ESP FORD CAPRI 1974 User Guide
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Page 121 of 205

)20 Chapter 6 M anual gearbox and automatic transmissio n
9 F it the 4th gCill syncluolliser "n9 to the 3rd/4lh sym;luOI"s(1f 'HUI with lhe c:ul-outs over the slidlllg k(lYs. then fit the UlPUl shalt asscnlhly i]n(l lilP the bearing fully into tho casing up 10 the rclo1llunu circtip (photo).
10 Invert Ihe \jCo1rilox so Ihil! the l
12 Us;n!).1 mel,lilllbe. lilfl the Inyshaf gear cluster be,IIPI'!J 11110 the inlcrmcd'
15 Seleci neulrnl. then slide 5th ge", IlItO mesh WIth the driVing Be",. 16 Slide the 51h gem synchroniser unll complete with sp"ce[ Onto 51h Oll"r. Then. usrng.l metal tube, drive Ihe dO\1 huh "lid 51h synchronlser flng OnlO Ihe 1ll",nsh,,11 splines whIle UlOld"l!) the synchronIse! 111111 onto Ihe shdlll[J keys. Fit the circhp (pholUs).
17
T"p Ihe sp eedometer drivegeilr "HO ItS COrreCI poslilon on Ihe mollllsh"ft -the dlsWllce belwoon Ihe HeM 'Illd the 5th gO,l[ dOll hub c"cllp should be 123.0 to 1 24 .0 111m (4 843 10 <1 882 Ill) (nhoto). lB Loc"le Ihc 5th He", selector fOlk In liS syn ch ronlSN sleeve "nd loc"le Ihe Interlock sleeve in Ihe uroov", hhol! Shollider 10 front). then InSurt the seleClor sh~1t through the sleeve ,1nd SeleCIOr fOlk InlO the "'aOll r.,lsll1\J (photo).
19 LocnlC the lSI/2nd "nd 3rd/4th Sf)I'~rIOr IOlks 1(1 Ihell respecllve ~Yllcillonlser sleeves. posilion the selectOl !ross
20 If If!rnoverl. 'ef'l Ihe seleCIOr sh,,11 (:"nlr,, 11~1I1!1 sprinU ",ui 51h \Ie",
.' /
15.9 FI1l1I1\1 Inpul shnl1 15.11 L;,ysh;r!t corruc tly located hefore inst,111,11101l 15.12 F,ltintllile Inysllilft hearing
15. 14A Tlghtelllng thc rn"insha fl nut
15.16B F'lllI'\) 5th genr synchlO to m~inshalt
15.148 Slak,n\1 the rH.lloslrall nul
15.16C 5th \le,,, haulk flng Jod hull
15.16A 5th gem synchro spacer
15. 160 51h gear hub {:ilchp
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Page 122 of 205

) Chapter 6 Manual gearbox and automatic transmissio n
121
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i
...,
1 5. 17 MC~Sll"nu corchp· 10·SPCI1(lOIllClcr drivcgc,l' dImension 1 5 .1 8 Sc lcCl0f Sholl! t1sscmlJ lcct 1521 FIlling selector sh1lft/boss fall pin
15.23 Speedome ter dJlvcgcn, cove.
IOCkmg cOI1l,ol hy Inserl;"y the 1)111 ;lnd 1>lu9 2 1 Ahgn the holes. then (lillie Ihe roll pin il1lo the sc lcCIOf boss ;111\1 SI~ICC1Of s h
main c .. sing ... pply se
29 Check that the 5th gea. interlock slceve is corrcctly .11ognoo. then 'nscrt thc Sth geil' locking pin and spring.
30 Appl y some scalallt to the 5th geilr locking plate. 10Cilte It on thO extensio n housing. an d inselt nnd t igh ten th e bolts to I h e specIfIed torque. 31 Fit the Ueilrbo~ top covcr. together WIth a new gas\(et. and lighten
the boilS to t he sf1eclf.ed tOfQue in diagonal sequence. 32 F u the clulC h relCilSe bearing guide sleeve (oil slot dow nwllfd s). together with a new gilsket. and lighlen th o boi lS to the specillt~d torque in d;ilgon;11 sequence. Where neceSS;1ry apply seal,.nt to the bolt threads_ 33 Fitthe clutch bell housing to the Iron t 0: the gearhox. together woth new gaske t. Apply sealant to the bolt threads. thcn inse n the boilS .~d tigh ten them to Ihe SIXlcllled 10rQue in diagonal sequence. 34 Inscrt and trgh le n the .ev(usinl.l Ioght switch in Ihe ex tensio n housing
1525 Selec tor sh aft spring pin (arrowed)
35 FIt the clutch reLease l"l'lIIng and a.1Il wuh .efercnce 10 Chnl)\ el 5.
16 G e(lr box (5-spee{l) -d isellg i:lgem enl of 5th gear
I I
is possI ble 'or vducles hu,l t bclo.e NovcmiJer 1983 to have i:l p.oblem WIth 5th ne". Illillplllg Ollt of cnuanClllcn t during normal
(hlv lnu
2 ThiS 1I0uhle Cilll he rcc tl',cd hy suhstitutinu nlod,hc
3 Rem ove Ihe gearbo_ "s de$("bed in SectIon 3. This wrll nCCCSSlla te lemov ing the ge(l' Icvcr "nd lu"C I cove. whIch is held In ,)OSltlo n by TOOK typc sClews . 4 Removo the clutch Hlleilse bearing and tevcl 110m the bclthousing . 5 Unbolt ami lemovc the lOP covel. 6 C"ory out the opel,1t'0"S dcsc llbed in par "graphs 8 10 1" 01 Seclion
" 7 M"r\( Ihe ex.1Ct IIOS""o n of t he speedometcl wormdrive on the milinshil lt (lnd then draw it off using a pulter .
8 Extr"ct the ci. et,p "nd H)move the 5 th sp(lcd sync hro unil/rom Ihe
mJinsh"lt. 9 Dismanlle the synr.hro "nd reasscmble using the new p" rts, When I Itting t he b"ulk lings. m"ko sure that theil bevelle( 1 side is tOwa.ds the
re,,' o f Iho ge",box. 10 Caffy out the ope,,,,,ons desCfibed in jh"lfilgraphs 16 to 22 and 25 1027 in Section 15. 11 Inser t the 5 th ge
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Page 123 of 205

, 22 Chapter 6 Manual gearbox and automatic tran smissio n
17 Fllult dingllosis -IlH IIlU
Weak or in effec tive synch romesh
Jumps out of gem
Excessive noise
Exces~ivo difficliity III enonU ing (]0,11
P ART 2: AUTOMATIC TRANSMISS IO N
18 Gen eral description
Thc aulOma llC l,an~nHss'on ,;rkl:~ lhe JlI"Ct~ uf the clutch and Hcmhox. wh,ch ,"c. of cow se . mounte(1 heh,nd lhe enu;ne . The unil has a 1"'{lO nluminl"'" content which helps to .elluc" liS
overall weinhl and 11 IS o f compact dimenSions. All 0,1 coole. 's filled ,IS
Reilson (s )
Sy nchronising cones worn, spilt Of dmnaU ed O~ulk rin g sy nch romes h dogs worn, or dmnagcr!
Broken gcarc h,lnUC fOfk rod spring Selector fo rk rod !IIOOye h.ldly worn
Inen!!cc! 9(,1(10 of oil in gc,llhox 0' 0,1 level 100 low Bu sh or ncc(tie roller hC
l;'lync:u 1hru st W;'\ShCfS w or n ililowing excessive cndplilV (folll,spC
Sliln da.d .. nd ensules cooler OI)(lI.lI1Qn of the \.,lnSUlISSlon lind!)! l.a>l." lowinU ;lnd sunlla. conrll1i0l15 . A VaClIl,Hll conncctlon 10 lhe IIII~I manifold p,ovldes smoO lh cr anrl morc conSI$1r.1l1 clownstlll,S IIndc. load than IS the case Wilh IIn,lS nOl !IlcOlI)Or.11U1IJ lh,s f,,(:Illly The sysle m cotlllJltses lWO tIl.lin com(lonenrs.
(.1) A /"ree e/c'mcnl "v,/lokinc/ic IOUIIIII I:Ollvcrler cOII/,lmy 1:;'I'.1h1(.' o f /orqu c 1II1I!lIplicii /iorr ;, 1 .1/1 irr"mldv Villl;,hle r.1/1O (h) A /unluC/Sln'cd respOlIsiv~ .md IWdwlllrI:illlv IIIIL'f.1lCr! cp'· qL"fie f/c.1rbox COIIII}liSIilf/ pl.wel.l/V m:.lISII/S /IIovidmy tlllf:C forw.l/d 1.1/ios "llff OIlC Icvcrsc ril/'O
Fig . 6.24 C utllw ay view of th e a utomatic transmission (Sec 18)
1 GovelllUi ,'ssemblv 6 rop/leve/sc clu/e h 10 FlOn/ SCIVO 2 GOVlIIJI OI IIlIb 7 FIOIII blilkc bil/Jd /I Valve botlV 3 Olle ·w/lV cfalclt 8 rorquc convenor 1 2 V/lcuum diaplu/lym 4 IlCill bfiJ~C baml 9 Hvdraufic pump 1 J Re/ll servo 6 Forwlllfl cia/eli
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144 Chapter 9 Braking systom
9 II there Dre no inspec tion holes, remove the wheels and drums In inspect the linings . 10 Where any lining is less Ih,111 the nllnimufll thickness, renew Ihp. complete SCI 01 re,ll b,~ke shoes. 11 Refi ' the drums lind wheels as necessary then lowe. tho em \0 thl) 9lOund.
Ch eck operation of servo lIoil 12 Visually inspCCllhe vaCUUll1 hose IClIding hom the inlet mlllllfolll Of air box 10 the servo unit fOf dc\c,iOf1l1lon and security. 13 Wit h the engine Slopped. dCI).es s the bra ke pedal several ,imes to dissipate t he VOC U\Ull hoUl the sorvo Imit. 14 Depress the b'i1kc 11Cdll1 wilh moderate pressure then Sin' I the
cnU illC . As the V
R/mew fhe /)rilke I/Ilid 21 lJIucd Ihe hyd.; ."loc sySle m as d"scllherl III Seelloll 15 ilUOwnl! II",
Ihe new h ,,,k\) Ih"d to COnlph: lely 1,lIlhe C:"CUtt he"I!1 bled . 22 AI Ihe sanl\) I"ne rcn,uve Ihe 'Ci" ",ake \I'lOn,s alld check tho wlu,,,1
cylonclers 10' leak"IJe.
3 Front disc pl1ds - renewal
Apply t
he handbr
I .
. ~ .. " ,) •. :Y.
2 RemOV(l Ihe hont wheels.
3 It Ihe fhnd level in the maste' cylondel reservoir is high. when the pistons l1re moved into thei, respecI,ve bo,es to accommodate new pi1ds. thO leyel could rise sulticienlly fo, Iho fluid 10 oyerflow. Place ilhsoruent clOlh .1round the reSe,yO". o. syphon a Imlo Ituid oul. so 1)'Cven tUlg Pil"ltwOlk
<1 F rollt brake caliper _ rcmoy'll iltld refitting
1 nemove the f,on! disc pads i1S tie sc"lJc(/ in Section 3. 2 1111 'S Itll,,,,d,,(1 10 lit ncw Ci1tiper pistoll s "nd/o, seals. dep,ess the tH.1k'J Iwel,,1 10 hlUlU the pistons i"to COI11i1ct with thO (fisc and
'-.. ~
, .
3 .9B Fitting the tenS ion springs
.--.::.:.:; .
....... . ~,'
灲潣慲浡湵慬献捯m
Page 167 of 205

,6 Chapter 10 Suspension and steering
A
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, " I : I 'II
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FiU · 10.11 Fl(Wr stniJiliscr b;H flnd piece positioning (Sec 11)
A IJ 2620 I J!J 111111 (/03 101m) 100111111 (0·1 mJ
1"'5 ;",(1 ,0.:1'1 tile t;1\{1 sHoec When l ilted. the wHip'cec should he 1'''~'ll'''H,,1 .15 shown III FlO 1011 DIIIlCIlS'Oll A should he betweell ?!.i 59 nlld 2Gtl 5 ""ll (102 ami 104 JI') :lnd Ih" (h(fmcncc IWlwr!f!1l IllI! two s"I"5 IIll1S! nOI he \l'catc, th.1rl 2 5 nUll (0 1 m)
(l II Ihe IJl,~hcs "' II", (,11(1 11".:';'$ "''1''''<) """,wi,I, II 'llaV I", found "'O'e COI1V"Il
h",,/.ul1,11 h.'vel (the wUIOht ",qlllred IS dpp'ox,m
J.!Ck lip the front 0 1 thn C,lr and place s1
2 Remove tile nul ~lId holt from the elnmp at the front of tile fleXIble COllpll ll(1 on the steerm!j colllllln, Tills cl,IInp hOlds the couplln(J to the pillion splines.
3 Working on the front crossmemlier, knock hilek the lockmg wbs orl the two bolts on each IJck houslllg U ·C lillllp. undo the bolt ~nd remove tbe locking tabs ~nd clamps
4 Remove Ihe split pillS
Th iS cnn be done by ensuflng that the d,swnces hetween Ihp. ends oj bOlh trllek rods 1111(1 the Stec1inu geilr hOllslng on both sides ~re the same .
7 Place the stee"ng Uear in it s 10c
-,
Fig. 10,12 COfrect position o f stnhiliser bar ruhher bush {Sec11 )
T'!jht(:n the holts to Ihe speclf,(:{! to"lne, 9 Relit the I.,lck rod ends into the stO)(:IIn!) illluS. refIt (he I:a';[ellolted nllts and II!Jhten them to the slleclfl{)d tOlque Use new spill pillS to '!:t.nn the nuts
10 T'!lhten tho I:I,II"P bolt (HI the steeru'!J COItIllHI lIex'hle couphllU to 1f1n spec""~d torque. h,)vIlI!) fll~t rnil(\e SlJlOl tholt tlul pin lOll is cOlfecily 10(;"101(1 III t he S"III1CS 1 1 Lower the cm to tho urOllnd. thcn check nrld If neceSSo1ly ildJlIst the front whlwl ;III(J 'Hncnr 015 descrd)ed in Sec lion 20.
13 Stcerinu geM (Illanual) -overhaul <111(1 adjustment
Remove tlllltr ilc k rod nnds (Section 14) then .elllove 1)nd discard the Wile retalnlllg cliPS. remove the hellows and drall1 the I"hricant 2 Mount the stee"ng Ijear in
15 LubrientIJ the ball Seilts. balls and housings. with the specified gear 011 Screw the locknuts OntO the ends of the steeling (1)ck. 1 G Assemble t he sprlllgs. waShers. bJIl seJts. track rOd ends and housing. Tighten the hOllsmgs. to obwin a rowtionnltorque of 7 N m (5 Ibf It). then lock them w ith the locknuts. Recheck the torque alter tiuhtening the locknut 17 Drill new holes (even If the o ld holes Jre in aliunment). 4 mm {O, 16
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Page 172 of 205

Chapter 10 Suspension and steering 171
19 4C Removinu the top steering column Shroud 19 G lunitlon SWitch ,1nd wirlllU (A). also COllll'lII upper mOlUllnl!J holt (0) 19.7 Removing the steering column uppcr mounlul(J holt (arrowed)
'5 Secure Ihe SIt:(;(1I1(1 lock 10 Ihe colulIlIl ,lIal ~heil' the h eads I,om ,he m:w holt~ 11) U~e the stecrin\J lock to locate the shaft in Ihe column. then III Ihe )ct,on mdlGltor OICIlJalinn GUll alld Stecrmn wheel. CtlCC~ that Ihe ruadwheels afC st,lIln the 5trai\jht·ahead P05,110l1. 17 Install the Stce!Ul(J column orommet Oil the lowm en(t. 18 LOCille the column assembly ami sr:c",e It wrth the Iwo mOllrlllng bolts. 19 The ((,milliuler of the rellllUI\J proccrl",e ,~ th" reverSI! of lhe removill procedure,
20 F ront wheel alignment and steering ilngles
Accurate front whcel alignment IS essential lor good stoer"'g and lyre WOiJr. Scion) cons,dering the steering angle. check Ihat Ihe tyres
are correctly inflated. tllnt the front wheel s arc nOI IJlJckled. the hub hea"nns arc not worn o r mcorrectly adjusted und thilt the sleflr"'g IlIlkaUfl is in IJood order. wllhout slackness or we,ll at thu Jo,nls
2 WIH;f; 1 "I'!JIununt co"s'st~ 01 loUl I"ctors, C;"lliJcr_ IS the ""Ule "t wilich the front whet:ls ,lie sci from Ihe
verllcal when v'ewud 100'" the IrOnt 01 the c"r 1'0sIt,ve camber 's Ihe .. mount (111 de\J'ee~) th"t til() whucls ,ue toited outwards at the lOp 100'"
thu vert,c;,1
Castor. ,~tho i"'~Jlu between the SIl,erlIlU ,,~,s OIrld.1 v..,'I,e.11 lone len viewud IrOIll p,lch ~,dfl 01 the C,lI 1'0~;llIve castor 's when the ~tcermu ",x,s 'S ",cloned rUiHw,,,ds ill the top jStcerinu ilxis inclin,,{ion 's lhe illl\Jle. when VIewed frOI11 the .It 01 the Cilr. bel ween the verltcal and "n 1Il'''U>I1.1ry hne drawn betwCl)n the upper ilnd lower suspensIon strut p,vots, Toe-i n IS the ilmoUl,t by wh,ch tlte dl5li"'Ce helween the frOrlt
IIlsuJu ed\Je~ 01 the rOildwhecls ('He,lsu1ed m huh heiuht) ,s less thiln lhe d'sWrlCI) ",e
6
Oht"in or m"ke
ne:w components have heen I'lted. set the ro"dwheels ,n the stral\jht·ilheil(f p05otrOn and also cent",lrse the steering wheel. AdJ"st the len\Jths of the track rods hy lllll1ing tltem so th,,! the track rod end IJ,litJoinl studs w,11 drop eils,ly onlO the eyes of the steer inu ilrlllS Measllfe the dislilllces between the centres of the hilllfOllllS illld the grooves on Ihe inner ends of the track rods and ildjust. ,r neceSSilry. so Ihiltthey me equ,ll Thl~ is all lII,t,,,1 sellinlJ only and prec,se ildillstmellt mu~t he carried oul as descrrhed earheL
21 Wheels and lyres -uonNal care and milintenl1nce
Wheels ilild tyre~ shOuld give no reill problems in usc provided thm ,1 close eye IS kept on Ihe", with re\janlto excessive weilr or dilmilge To llns end. the following pOllltS should he noted Ensure thm lyre pressures ",e checked re\Jularly ami ma,ntallled correctly. Checklllg should be c,Hried out woth the tyres cold alld nOI IIlHlledialely alter the vehicle hilS heen "I usc. II the pressures are checked w'th the tyres hOI. iln ap(l,Hently hi\jh readmlJ w,1l be ohw'lled OWlnH to heilt expJnsron. Under n<) Cllcumst
eSpecii\lIy 111 the s,dewalls Remove any na,ls or stones ell\bedded 111 the tread hefore they penetr"te lhe tyre 10 cnuse dcfliltlon If remov,,1 {)i
dilll1i1ged by ·kerbing· wh,lst par king. and simililrly stee l wheels may hecome denIed or buckled, Renewnl of the wheel rs very ohenthe only course of rellled'ill ilct,on poss,ble, The balance 01 each wheel Jnd tyre ilssembly should be mainta,ned to ilvoid excess,ve weilr, not only 10 the tyres but illso to the s teering and suspension components. Wheel imbillilnce 's normilily S'\ln, f,ed by v,i)rilllOn through the veillcle·s bodyshell. illthouUh III many c~ses it IS piullcularly nOliceahle Ihrouoh the steenng whuel. Conversely. it ~hould bc noted thilt weilr o r dilnlaUc 111 suspellS IOll or steer ing components may '.:ause e~ceSSlve tyre wear. Out·of·round or out-of· t!Ue lyres, damaged wheels and wheel !leafing weilf/ nlilladJustntent also lilll into th
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