shift FORD CAPRI 1974 Workshop Manual

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
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Chapter 6 Manual gearbox and automatic transmission 123
When towing a vehic le wIth automl11ic uansmission it is impoltllllt to observe the precautIons gIven til ,he 'Jading and Towing' se<:,ion at the Iront 01 the manual. Due to the complexity of the au'oma',c tran smission unit. If performance IS not up 10 s tandard, or overhaul is necessary, it IS impera tive that this be left to the locallllain agents who will have the special equipment for fault diagnosis and rectiflcallon. The content of the following sections is thereforc confined to supplying gener", Informl11ion 1'Ind any service information and ins t.uc tion tha i cnn be used by the owner.
19 Routine Illilinte,wno
At the i!lle.vnls SI)CClfiecllll Iho ROllllne Milintennnce seCIlOll in the I.onl 01 th e Illanllal cnllY Oul Ihe follOWIng p'ocp.dwe
Luuricow selector link'1[}() , Applv the h;rrldh.,lke th(:n J,lck \lp the front of Ihc Cill ,'lid Support
,n nxle Slnnds
2 Orlthe Irnkn!JCs at cndl end 01 Ihe genrsh ,h rml on the Icfl·hnnd "le 01 Ihe Iransnll~s,on lowel the cnr \0 Iho wound,
Check /mn.Wllissioll fluid level 4 Elrlll!! the engIne and trnnsnllSSlon to nOllllal ope.IlIUl!IIp.llIperillllfe
and I)alk tho vehlchl on le vel grOllnd 5 Wi,h Ihe engIne idllll(l. move tht: 1.,lnsnllSj"on St:leclt>r lev!]r through ill! pOSlllons 1!lIee lImes. Ihen onuaue '1" ,11111 wall for ;rt lea~t one minute. 6 With ,he engine 51111 idling, wllhd.ilW Ihe lr.1nSnllSSIOll d,psllck.
Wipe it dean, reinsert II, wilhd •• 1W 11 for Ihe second !line nnd read off the levol. 7 Two tv pes 01 automatic transnllssion fluid a.e nvarlilblc (sec SpccifiCiltions 10' tv,>c numbe.s) .1nd It is ImpO,I,ln , Ihilt IheV 'lIe nOI mixed. The colour 01 the dipstick. 10' flUId level checklllg denotes which fluid tvpe to use , 8 If a tlr1nsnllssion requlII"U 1,1ter tvpe fluid IS I'lled 10 " to'<lue COIlVOIlr!r preViously used w<lh oarl.er tVI}e fluid, or vice vr:&#39;.~iI, the compollellt~ shOuld Ire Ilushed 10 ,1IIoi(1 mlxinu o f the two Ill/Ids
COllsult your I'ord dealer rI thIS cond,t ron arIS&#34;~ 9 If III)r.CS~.1rv IOp·up with til'.! spec.rlled orl, thr ough tire drpSlrck tube. 10 tire MAX m, uk, The '1"<rlllrty leqlm ed 10 r,IIS!] tile level !rOllr 'V1IN In MAX IS approxlmatt:lv 0 3 Illre (05 pIIIl)
Adjust Iront brake /)(In(/ '" ApplV Iho handb."ko tholl lack 1'1) th'.! ',ollt 01 the ca. and sUPPO.I axlo stands 11 D,sconnoC t the downshIft ca!)le at Iho t'.1nsmISSlon 12 Slacken Iho brnke band adJusto, sClew locknut and unSClew the
adjus'or screw n lew h,fIlS . 13 Tlghlolllhe adJuslo, sOcw to 14 Nm (10 Ihl II) IISIilU a SUItable lo,que wrcnch From Ih,s poSlllon slaCken the adJusle r screw bv exact Iv I'll \Urns (pre·1983 models) or 2 Iwns ( 1983 and late,
model), Ihen tighten Ihe locknut Wllhoul diSlUrblllg Ihe pOsition of Ihe adjuster sc,ow .
14 R econnec t the downshift cable and lowe' Ihe car 10 Ihe ground.
20 Automalic transmission -removal (HId refining
If l)Osslble, ,aise the car on a hOlsl o. place it over an inspectIon pit. Alternatively, it WIll ho necessary 10 Jack up Ihe car to obtain the Illaximum possible amount of wOlking room undernealh. 2 Place a large d.ain pan benealh the transmiss.on sump (011 pan)
Ihen. working horll the ,car, loosen the a!laching boilS and allow ,he lIuld to drain. nemove all thO bohs excep t tho two I.onl ones to draIn as mIlch fluid as pOSSIble, th on temporarilV .efit Iwo bolls at th e re,1I 10 hold it in place . 3 Remove tho Slilrte. moto. as desc.ibed in Chapter 12 . • jWhero apphcable, rernove the access cover Dnd ad3pto, plale bolts,
Ie the engine untrl the to.qu e converter drain plug is visible, then
unsc.ew Iho plug and d.ain Iho Ihud Into a suit3ble con winer. Refl! and l'Uh ten Iho plug.
Fig. 6 .25 Checkill{J tho au tomatic transmission lIuid lovel (Soc 19)
Fig. 6.2 6 FrQ,1 bn'ko band adjustment (Sec 19)
A Arllf/SICI sc/t'w a Locknut
C Downslu/t Icvel D Downs/u/t c.lblc
Fig. 6.27 Torquo convorter to driveplato boll -arrowod (Sec 20)
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Chapter 6 Manual gearbo x and auto m atic transmission
5 Unsc rew and remove the tolque conve rter·to·driv eplme b ol ts
t h rough the stader mot o r openrng. turning the engine ,1S neces sary to position the holts rn the opening.
6 Rem ove the propel ler s h alt. reI erring 1 0 Chap te r 7 as necess,u y.
Place a po ly thene bag over the end of t he transmiss io n to preven t dirt Irom ente ring. 7 Detach the sp eedome te r cable from I he extension housing .
8 D iscon nec t the shIft rod althe trans miss ion manual lever. an d the downshift c<lble at the tl a nsmission d ow nshi ft le v er. If necessar y, the
sh if t r od may be completely r emove d by d isconnec ting il frOIl1 t he
selec to r level.
D D isconnect the downshift ouler cable hom the support bracket. 10 D,SCOI1l10Ct th e StMter rnhlbilOr (noullal Start) switch leads. II Disconnoctthe vacuum lines from the vacuunl unll. 1 2 POSItion a Irolley lac k bcne<lt h Ihe Iransmiss ion and raise II 10 /US{ I"ko the transmiSSIo n weig ht. 13 Remove the engme rllar suppor t 10 crossmember nll t <lnd Iho tlanSI111S 510n extenSion housing r.rossmember 14 DIsconnect bOlh eKhaus t pIpes at the m anrfolrfs (Ch<tpter 3) ,111(1 support them ilW<ty from the transmission ! 5 Lowe r the lla ns rll1ssion and also support Ihc 11011 cnd of the ~11!lille 16 D,s coll,lect the 0 11 cooler hnes <It the lranSIlHSSIOn and pili!) thel1110 lev el)! dut from entering . 17 R~move "II the corlVf&#34;t~r hO\l5111g to·onUII1O hott s. and Ihe tl;1I1~I1HSSIOll fIller lube
Fig . 6.29 Downshifl cahle locknut A. Ir[lnsmission lover B
<llld st<lrter inhihitor switch C (Sec 20)
F ig . 6.3 1 O il coole r pipes (Sec 20)
Fig. 6 .2 8 C onnecting d ips A ,m d shift ro d B (SIlC 20)
-=<
~:=~~3
-: _~e~~-=--'
Fig . 6.30 V ilCUUI11 line connection to the vilcuum unit ­arrowed (Sec 20)
.... ,' ,',.<.
~
&#34;i&#39;i.
~&#39; ..
F ig . 6.32 Oil fil ler tube - arrowed (Sec 20)
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Chapter 6 Manual gearbox and automatic transmissio n 127
2 Select position O' th en pri$e off the selector level escutcheon nnd. Irom under th e cnr. re move the plug in the side 01 the selector housing. 3 Adjust the inhibito r cnble locknut X to giv e a dimension of 0.1 to 0.2 mm (0.004 to 0 .008 in) (Fig. 6 .36). 4 Refit the plug nnd escutcheon. S With the trnn smission shih lever and the mnnunl selector lever in '0'. ndJust th e selector rod link until it cnll be reconnected without strain .
23 Downshift cable -removal. refitting and adjustment
Support till! front o f th e cm on Jxle Sl<lnds . Remove the spirt pin and d ,sconnect the cable from the cmllurenor Ilnknge . 2 SIJcken the adJust")I} nut hom the upper mount>ng brncke!. pull b~ck the outer sheilth and unhook the c;rble hom the slol. 3 Unsc!Cw the nut at the trnnsrnissiorl rnoun trr\\) hracko::t and unhook the outer she,l th. 4 Unhook the inner callie from the tranSl\\ls s,on lever , 90::1011,n(l ,$ a reversal of the ,lllovc. but the II1Il!.:r nut nt the upper should be screwed on conlp!ctcly. nnd th e OllH:r nu t only il few turns. 6 'p,ess the acceter;-rt{)r \lo::dal hIlly. ,,,,d chcc k thnt the thlOttle plate is ' ... ,y open 7 Us,n\) a screwdrrver. Icvo::r the downsl,,!t cab le lever UPWMt!S. pulling t he mner cahle lully upw,uds 8 Tum th e adjust in\) nut 10 lenuthen or shorten the cnhle to (Jiv e J clearance 01 0.5 to 1.3 mm (0 .02 to 005 Ill) between the downshlf, lever nnd th e accelerator shnl! (Fig. 637) TI\Jhwn the locknut
24
S lnrter inhibitor/reverse Inml) switch -removal and re fitting
1 Pull the cable connector off the switch" 2 Unscrew the slnrter inhihitor swilch and remove the a"int[ 3 To rel'llhe swilCh. fil a new a·ring nnd screw the switch into lhe housing longer. tight. T'gh ten Ihe switch 10 the lorque wrench settin g
given ,n the Specilicntions. I t is imporlnl11 ,hn t thiS torque is not excee dud, 4 Ro::I't the cnhle plug conn ector to the sw,tch,
5 Chuc k th,ll th e en!J"'c will st",t only w,th the lever '" the '1" and "N' posilions and in no other POSlt'on. S TlIIn 0 " the ignition without startll1g th e engine, Check IhM the
r ' ;inU light comes 0 11 in th e "R" po~rtlon, but not in any other.
25 .tension housing o il senl-renew,,1
1 Remove the propeller shnl!. ns do::scrrhed III Chi,pter 7.
2 Jnck t he r enr of Ihe c,u to [1Hn",HSe the loss of 011 from the
transmission . then carefully pr ise out the od seill. being cJrtJIut not to (JamJ,Je the machined recess into which the sc,rI I,ts, 3 E'lslIfe that the recess is cle<ln <Ind undamage d, then press in iI new senl with the lip of the seal inwards. Tnp the senl home fully with n tuhe of suitnule diame ter. or with a hammer nnd ,1 hlock of woorl. being careful that Ihe seal is inserted squnrely. 4 Refit Ihe p ropellur shaft. lower th e car 10 the \)roond Jnd th en check the leve l of Ihe Iran smission fluid as descrrued in Section 19 . F
ig.
6.37 Adjusting the downshift cable (Sec 23)
Depress Ihlollle hJlly (bloken arIOw). Pivol/he downshilllev,·( ,)wuy frum Ihe ,1ccelef,1{Qr sllMI lind UdjllS! Ih e clcarance at Ihe MljllSling nul (solid arrow)
~r:;0/,/5.;~··ll ~
Fig. 6,38 Inhibito r switc h renewal (Sec 24)
A Wiling connector B Inhibl/Ul swilch C O-riny
26 Fault dingl10sis -nutornatic Ir<lnsmission
FJuit in these units Me most commonly the result of low fiu,d level. Incorrect adJustmen l of the selecto r linkage or downshift cable. or <I I<lldty inh ib itor switch . If the problem st ill exists <liter these points hilve been checked. it w,1I be neceSS<lry to t<lke the car to 11 dealer with equ'pment to diJgnose internal f<lults .
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) Chapter 11 Bodywork and fitting 189
/~
32 8A I&#39;,,~c 0111 Ihe alp 32 an ali(I ,(,mo .. c the console screw 329 Removing the hnndbrake lever boot find be~el
Fig.n.la C lock ro:.,,"ov<ll tools (Sec 32)
1 () "'I!! (0 If; "') /J IOO",m (()/I() III)
32 Centre cOIl~ole·· fUIllUV,,1 ,,,,d refiUinu
IJasic tYlle '.111 Ihe caqll:l 110m ;!lolllni the r'OIlI of t im t:()Il~()lo, thun push the " .J <llld hel..,1 out of Ihe hUlls&#39;&#39;&#39;~J DlsCO""CCI the dock 1r~<](ls 2 Remove 11", two SCI(lWS il( Ill(.' reiH cnd ,inti two (I101e hom the clock emt. to 1!.,lu<lst: Ihe cOllsol", 3 rlell10vc the \lP;" l<:vcI ~&#34;(lh, or T·h""dln 1 Lilt 0/11110 consul" As dpphcilhlc. !(:r!'UVC the clock 11l0llrlll1l!) pl<lIC screws "ud/or UCilrstuft lever hoot 5 flchtl;nu 15 the reverse of the 'clllov,,1 1110<:odlllO.
Gfli,1 type (also Il((ed fa I(I/ef nVI)-Glli" modrds) 6 Lift the Cil'PCl hom ;"oulld the IrOll1 oj the console 7 F,.brIC<lte twO sm~11 h",cke!s f,om 1 5 ""n (0 06 ,n) sheet sleel (sce Fig . 11.18) ,1I)d ,nsel1 (hese hel"nd (he IJlilck hewl to ,emove the clock Disconnect the w,,,ng. 8 Remove the two console ,etammg 5c,ews. then prIse oul the Cflp in hOIl! 01 the gearshift lever ~n(f rcmove the screws heneilth (photOs). 9 Cilrefully p,,~e the h;Ul(llJrilkc lever hoot ilnd belel ;)ssembly from tlie conSOle ;)nd remove II (photo). 10 Cnwluily PrlSC out the Gellire pflilel cover hom behind lhe gear lever. 11 Lilt up the cenlle il&#34;llfe~1 and remove lhe screw hom the bottom of the comp,lrtmen1 12 Remove the ;)rrn(CSI h"'\Je screws and place the ;)"nrest in the comp;),tment 13 Remove thc lwo screws ,I[ the hont end 01 Ihe iI&#34;,&#34;e~t rUSC out the cap at the r"ar 01 the console and remove th e scre w • Ca(elully lilt Oli! the 'eilr seCllon. I,onl s(:ctlon and console COlllpilftmcnt 16 Remove the he,ll "'5ul"tll1g pad Irom bene,l1h the consola Cornpnrtment ilr..,a
17 As appliCill)le. remove lhe eleeuical connector from Ihe base 01 cilch senlhelt s(;llk and rcmove the stn lk ".lI1g boll th,ouOh the top of thc consolc. Rcmove the stnlk ilssell1hly thrOuoh tlHl II1SIdc console suppo,!. 18 Pull the cMpet awny hom the SIdes of the 5UPPO,1 assen,bly. then detilch the support hy removIng (he eluht S!)CUW1!J screws. 19 Hefil!lnU is bilS'C,1I1y Ihe reV«($e ollhe !«Illoval procedlHe. hUI Illst ensure lh,11 illl Ihe splle nuts ilre corrCClly loenled on Ihe brflCke(s. Tluhten tile sefllhelt SliIlks to the specilied IOlque.
33 Sunroof piln el -ndjustments
Gap adjustment 1 When closed. a Unp of 5 8 10 6.9 mm (0.2310 027 "') should eXI~t hetwecn thc slIn(oof and (h e CM rool. II;) vmyl roof cover IS lilted. Ih,s gap should he reduced by 1 .78 mm (0.07 Ill). If adlllst'!\(Jnl IS requued. pwceed ns detaIled below. 2 With the sunrool hall open. remove (he sunrool heildhlunll hnlne 3 Close the sUllfool. then pull Ihe hei!dhnll1H hOIll (he Ie." and remove ,I. 1 To ndlust the hOnl 01 the sumoo!. loosen the front Uu,de relillnu1U screws. then whIlst p,essu1!J (he Uuitles IIlwilrds. lighten thc screws. 5 To ;)d,ustthe rear. loosen (he twa h.II1!) screws nt eneh Side of the ,1dlustinU hnsc. thcn p,ess (he reilr shdes mw,uds ,1"d t'Uh!Cn . 6 F,t the hCildllmn(J and hemU",,,,U h,,,ne 7 lithe ild)lIsunenl is slill Incorrect. ,emove (he we,l\hel$I"p from Ille rool panel ;)11(1 hend ,IS mountll1g lIange as necessary
.,.,.&#39;~ ..... ,,--...... ;;
• · .. ···"'·' -·0 . .'--
,"·""",-- 'r
FiU 11.19 Sunroof controllllechanism (Secs 33. 34 and 35)
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)
Index
A
Accelerator cilble removal ilnd refining -14 shnft ilnd pedal removal and refining -75 Air cleaner removill Jnd ref,nrng cal buren or mod cis -68 fuel injecllon models -80
P rnator .,rushes inspecllon. removal and refilling Bosch -202 Femsa -203 Lucas - 202
dismantling and rcassembly -203
removal and refining -201 Antifreeze mixture -60 Automatic transmission descrip tion -122
B
downshift cable removal. refi11ing and adjustment -121 extension housing oil seal renewal -121 faull diagnosis -127
maintenance. routine -123
removal and refOlting -123
selector mechanism ildjustment - 126 rcmovill. overhaul ilnd refl11lng -125 speclflf:iltions -103 SI.1r1er IIlh'bilm/reVerse lamp switch remov<ll <lnd refIlling - 127 lorque wrench senings -103 'iliary (driving) light ,oIigrllnell t 212
Bilttery clrilrgmg _ 201 description and testing -200 removal and rcfll\lng -201 Big-end bearings -37. 52 Bleeding the hydr<lulic system brakes -152 power steering -168 Bodywork IJnd fittings -173 el seq Bodywork and fittings bonnet -186 bumpers -1 78
centre console -189
demister
noules reOlov<l1 and refi11ing -197
description _ 174
doms-178.180. 18210 185 face level vents removal and refItting -197 facia panel -188 fuel filler flap -188 heater -192 to 194. 196 10<ld space trim panel removal and refitting -186 -'alnlenance
) bodywork and under/rame _ 176 routine _ 116
uphOISlCry
and carpets -176 mirrors
-
192 open rem quarter glass assembly
removal and refitting -186
re~r qllMlcr trim panel removal and refitting -185 repi'lir millor damaue -178 minor damage -176 sent belts -191 seats -192 sunroof-189la 191 lailgate -180. 187. 188 torque wrench scuings -173 windscreen -180 Bodywork repair sequence (colour) -174, 175 Bonnet release c<Jble removal ilncl refitting -186 removill. reflt1ing and adjustment -186 Bml<ing systll'm -14201 seq Braking system deseriPlion -142 lilUl1 di<lgnosis -156 fOOlbrake ped .. 1 removal ')nd rel ining -152 fronl disc brakes -144,145 handtHake -153 \0 155 hydraulic system bleeding -152
p ipes <lnd hoses -151 n1<lintcnance. routine -143 n1<lSler cylinder -148. 149 presslilc uIHe&#34;~llIial switch removal and relitting -150 pressure reducing v~lve rernov~llInd refining -151 rear drum brakes -146 10148 specif'Cil!ions -142 stop IJmp swilCh removal. refi11ing ilnd adjuSlmeJl1 -152 lorque wrench se11ings -142 vacuum servo unil -156 Bulbs. lamp 'Tenewnl -213 to 217 spcclflcntions -199 Bumpers removal and refIlling -178
c
Camshaft (3.0 litre engine) retitting -54 removal -50 Camshaft and camshaf t bearings examination and renovation 2 _8 litre engine -35
3 .0 litre engine -51 Camshah and front intermediate plate (2.8 litre engine) refilling -41 Capacities. general -6 Carburetlor (Weber) aulomat ic choke
adjustment -71 removal. overhaul and retitting -71
dismantling and reassembly -69 general -68 idling adjustment -73
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