfIIll MId .11/emMa. !lnvalid/(s) ,15 d(!scfI/)ml in Ch,?pICIS 10 i/lld 2 f(!SpcC/lv(!/y (!I) Fill Ihc cooJillfl sys/cm (el,.l/'/C' 2) ,md /lOW,!' Slcc/IIIY
SVS/l:tII (ella,'/Cf 10), 1111:11 fIIlllle mlylllc Willi od (SeC/lOll ti~) ("ho/Q)
92 E n £line -initial start-u p after major overlwul or re pair
Hel",
10 Sect Ion 38
PART C, FAULT D IAGNOSIS
93 Faull diagnosis -engine
Sympto m
(n!Jlne f.111s to tllm OVCI whim ~t;llt&#34;, IS Opc,;) lcd
Enll"n) lUIIIS ill no.",al ~pced. hili dous not 51,IIt
E"u'ne SlOp s ilnd Will not 'estill t
Enll'Ile
.",slucs, O. lUll S unevenly
L~ck of powc. illlt! poo, comp.esslo ll
91 1 T OPPln! 1 lIl) tile ""'II"") wIth od
ReilSOn(S)
DI~ch.1&#39;Hed 01 delec tlv" 1o:,lle.y
Dilly 01 lI)os" lI.11tc.y le.,ds
O"f '!I:llve sl; IIt", soL"",,,, I. ,II SW'II: " Odl'ctlvl' s lillte. "UIIOf
Dilly 0 ' III"ken e"!I"IC "'''1111''11 SIt;IP
1\I1'"111 ':Ol1lpOlu",ts Will (If ,1;""1) DefectIve low te nSIOIi le"d Detective o. InCOllec,ly :,,, 1 ,:"III"C I h,e;oke. (,I "PI.I,,:a"fe)
Oe f"ctlve condense. (If '11'lllIo,;.,"lc) O'st"hulor cal) defec tIve. or celltral h,ush HI (irs l,,"uto ' cap Ilot m,,~, COfltilf.t w'th th e .otor a"n Ifls.ulhc,em petrol "' tilllk V.1pOOf Iud '11 luel hlle (," hut cOl1{lIuolls)
Fuet pump I:uhlfe E~O:Hs51ve c hoke, caus,,,u spillk pluUs 10 hccolllt) wet
IU"I1I(HI 1,,,IUle result Ill!.! 110111 b.cakdown. or prescncc o t w;'1ler \,Inti w(: 1 cOnthllOIlS l:n:k 1.11 tud. at luel IJlock, l!Je
loose 19111tlon Icads F(luIIV s J)n. k 1)Iuli T'(1ckin£l on d,slllbuto. cnjl IIlsuliltion
InCOIICCll11lxtu'e 'Ullilion 100 telilldcd Dilly con[,lCI blcakc. POlll1S (,I ajlplPcablc). or loose connection'
<I'SI""\,IIO'
Faully Of loose condense' ( II ~)JpIPcilblc) Lea kin U ca.hu.eItOJ. o. lII.lll1fold JOlllt
D"lectlve v.,lves Blown cyIP"de . head £lasket
WOlll bo.es OJ dilm ilye<l ,,,slon
Wo.n cylinder bOles Do::tt)cllve v~Tve Stenl seals Le<lks
procarmanuals.com

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.
procarmanuals.com

)
Chapter 6
Manual gearbox and automatic transmission
Contonts
oIrt 1: Mamml gCMhox
It d'''unosis - m,Ulllal ijc(l.box .!l)()x -'emav,1I ;lIld ,efluing . Gc;ubo. (II-speed) -d'smamlln{J GC:UhOK (II -speed) -cxarninallon and renovatIon GCiui)o x (<I-speed) -rcasscllltJly Go,ulla. (5-speed) (hscngn(jcmcm of 51h gear.
Gc;'ubox (5-speed) -(hsmnnthng GC;lrho. (S-speed) -cxnrnin;l1iOIl <lnd renovatIon Gambol( (S·speed) -rcnssemhly ..... _ ........ . GCilrchangc lever (4-speed) -mo(hhcations .. Gene.al desoiption .. Input shah (<I·speed) -dIsmantling .. nd reassembly ............ _. Input shah (5-speed) -dismantling ;Inc! 'Cilsscmbly . LaYllcar (4-speed) -dlsrnall1ling imd rCilsscmbly
Specifications
Plut 1." Manual gearbox
Type ...
R ntios
Four·speed gcarbOI( : 151. ')n(! jrd 4th .... __ ........ .
Reyerse ....... _ ....... . 17
3 ,
8
9
16 11
" 15 10 1 6
13
7
Mil"'shah (4·spccd) Millnsh;'!!! (5,sJ>Ci.Idl nOut,nc Ill"mlcn;",ec
d,smamhng and reassembly _ Ihsm<lnlhng and rCllS5embly
Part 2 : Au(oll/otic (mn$mission I\lIlOrllill lC triln snHSSlon -removill ilnd re titt ing
OownsllIll cillJle removal. reflUing ilnd adlusunelll F.~ttlns,on hous"lg all seill -lenewal
Fault dlilgnOSIS ilutomilllC transmIssion ................................... . General dCSCflPilon ............... . Rouline milinlen;lflCC SeleC10l mechilmsm -MiluslfllCnt ................ . Selector mechilmsm removal. ovcrhaul ond refitling ................. . Stillier Inhllmor/revcrse lamr> switch _ removal and refitting
Four Or "'Ie forw,ud speeds (all synchromesh) and reyerSe
3.16 : 1.94 :
1.41
1 1 3346: 1
5 12 2
20 23 25 26 18
I" 22 21 24
E
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104 Chapter 6 Manual g earbox and autom ati c transmission )
PART 1, MANUAL GEARBOX
Gener"l description
The nl<ll1u,,1 \je<lllJo x IS 01 lour or live speed type with one reve rse gear. All fOlwiud geMs Me el1gaged through p,.,ulk rmg synchromesh units . The 1I1"'I1$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
procarmanuals.com

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 transmission
3 Unscr(lw .1ml remove Ihe reversrnu IrUtli SWilch (rhOIO). 4 UnbO lt the clulch bellhousrrl\J f,om the /,onl of the ge~rbox. Removo Iho gaske t 5 Unscrew tllo bolts .111<1 w,thdr<lw the r.lutch releilSe heilring gUIde
sleove 1101(1 tjolskCI from Ihe I,ont 01 the w~nrl)ox (phOIO). 6 Unscrew Ihe holts ilnd lemove the tal) cover lind gaskel (photo).
7 Inve,1 the UflilrllO x <Inc! allow Ihe 0,1 10 d',lrn. then lurn H upright ngain. 8 UnSCfew Ihe holts ,lnd hh Ihc 51h !tcm lockmg platc from the extcnsion hous,ng (photo) 9 hl,nct the 51h neM lockmU sP""1J lind t)'" from the extens,on
housrng (photos) Use il sc,ew to 'elllove the I)'''. 10 WOrk'no tllooulIlI the \le"r lever npr:,w,e. usc ,1 screw(l"ver 0' sm,,11 d,,/t to 1np 0,,1 Ihc exlrlO1s,on hOllSIII!] ,(:.lr covc, (l)hOlO)
I I Select revct~e !Ica, <Inri pull Ihll seler.ln, Sh.lft fuliV 10 the ,e;I' SUPPOfl tile Sh.lh w ith <I pu;ce of wood. th en II"ve out the roll pin <lnd w,t hdrllW th e r ~nn&#34;&#34;Ctor Irom the r";'1r of tll(1 s"l(lctor sho1ft (photos)
, .,-
12 Unholl and removc Iho extension housing Irom the ,ea, of Ihe
!)en,box . t1 nece5snrv lilP tho housing wrth a soft·/aced mallet to releilse ,I t,om 1he dowels. Removo tho gnske ! {photo}.
13 P"se Ihe cove, from th e ex 1ension housing Dnd withcfrnw the speedome1e, d"vc\Jenr (photo). 14 Selec i neut,<ll then. u511lg nn Allen key. unsc,ew the sOIO(:tor 10ck,,,U IIlCCh<lrHSm ptug from thO sille 01 the mnin casrng. EKtrnc\lhe spun!) nnd tock"l!l pm. ,I ne<:essmy USIl1IJ a t)en m<lgnet (photos). 15 O"ve 1he roll llUl hom the soleclor boss Dnd selector shDI!. 16 II nccess,1'V Ihe sclCCIO' shnlt centrnhslng spring nnd 51h gear 10t~krn!1 I;onl.ul ""'V he femoved U sing a small sCfcwdrive •. push out Ihe pili <llll! ph'!1 nu" shde the conllOl hom the selec lor shnft (photos).
1 7 Note tho loc.,t,on of Ihe selec to, components. 1hen w,thd,nw the Scll!CIOr shafl I,om Ihe rellr 01 the Ue<l,bo~ <lnd remove Ihe selecto. boss ,"'11 lock",!! plain, lSI/2nd .1lld 3rd /41h selecto r fOlks. and 5th oe~, Sl,rm:IO , lurk ,UHf sl"eve. NOte 1I11H 1he ,all pm hole 1(' Ihe selector boss ,s InwlI&#39;lI~ Ihe f,ont (photos)
,
)
r
I
~~ . '
~~~,.,::
11.3 Revc,sm!t lilmp switch 1 1.5 Clutch rdense 1.K.'111"'!1 gu,dc sl(:cve 11.6 Tal) cover and tPske
I
( j • , .
'r" i'
I ,,J'" , i
I I
Ji;:;:~&#34;&#39;-&#39;--·ft ; . -. '" . I
•
.-~:~&#39;&#39;:&#39;&#39;-&#39;&#39;,:.-.,
I .-. " J
11 85th \)e;II lockrrlU plilte 1 1.9A 5th eil' lock"' SP""!t 11.9B 51h !)C<ll lock,n u pm

11 1 1 B Ilemovong scle<:tor shaft connector
c
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