oil type FORD CAPRI 1974 Workshop Manual

a
26 Chapter 1 Engine
PART A, 2.8 LITRE ENGINE
General dcscril>liOIl
The 2.8 !lIte cnnlne IS of GC,Il1;l1l V(l Qve.hctld v<llvc type. The (OI,llsh;,l l .s loe;lIed centrally In the tylimler block ;lnd IS (Iliven by hchcill \JC~ars from the 0,'nk5ho1h, The vtllvc$ mil opcrillcd hy !:lppCIS. pusluods ill'\(1 rocker 'UIllS. The cylinder hCilds ate of the cross flow (lcsl\J1l With the mlC1 11\,111,lold IOCiltfld on lOp 01 the cylinder hlock between the twO cyhmle. hCilds .111(1 the exhnust m.1nofolds on the outside of the heads Tho r.omhincil c,ankcaso ;1I1d CylUldc. hlock IS madc 01 ens! "011 AllilChcd 10 Ih .... 1>01l0'11 ollhe clankcl'ISC IS a pressed steel sump whIch ,lets ns a &#34;&#39;~&#34;\lOIl fa. the cnWllc 011 I\hlll1l1l1lll11 ,1110y p'Sl0ns illC conl1CClcd 10 lhe Clanksho1l' hy ~I !.1·C"OII 10lucd s&#39;l~1 COllnCChng lods ,1n(l glld\Joon pillS Two I:Olllp'f'SSIOII 111'\)5 a/HI onc 0.1 (:onllol Illig, ,,11 101:;111,,1 al,ov(! lhe !llulgtJon 1)111. alo Io110d. Till) la'lIed c."nksh"'1 ""'s in lOll' ilia", iJca'lI1gs. and en(lIioal 's (:Olll.ollcll hy II110M w;lshc.s 00 No 3 1I1;lIn bO~&#39;IIl!J. The dllv(! 00'" IOf
the d'SI"hutOf ,m(t 0,1 pump is located in flont 01 the 'Oil! Cilm bC;1rIog lub"cation IS by means of a bi-rotor 011 pump
2 Routine lll;lintelHlnco
I\llho inlo.vals sj)ecilio( in 1110 Routine M~&#34;&#39;lcn,1ncc $CCllon II from 01 Ihe m~nll;ll carry 0111 the 'ollowlng p.ocedu.es.
Change engine oil. renew otl tiller olld clean oil filler c. 1 Apply Ihe hil&#34;clb.~kc Ihon jack III) Ihe lrolll 0 1 Ihe Cill and Sil l on ilKlc Sliln(\s. Alle'nnlively pOSll10n Ihe Cill ovc. ,111 &#34;,~pcCtl(ln I 2 rlace a SUlliluh:1 cont~Ule. beneillh Ihn sum1) Ihen tlns.;."w dHun ph.!) (photos) ~nd (If""' the 001 3 Wh.le the o,l.s cI.,}lninu unserew Ih" 0,11.110. '-:;111,,<190 USII'H a' wl()nch ., Clean Ihe d.;IIn plug and Sltllllllhen ,elll Ihe pili!) and IIUhl"!! 5 CtCill1lhc IllIer COlllil(:1 mea 01 11i(, CXlenSIOII blackc. 6 Sme:1f a fIlm 01 enUlnc 011 011 Ihe now 0111.1Ir,. ",hhe. u,&#39;~k(&#34; I screw lion IImoi " JlISI CO(l\;1CIS the t&#34;n~k&#34;l 1 ,1(:(, (photo) 1'",111
Fig. 1.1 EKptoded v iow of tho 2 .8 titro engine Illain c0I11I)ononl5 (Sec 1 )
I T!,ellliostnl hUl/slII!) 5 U y poss /Just! /l,J/Jyc
"
Cr;III.sllllll gear 13 Od pump dflVOS/l,l/l
2 'h':III.ostn/ 6 Ifl/.:1 " ... ",ilold 10 Flywheel 14 M{J;n b e{Jflng CilP
3 W,J/er PUJllP , C{J/lJS/",/I/llfI/SI/J/OJ//! /I Cr{Jnbh<J/1 splgol bO<Jring 15 Od pl/mp 1/ I mllllg "over 8 COJmsfwl1 gem 12 Od seM
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o
Chapter 1 Engine 35
3 Examine the rocker shah ,md ,oc ker il,ms for we~r, II the rod", alill rl tha t conwcts the valve stem IS conSiderably worn. n,new the " ."'"nl I f it is worn shqhlly step-shnped it may be cleaned up wIth rOc e r ". . a fi ne oil stone. . , commencing Jalluary 1984. modolled ,oc ker shah sp"nOs have ~een fi n ed. Where wppet no,se IS evident 011 e~rlier models hl'lw",en e n g ine speeds of 1500 ,111d 2000 'p'll. the later type 01 SP,,,llIS nl.1Y he
I , n ed .
.
5 Od t he parts and reas~r)!llhle them on therr shahs III thO) n"lI,n;.1 or der With both rockel shafts f,tled the 001 holes must face downw.l,ds to th e cylindel heads Th.s po~&#34;tlon IS lIl(hcated by a notch 011 Oil" "nd
lace of th e rocker shaft
13 Tappets and pushrod s - eXill11inalion 1It HI renova tion
I Examine the v<llve 1;11'1"'1'> 101 wr:<lI "nd (lan1.11Ie. r",new II ~I,·,t&#34;&#39;Lt 2 Check the pusluods for ~&#34;I&#34;S 01 hendiPl\l or we"l Co",,<;t '" 'o:11O".\'
JS ncceSSary .
14 Can,shaft ilnd ciln ls h Hft b earings -cxmninatio n "" d
rCll ovntion
II there is excessIve WO),11 III lhe camsh;lft thp.y will h,lVl! t" lJ" lunc wed. As the 1'1lI1'11 ul '''"1'11 Iwarrll\lS w!(lI"es speel,lI [(",I, thl~ ~houtd be left 10 your 10c,, 1 FOI(! dealer. 2 The camshaft n1;IY show SI\II1S of wear Of) tlH! I)(:''''''!I 1""""'1s 00 C;In lobes. The main d(:elsloll to lake IS what de!)",,, "I I'll"," n ec e ssitaleS renewIng the camshaft. which IS e xpensIve S<:'H"'!IOI da&#34;,~ge to t he bearIng 10",()"ls cannO I he ren'OVNI hy ''''I,,,,,I'''!I. runew,)1 0 1 the camshnft IS the only so lutioll J The CJm lobes mny show SlUns of ridgIng or piltmg on Ill" I"U" poin ts . II ridging IS sllghl then It may be pOSSIble 10 rel\\OVC It woth "
lonc oil stone or emery clOlh. The cnm lobes. however. ;"" ~urf;It:e hau Jencd nnd once the h<l,d skill 's penetr;lled wem Will he v,,,y '''pld
.'
,

15 Cylinde r heads -dismantling . renova tion and rCils sembly
Clenn the d "t nnd oil off the cylinder he<lds. Renlove lhe carbon deposits Irom tlie combusl10n C I\11'11be,s <lnd vnlve heads with il scraper 01 ,olary wire brush.
2 Remove lilt! valves by comp,ess>llg the valve springs WIth a suiwble v"lve spPlng compressor and loft,ng out the col lets, Relense the v<1lve sprin\j compreSSOI nnd remove the v<1lve sp"ng retainer. spril~,) ami valve (photos). M;llk each valve so that Ihey can be fltled u, the S<1me 10CfltIOn 3 WIth th" v,llves removed. clenn out thC Ci1,lJon Ir{)m the POltS l EXnlllUH! the hearts of the valves nn<lthe v"lve SC,lts for pIt lIng and l1urn ll1\1. If thE' p'tton\l on vall'c and sent IS 511\:)111 II CJll be removed by Uflnclong the v&#34;lve~ and sents togelh(" WIth coalse, ana !hen fIne. valve ~1&#34;ndon!1 P&#34;~h~ Ilihe jll!1lnu IS deep l1lo vnlves will h~ve to be leground on" v;,lv" O""dlnUl\1iJchinc Jnd t h(: S(:ilts WIll have to be reCli t WIll' iJ v;Ilve So,It CUlh" rloth these op(:ratlons .lre n loh 10' your 10(";,11 Ford
d ..,;II(:, or nlUll>l fJngmeerini) speCIalist. 5 Check IhE' valves guides lor wear hy "'s(:'II"U the valve on tho (J",de. the valve stem shovkl move eJslly '11 tho gUide withoul SIde
pl<ly R()newa l 01 wOln gui(lcs requires speelnllOols <111(1 should be left
t o yOl H 101:,,1 Fo, d de"ler G When !J"ndlnU sllgh11y pIned vnlvcs ,'11d '· .llve se"ts w ,th ca,ho,uIHI"ll) pas1e pro1:eed as fOllows Apply ,I Illtio coalse I) "ndon>! p;,S1C !O tlo" valve seal <Ind &#34;S&#34;I~1 ,1 SuctIon lype valve fJ"lHlrn\j tool. UIIl1d th" v"lv" ,nto I1S scat w'th n scnll-IOWry 1\10&#34;&#39;:~1ll0&#39;11. IIftu'\I the vil lve fro"" Hm o to li"lO. A light sp rmi) under the valvc head WIl l ass,s l '" 11"5 ope,,,tl"" When a dull mati even surface firnsh ,'jlpeJ,s on bOlh the v"lve ,,,,, I the v;llve seat. clean off the con,se paste .lnd repe"t Ihe \1,ond,nU OP,,,;IlOOI' w,th n I, ne grindln(J paste unli! n contInuous rlnn 01 trUIH U 'ey l1I.1tl I"llsh appears on both vnlve nnc! vollve seat C.1refully
clean off ,III lr;lC()S of 9,in donu paste . Blow Ihrough the gas pass<1ges With comp",ssed air 7 Check the valve springs for dn!1ln\le and .1lso check the free len\jth. rcler to the Spceo/ lcntions at the beginnong of this ChJpter, Renew II defeclive .
.. ··'1:
. ,
•
,r· ' .
t5 2A Comp' ess the SP'Ii") woth II valvlJ
! ' Il "nU comp,esso, . 1
5 .2£1 thu" """ove the collets (n'il\l'lellC 15 2C. followe(1 by the ,elnmer
1520 ... an d valve SP"Il\!
p,ohe show,,)
t;. "" &' '
'('ii" " 18 ... ,,,
'" ' .
. '
15 2E RlInlov,nU nil 'nlel valve 15 2F Inltl valve (top) and cxhnust v<1lvU {bot 10m) COlllpo"ents
.. ----------------------------~, 灲潣慲浡湵慬献捯m

Chapter 4 Ignition system
Contents
"'ondcnsc! (30 Iotre cnUIIlC) teslI llU . removal and rc h1!ln g .... 5 '"tact b.ellkc . POIllIS (3 .0 litre CIlUIIlC) ,lI 11us1mC lll 3 ConlilC ! brCi.ke< POintS (30 lIue cnumc) -Hlllloval fllIIl rclr ninH . " f&#34; &#39;~lnb\llo, (1111 CIl\ Ji llCS) lema",,1 .lIlt! .cll1l1n\) (j nhlllOr (28 lilre Cilomo) -overhalll.. 8 D,stributor (30 h\le cnuinc) overhaul . 7 Faull diagnos is -iUm\loll system. 12
S rICcificin ion s
System ty pe
3.0 lit.e engine 2.8 litre engine
Convent ional ignition
Distributor
ROIDlion Condense, cnp<lcity Cont<lC' blenker U<lP Dwell .1llule . HT lend res.s t""ce .. FIIIIlU orde.
Iqnition timing
c 1 !H6 model yC<l' 1976 model ye.1. onw<l.ds
Jil
I',im<lry ,eSI~\<lnce Second<l.y &#39;C~lst<lIlCe
Spark plugs
Type Elect. ode U<l$> .
8reaker/ess igllilion
Distributor
Rotation .. HT lead rCSlstn llCe .
Firing order
Ignition timing
Coil
Primary rcs,sWnce
Secondary resis lan ce ............... .
Spark plugs
Type Electrode {jap .
,1/ systems
Torque w rench settings SpD,k p lugs (3.0 litl(l CIl!JUlC) SPD,k plug s (2 8 hl,e engine)
Geller,11 dCSCfll>, ioll 19r1lllon tnnphlicr Inodule (2 8 hire engine) -. emov,l l and 'Ch1tmO ... ......... .............. . IUrlltlon timinlJ -ndJuslmcnl . flOulUl!) Ill;untenancc . Spark plugs -rem Oval, servicing an d .cl'!lu \g ,
ConvcmiOllill. with cantilCl tu cilke. Br eake rlcss. clCCltOnic
Clockwbe 0 2110025 mid
0 .61 mm (002510) 36" t o <10 · 30000 ohm mOlX"U,uU 1 <1 2 5 3 6
10"' B1 DC 11\· BTDC
0!l5 10 1.60 ohm 50001 0 !l300 o h m
M ot
o,,,,,lt AGR 22 o. Ch;lIllp lon RN 9Y C 060 IlHIl (0024 in)
Cl ockw,se 30000 ohm Il1<lXII11l"11 1- 4 2 5-3 6
12 *
BTOC
0 .
75100.85 o hm 5000 to 6000 ohm
Moto"ra" Super AGR O .GO mill (0024 in)
N rn 30 to GO 25 to 38
22C 0' ChJlllplon RN 7YC
Ibl It 22 to 30 1 8 to 28
10
9
2 11
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Chapter 5
Contents
CIUICh il$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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)
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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Chapter 6 Manual gearbo x and automatic tran smissio n
F1VO.Sp()od \joiuhox:
'" 2nd 3rd 41h .. 51h f\ovr;,so
Laysh aft cluster gear (f our-speed gearbox )
Elldfio<lt .. Thrusl w,lshm tluckuoss .
lubricatio n
Luh"(.<lnt typo. LuIH'Collll C,IP<lClly F,,,,r·~peed . F&#39;VI~·~pf)ed .
,rquo wrench settings F(}(If.SI!(&#39;,~d !lcar/lO x r fh h01l5,",0 10 HOol,box (. •.• ,(;1> Iw"sIIIIJ to 1'1I1J111H M.1,.\~halt "."
InplIl shafT hoaun» 11,IJIIUlr ExtellSl!lIl hous',,» ... Sf:h,ClOr Shilh IJJil~kel . Sciccto! housinO cove, .... Extension housin\1 cover . GeJlhO x casc cover
Flve·spccdgc,lfbox Guide sloeve Ex lOnsion housing. Geol,hox top cover Seleclor locking mechanism .... FilII), plu(1 51h He,ll cull,H nul 5th <j(:;11 Iud in\) plalf) . GOolr !I,vo,
Pari 2· Automatic transillissio n
Type
Torque converter
if! IWtlO
Transmis s io n ra tios
1 st 2nd. 3'd . Reverse
Lubricant
C~pacily (ilpprOX) . Type :
Early models (blnck dipsl ic k ) Laler Illodels (red dipstic k) ..
T orque wrench settings Torque convcrter 10 dr;veplille .
Do wnshift cable brac ke l
Downshift lever nUl: Duler. Inner.
Inhibito r swilCh
R'ake b;"Uld ~d!usling screw loc knu l .. .
lid l ine .... ... .. ...... ........................... .... . ULI cooler Ime . AU10lllilllC t&#34;,n~lI1ission t o engine. To rque conveilei drJin plug
3.36 : 1 1.81.1 1.26: 1 1 ,
0.825. 3.365 :
0.15100.45 mill (0.006 to 0.018 in)
1 .55 to 1.60 m!11 (0.061100.063 in)
SAE 80 EP oil 10 Ford spociflCatlon SCM 2C 9008 A
20 lit,e (35 pim) 1.9 lilH! (3.3 PUlt)
NIl
39104 8 30 to 37 35 to 4 1 17 10 2 1 54 to 61 71010 161021 9 to 11 17 to 21
9 to 11 4 5 10 49 9 to 11
17 to 19
231027 12010150 21 to 26
2 1 1026
Ford C3
Tnlock (hydrnulic)
222.1
2.47 : 1.4 7 : 1: 1 2 11 : 1
7 .5
htre ( 1 3 2 pUl1)
Ih l It
29 10 35 22 to 27 261030 12 to 15 40 to 4 5 5107 12 10 15
7 to 8 1 2 10 15
7108 331036 7 to 8 13 10 1 4
17 1 0 20 89101 1 1 1610 19
16101 9
ATF to Ford spec,fIC~lion SaM 2C 9007 AA ATF to Ford specification SCM 2C 9010 A
N m Ill f It
361041 27 10 30
16 to 2 4 1
2 to 18
1
010 15 7
to 1 1 41 1054 3010 40
1 6 10 20 12 10 15
4 7
10 61 35 10 45
9 10 1 4 7 10 10
1610
20 12 10 1 5
3010 37 22 1
0 2 7
2 7
10 40 2
0 to 30
, . ,
!
.5 ________________ ........... ........
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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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)
Chapter 7 Propeller shaft
Contents
Cenl,C be"wl(J rCl1<,w,,1 !':HlII d'''!I(lOSIS 1',01'"11,,, Shill, Gel,..,,;!1 li('SCIIIIIIO"
Specifications
Type
Torque wrench settings C{:II(,,, I,/!,,, ,,,! )
(',op"lll:r shall (" "',II i,xlc I I,moO]
Cello!',,1 duscriptioll
3 , ..
o"V() IS lI&#34;Il~&#34;&#34;w,d 110m III!: HP.;uh<)x 10 thCIVill ,"xlc hy mpdns "r " r",,!ly 1)"I,lIlted two 1''',Co) tuhul;1I p,opcli.:r ~hafl The u 'Hv""Si,1 JOlin ;" 1he 1'0111 of tile ,hilh IIH:()rpOI,lICS;) sphno"r yoke winch IS,' ~hd&#34;&#39;!II&#39;1 Oil Iliu \lUilllJu x "''''''SIHlft A (w Illel lIIuvcrs"r lUll)! ,11 11'0 leill uf the f.Il,1f1 IIl(;orpOr;\I(!s iI [lill1lter! yoke which IS holled to the Ie", ,1xle drive !lilll\IC The honl ,111<1 "."" sh"hs illU cOIll"'cl(,d vIa a COI1~1<I1lt vulo(;lIy )'''''1. ;lIlt! ~ ccntre bC.,roll(J IOC<lICd 011 11,,~ ICHI 01 the 110111 shalt sl1ppnllS lit,! nsscnlllly on the \. nriCII>ody .
!'wpldlc, ~h;!h ,ctl1()v;)1 ,md rcf,UIIlU l)n,v,,,,,,II'''''IS '""pectln!) 2 .,
TWO'IHCCll tl1l>\lI., •. w llh lwo HMdy,Splcer type uillvelsitl 10lols an d 01'(' COIISWII1 V"loc,ly (CV) ccnl.e 10"'1. CC"lIC SUppO' 1 IUI;II">!)
NIIl 1 B 10 23 (;0 hI tj~
'1)111 13 10 17 114 10 48
II", 1110) ",11." ,hol!1 ,,,uv,,,s;r ) )OUlls C;IP"lOl hc ICllewed wllhoul ,purloll "'l"'Pllh:ll1 hcciI",e Ihe )01111 s pldels ;IIC sl"ke(1 11110 Ihe yokes ,n i> I'OSl1l011 dUWln)lnud dUlln9 elccl ,olHC h;>l;lI1cin\j When 101111 we;u IS dd,'Cit,d (seu SectIon 11). "ilher .1 new IHopelh;. sh~1t should he ohl;"""d. 01 lilt) cOlllpl{,tc plopelle. shah shQuld he p;rss~d to;> SIIII.IUly
equI pped el1!).necIIt>\j wOlkshop lor I~pn&#34;
2 Propeller sh<lll ~ rClllov<l) nnd relitling
Chock hOlh IIonl wheels Ihen )<lck up Ihc IC<1l 01 the citr .111(1
F
ig. 7. 1 Two-piece propeller shaft showing tubular section (Sec 1)
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Chapter 8 Rear axle
Contents
Axle rear cover .. lemoval and .etliling Axlosha!! bearing -renewal Adcshah -removal and refltllng . Fnul1 diilgllosis -re3. ,1xle Gcncr<ll description. Limited-slip difterenlial -generill
Speci fic", iOl1s
Gel \cra' Axle dcsI\)n<lIoOIl _ Type
Hallo . uhllei'ml C"llilClly •• I>IIC;1I11 type. O ,lIcnmll.1I sIde 90;u ('"dllo;u 1'''''011 turning torque (~ell&#34;llJ) Crown wheel and pill 1011 backlilsh
Torqu e w re nch settings Bc,uinu (31) \0 axle Cilsing Cover \0 axle caSing CrOWllwheel Axlcshalt bearmg retainer /backplate . Drove pinion nut ....... ....... .. Rear 51),ing U·boh Stabilise. bar clamp boll _. Propeller shnfl 10 lear <Jxlo drive flange
General descrilHion
6 !i ,
11 1 10
The rear axle IS of the hypol(f seml·floallnO tYI)oO and is located hy semi·elliptic ro~d springs, In conjunction with a smhlliser har. The dilJerel11inl is intogral Wllh the axle hOUSing and Ihe rear axlo
InuSt he removed to carry out ilny rePil" S to the dll1erellt,,,, wh,ch milY hecorne necessary . J The drive pinion runs in two lapered roller UeiltlllgS, which are "reloaded by a spacer . Early a.l"s have a ',xed lengltl Slh'lcer and I<lter ones a collal>sible spacer (F'{ls 8.1 and 8 2). Both IYlleS of SI>aCer are InlOrchangeable. but c<lre mUSI be taken to ensure th<ll the appropriate
nle lhO<J of delerm ining drove p'nion bcarrng preload is used
The COrfeCI deplh of me~h 0 1 the p,nion in the crownwheel is
PUlIon 0.1 so,, , renew"l . fie;]! .1x10 ove.h;wl Ilear axle ,emOYil. and refIlling f1ollll!w 1ll00intCIHlIlCC • Wheel siud renewal,"
() (Sahshury)
7 8 3 2 ,
Ilypo,d. sem,·flo,lIU1!), onteorill dolle/ent",', limited-slip dollelenl,')1 on 28 Speciill 300.1
I I loire (1.0 l)il11) SAE 90 015 mill (0006 'n) 2510 2 7 N,,, (I 8 to 2.0 IIlI tt) 010 to 020 ,nm (0004 to 0008 in)
Nm 60 10 68 35 to 45 801087 27 10 31 100tol20 25 to 36 401050 60 to 65
Ibl It 44 to 50
26 1033 501064 20 to 23 74 to 89 18 to 27 301037 44 10 48
obwined by Ihe use of selected shims inserted belween Ihe pin ion and rear t<lpered loller bearing. The crownwheel is boiled 10 Ihe dilferen lial c ase, w hich is mounled on IWO lapered rolle r bearings . These bearings ilre preloaded by selec tive· fil shims, positioned on eilher side 01 the dlfferenti<ll housing The d'fferential <l55embly is 01 Ille two pinion Iype, 28 Special models ;lre filled with IIlimiled'slip d<llerential. Th e adesh<lfls are splmed co ehe dlHeren eial side gears <lnd supponed at ehe oule. ends by b<lll· bea.ings . 011 seals <lre filled .11 each
end 0 1 Ihe axle housing . Ove.hauling ehe lear axle requires a variely of spedallools and it is no! recommended Ihal any allernpl should be made tfJ do Ihis unless these lools ~re <II hand,
d
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Chapter 8 Rear axle 136 )
5 C~rellJlly cle~n Ihe Ir Oll 1 01 the Im,ll d"ve housinU ~s there will Ilroll<lhly be a considerilble <!IllOUni 01 drll and orl rl Ihe se<ll has heen leilkillg lo r a willie (phO IO). 6 Remove Ihe wheels ,lilt! b.ake drums Ihen U Sing ellhe. <I sp"ng halance and a lenUth of co.d w'illlpcd .ound lho drove pUlion. 01 a
10lque w.ench. check and . ecor d the lurnrng IOrque of the pillion. On eally models lilted wllh ~ tl~ed longlh spacer (see SectIon 1) lI11S procedure is nOt neceSS<lry . HowevC/. unless the ',nill drive hilS beell conlplelely dismanlled prevIously. there is no WJy 01 delerminlng which spacer is !rued. 7 USIng a suilahle long·hilndled tool or large w.ench. g"p Ihe re", ,"xlf) p,nIOn flange and wllh il socket undo and . emove Ihe pillion lIan\Jo ,elainmg sell·lockmg nul. ThIS nUll11uSI be dIscarded ilnd il new Ollr. oblalned .e<ldy for rea ssembl y. 8 PI,lee il conWlIler undcr tho ir ani at tho lon<ll drove hOUSlllg to ciltch ""Y all Ih<ll rn<ly como out. then uSIng a unlvorSal puller and sUlt"llle thrusl p"d putt o ft tho 10 M <lxle pillion lIanUC from the alive pInion 9 USing a screwdrivcr 01 slllJl1 chlsol C<lrel\,lIy renlove the old all sl!,,1 It Will plOb"bly be necess<lry 10 p<llti;;llly destroy rt Note t he COIII~&#39;:1 way round is wrth the hp I;;ICnln ulw<lrds to Belo.o Iruill!1 a ne w so;;ll apply son'e !)re"s o 10 Ihe lillIe. 1.1I:e )I\\ICCII the two h,)S 01 the so,,1 11 AplllY;1 hule IOlnlon\! compo"nd 1 0 Ih,;! outer I,lce 01 tlie 50,,1 • USnlg a tuhuh .. drov o 01 :,ulwhle <I.;;III1<;tr:r. c;ucluliV dnvc the all
.,1 "\10 Ihe l ,n ,11 dllv!! hOllslnu unto! Ihl~h w'lh Ihe cas",o 13 Ilcfo1 Iho 1(';;1' "xlo p""nl1 fI.1IlUc ilnd on,:o "!I'"n hold sqll;,,,:ly wllh til" luol 0' wrench. 1~ SClew on " ncw s&#34;II·I()c~&#34;lll I1l1t IJIlIII Illl: (,ndllo,,1 ,s III~I dlll"n.llcd . II"", l'Uh h,n Iho nUL .1 1,;,,:11011 ill;r I"'h' whll" du":k"'!lII,,, prmO" lumlnu lor<ll'" wllh Ihe SI""'!I IJolrolllCU or 10r'l"0 wH;nd, COlltinuc tluhlen,"u untIl tho to '{ lue Cllu;rrs IIr<lt recnHle<l III l'a"'\I'''llh 6 1)lus <I furthel 02 1 0 04 Nm (015 to 030 Ihl It) to .1110w lo r tho ,l(ldruonallr,ct,on 01 tire new all se,,1. Do nOI trHhten the IIl1t lurtl"". olherwlse. rl a collapsible SllolCOf .s Illled. II Will he over·cornprr:sse<l and the assembl~ Will Ihell h,lVe 10 be drsnwntled to hi ;, new ~p;rcu&#39; Howover. il Ihe minimum speClfred torq uo wrench scWng lor th e pInion nut h"s not been re"ched. the sp"cer I'lle d IS p.olJi"lbly 01 Ihe
fixed ICllnth type "nd I he nul should be tIghtened lurthor WhIle domu Ih,s cheC k Ih"l Ihe pimon lurnrnn lorque doos not mcre;;lse. 15 flelll the h",ke <I"ml mId whee ls I G fl" co.mec i Ihe IlrOIl()lIe' ~h;llt ;rhlinmu thl,! p • ..,vlousty rllade fII;'lks 1)11 Ihe lIan!lf:S. '''III rc!lttlrll holts wuh new Splillg w.1"hels TIUhll!ll tel lire spec"'ed ta.que w.ench ~C1llll0 1 7 fle llt lir e r.:ellile I'c;un'!] ~&#34;I)P(Ht ,.ecllllI'(J l,olt5, ~I&#34;&#34;&#39;!J ;uHI pl.1111 w;r~lrerS ;;Inti t'lllrll'lI. 1 B FIIl.1l1y check IllI! (HI IlIvr:1 "' th" "';11 ,1>1" ,,"d l O p up II 1\&#34;,:eS~lIly
P ReM axle -o verh;;lul
Note: Mosl ymilycs wtlf Ilft'h" 10 If.'IWW Iflt' comfllelC IC,ll ,Jxfc ,15 .1 111111 d II IS WOII! ,.II/IC' I/Ioll! 10 rf,SllliI",fc Ille UII/I 10 lel/t·w '''IV r/;/11I.Jycd 01 WOIII poll Is ro do tlw ,ob correclly Icquires Ifle usc 01 spccial <111(1 cxpellsive loofs willch tin' "'",u/lly of y"WY"'S do 1/01 h,lVl' The P"n1<UY oh,eC I o f Ilrose speCIal lools is 10 e""hle Ille mesh 0 1 Iho crownwhcelto Ihe pIllIon 10 be very accur,1lely SCI "nd thus cnsuro that n o,se is kcpl 1 0 <I mm"num II illly lI,c ,e,lse In nOIse cmmot he 10loJHI\ed (p,ovlded Ih<ll the ,e,l, "de 'S nO t already na,sy due 10 "
, le lccl,v e Pol.l ) then IllS besllo Ilu.ch"se "II e~ch;lnHe bUIlt UJl le;;l. ilxl/! 01" Uoad secon (lh,lnd Uillt 1 Remove the rO;;lr "xle I,orn the ,:,1r (S(.'(;t,on 3) illld tha,oughly cleiln
,' . 2 Remove the a xlesh;;lhs (Sec lIon 4) "nd the;lxle ,e". covel (Secllon 6) . If rleceSS;;Jry remove lire !H" ke !liIckpl;,ws 3 WOlk,n!) inside IIlI! axle casUlU . undo .lnd .emove Ihe four bolts th" t hold Ihe IWO U'Shill>cd dlllerentl,ll be"rmg CilPS III the Cilsing. 4 W,lh a sc.iber. m<llk Ihe .e lilhve paSltlons ollhe Iwo be",,"U caps so Ih;uthey C,lll bo .elllled III therr o"g,nal poSItIons. LIlt away the twO end caps. the'e may ;rl .e"dy ho mallng numbe,s shown In FIg. 8 .1 1 . 5 OIJlaln Iwo,) JlIC'- OS 01 50 mm (2 in) squ",e woo d al le<lst 300 mill (12 in) long and. wrth a sharp knlle. !<Ipor the ends "iang J lenglh 01 150 mm (6 in) 6 Place Ihe tapered ends 01 the ..... ood..,o lr:vc lS rll the two cut'i1ways
i h a dlffl!renliiJl casrny (Illd. uS"'IJ the lea, cove. 1;;Jr.:e o f thl! Irnal drrvo asing as" lu lc ,um. CDielully leve , Ihe (Mle.entlal asS(!mbly I.om the Ilna l d"ve housrng.
15 Froni I'll Im<ll dflvo housing showIIlg pinIon n"nge ilnd nul
7 1I'lls IIfJcess,lIY la ",move th e Iwo (hffelenlral casc l1'-'alll'gs Ihese
",.IY I,,, ",move(1 Ih:xl uSlnU " ulllvers,,1 two·leuged puliCI and sui!<lhle
111111'.1 1,.ld C"rfully uase e;lch bca'"'IJ Irom liS local ron . necovor Ihe ~IIOIII p.IO:k s hom hehmll e"ch be"rrnu nOlmU from whIch SId e Ihey (.,rlOr'! 8 thou!] a sCflhcr. m;;lrk Iho relative positions of Ihe crawnwhee l ilnd ,hU",,"rtl.,llrousinu so that the oownwhcelmay be f,tte d on rts origin al p&#34;~H&#39;OII. unless ,t .s to be lenewed. 9 Undo ,11", r enlo ve the eruht holtS thai secure Ihe crownwheello the ,hl,,,""'11:11 hOllS"'II. U S1nll a solt·faced h"n""cl. I,ll! 0\11 Iho cllJwllwhuci Irom liS locillion on Ih e d,ffe,enl,,,1 housin!) I 0 lJ~III\1 ;r sU I\(Ih l{) (i"unete. parallel pIn pmch. lap 0\11 Ihe pin Ihal Iud , ... Ilu, rI,'lcrelll,;,1 Illnial1 gea. Shilll 10 the dlftmrmll.11 housrnlJ.
NOLI! : 1 hu h"le 11110 willch thc peu Irts IS shghlly "'I>c.ed. lind the I>pl''''.'I'! "",1 may he IrIJhLly peelH)d over ;'Iml should he r.:!e;rned with a ·.u,I.II,I" ,".11111;1". ,tr,ll 11 th'''!1 a ... "It IIlI;t.11 dllfl. "'i> out Ihe drllelenli"l p"uon Ue", slr"h. 1.011 .Iw.ly tlr" d,lh;u!Oltl;r1 pinian ue,us. sido {leMS "lid IhruSI was hers; IA"'!l':,"" 10 ell::ure Ih"t the th,usl washe.s ",e lell wllh Ihe ir relative
liP,"" 12 1&#39;&#34;,1&#34;~&#34;If)f .. ,1 Il1te.s (It Ihe <le<lle'5 usc a 51)OClal 1001 la r hlJldln(lthe pillion ,llIvl: lI;rllue StilIIOllil'Y wlulsl Ihe nul OIl Ihe cenl.e 01 rhe n"nge IS \l1I ... ".;w"d SI nce II IS ve,y \Oght ,I Wlllle(IUOfe sOllie lor ce 10 ullda il. ll,,! .IV\l,.IHe oWlle, w,1I not n O''''iJlIv hilV C the use 01 Ihls ~p(.&#39;C,.111001 so.,,~ .1" "11,,,11;lllve method. clamp the pnllon lIanU e in;r vic e "lid then unoi"lir" "ul Any (1'''''"\le cJused 10 I he edge of Ihe flail!] " hy the vice ~llIluld I,e calelully I lled smOOlh This nut must 1101 he u s1!1I .1\).111' SO II l1"w """ WIll he le' 11JUed durinU ,eilssem!)ly 1 J lJ.."'!I ,1 ullive rs;tl Iwa·lenued pullel "lid suilable th.uS I polll drllw (1)0) jllI"')I) dllve lIiuIue from Ihe en d 01 the pInion shMI 14 11", pmlon shalt m"y now be Icmoved from the I,nill (h ,ve housrng. C,'lI"lully "'SIICCI lire la'ge w per loller beirring behInd Ihe pUlIon gear .111(1 " ,I :.hows s'Ul1s o f weill or 1);lIing an tho roliers Of cilge the lm:ulIl\1 must Il() renewed. 1 5 U~&#34;ll1 " lllllversaltwo·leVged pulle. ""d soitable th.uS I pad. dr~w till! !>,)<III"\) 110m Iho 1)1Il10n shah 1 G Tllu slI1;;1l1e. taper rolle. heolllnu and oil seil l may next be ,emoved IlUm till! 1111011 (IIIVO housing. pillion dlivo flanVe end. 1.0 do Ihis uso a solt l\lr:wl drift wllh a I<lpered end 01 $ui l<lble d'ilmetCI lube <Ind. wo,kl"!) OIlsI(le Ihe housing. lilP Ihe bC,l'"IU circumfe,ence OulwardS so rel e;;lsII' U fllst the 0,1 se al and then Iho OOallnu . 17 AU,,"1 u srn g thO solt metal drrft and wo.kmU ,n Slde Ihe housing. d,,1t olllll1e I>carrn!) CUllS. These mUSI nOl be used wllh new beallngs. 18Th" Ilnal UIIV(! assembly rs now drSl1lilllllod and should ho washed ,,,,,I d,u,d wrth <I cleJn tinl· I,ee rag leildy for inspoctlon Check all be;;l,rrilis lor silIns at WColl or piwrrg "nd II ovidenl a new ~I&#39;I 01 h Catings ~h{)uld he ohlmned 19 Ex;r"",,e the lCelh 01 the crownwheel and prn,on or J/'Ulllg. score marks. ch ll >PinU and uene'ill weal. If a c.ownwheel ami pinIon is .equllt.-d. a mated c.ownwheel and p inion muSI be II1I..,d and undor no
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