transmission FORD CAPRI 1974 User Guide

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 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 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, , .,-
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, 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 ,
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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
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11 85th \)e;II lockrrlU plilte 1 1.9A 5th eil' lock"' SP""!t 11.9B 51h !)C
11 1 1 B Ilemovong scle<:tor shaft connector
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Chapter 6 Manual g ea rbox and automatic transmission
18 EXlra ct the r."dp and pull the 5th gcar synchronise r ur1lt f'orn the
rnn in c,lsm\1. Icavlllg I t loose on thtl mninshaft (photos). 19 S II(le 51h IlcM from the synchroniser unit huh {photo) 20 S elect 3rd gem and either 1st or 2nd gear by pushin\) the re~peclivc synchronsrcr sleeves this will lock the mainshllft 21 Unscre w hOldS t:' e \Jf:arlJox st<1tion;;lry (pholo) The nut is lightened to;;l hrUh torque settrllli ;;Ind i ll1 e,rl),,,j,.rte hotrsrIl,J {photo).
24 US"'(I;' ~oft·f;,r.ed Ill;-rllm. wp the intermedrate hOtJS"'~1 (,,!e of tl,,; ",<1111 c . '.~ .
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hO(lSII1\1 25 Using a soft metal drift from tlte hont of the m ain cnsing. drive Ihe
layshilft rearwards to <11101'11 the \ .wm d,,~tn' t o he lowered 10 the hottoot 01 tlHl cas,,'U .
2G Ease tlte input Shaft f'om the frOllt 01 tlHl c;-rSlng, if oecess " small droft inside the Uearbo~ to Il"JV(~ t he healing sl'ghtly forwards_ Ihe" lIsin,J levers bene"th the he"""!J r.nchp (photo). 27 Remove the 4th ge 28 flernove lhe nlninsh;lit alld 1Ill<""'Hrllatn houslnll f,om the main \;aSII10 {phO to). R emove the g.lsk"t
29 Wllhdr,lW th e I,lyshalt ,11lel 0"_" eh";t,,, I,om Ihe 111<1111 C;-rSlIlg (phOlO)
30 In:;'''I; ' sUlwble bOl t (M8 x GO) Illto Ih" ,,,v',,:;c !Je,1( ,die, shnft. alld
11 18A Exlrar.t,nn 5th geM synchro ci,clip 11.18B 5th u em syl,(IHU hul) 11 18C 51h ~Je;-rr synclH O
11.19 SlId l"!J 5th !/tlar from "' 11.226 Relllovmg 51h gear spacer IIIl\) 1 1 23 Extr l'.22A Wrthdli'Wlll9 5th ge 11 24 P"sl"g off laYSh procarmanuals.com

) Chapter 6 Manual gearbox and automatic transmission 119
11. 1~) 2nd (Ie", [Inti thrust w,1shcf h.1l1. showioO t .. llloctltinu hole
(",,()w~d)
20 Slide 3ul \jC,lf 01110 the f,aiH 01 the mninsh syndHOlllscr rill\) 011 the gOilf cone. 2! lUC,ll(llhc 3rd/4lh synchlOniscr unit on the l11.1inshaft spllllcs with the long side 01 the huh f"cinO the front (pholo). Tllp the unit fully hOllle lISIrl\)" melal tube. then fit the ci'clip . Milke sure th aI the sluts in the 3([) geM synchroniser ring (lrc synchroniser unit is being fitled.
13 Input sh(lf( (S·speed) -dismantling Dnd reassembly
!'ld!;! to Section 6
11 GCil,ho)l ([i·spced) -C)lamin,lIion [In(1 rcnov[ltioll
Ref or 10501:[ '0 118 hut now the lollowlng pOllltS :
(,1)
111<:,,) ,1fI! five sYllcll,v rillYs (h) /IlL' I"yshlft lI[1s 110 IIIlIIsl w,lsllt"s (e) (lielL',1ro IWO ball-/)cmiIJYs ,lrId olle ,01lcI hCMiny (d) Wile" ,cnewi"y Ihc IIL'cr/lL' ,01lcI /)(1,1/ill[lS ill I!lc I,Jyslml/, (ISO wllels 25 75 111111 (1 OTt! ill) fony. IIlhc Oligin,ll ,ollers W{!lC 33 111/11 (T 299 ill) lony, two exll,l space's will be requi,ed
(Fiy 623)
15 Gcarbox (5'SI}Cc(l) -rC I Loc~tc the l11il\j 11ellc disc In the uottom 01 the m(!in c~sin\j. 2 Fit the rcvcrsc relDy Icvel 01110 tilc pivot (llld retain with the cllclip_
Fit the \juidc to the leve r 3 Posit ion the reverse idler \Je~r in the m~in cDsill\j with the Ion,) shoulder facing the reill and en{lllued with thc ,eiDy Icver. Slide ill thc Idler shalt lInci t nee(lIe .ol lers, 1l111ke sure Ih1l1 the rollcrs used for an y onc location all
)me from t he SMne l"JilCk It more than one pDck is purchased, do not ,ni x lho needlc rol lers from sepilrate p~cks. 5 Insert the layshJlI in the gear cluster unlil the front of Ihe shah is flush With the frunt \Ie~r on lhe cluster.
1221 3 r(I/41h syl1chro unit
Fig 6.23 Layshaft necdle roll.)/ he 11 Lays""'1 o NCf!dlf! follf!IS
G Loc,.tc the lilyshah iln!! gCilr ell/stP' III tho hOllom of the .11il;n
caslnu_ 7 Pos.1I0n ,. n(.'w \Jaskot on the Ill;nll (;;05"'11. Ihen hi the mllinshah ilnt! inlCrll1ed"l\C houslIlg. and IClllpor;I"ly secu.e w,th twO bolts. 8 Fit the mll"t Shilh needte roller heilrrn\J to the end 01 lhe mainshJlt
or In the centle 01 lho input Shilh (photo).
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15.8 Input sh , I I
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, 22 Chapter 6 Manual gearbox and automatic tran smissio n
17 Fllult dingllosis -IlH IIlU Symptom
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 GeM welh exce ssively WOrtl 0' (l;Ullll!Jcd
l;'lync:u 1hru st W;'\ShCfS w or n ililowing excessive cndplilV (folll,spC C lu tc h cilhle .1(tjllsllllcnl in corrcr. l
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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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' COllsult your I'ord dealer rI thIS cond,t ron arIS"~ 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" 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 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 Fig . 6.29 Downshifl cahle locknut A. Ir[lnsmission lover B
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)
-=<
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Fig . 6.30 V ilCUUI11 line connection to the vilcuum unit ­arrowed (Sec 20)
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F ig . 6.32 Oil fil ler tube - arrowed (Sec 20)
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Chapter 6 Manual gearbox and automatic transmission 125
18 Carefully ~ove the lrilnsmission reilrwards ilnd downwmds, and
away from the car. Make sur e that lhe torque conver ter rema ins fully in
the transmission. 19 Refilling is the reverse of remova l but ensure that the torque converter drain plug is In line wIth the hole in the driveplate . To check
that the torque converter is positively engaged. measure the distance A between the converter housing to engine mJting fJce and the end of the $llIb ShilfL This should be al leilsl 10 mm (0.4 in) (Fig. 633). Adjust the selector cilble i1nd inhlbilOr switch i1S deSCribed later ill this Chapter. Reftll the 1riln smission unit with lhe specified flu,d before StDrlll1g the ennine i1nd check lhe level i1S describe(f in Section 19.
21 Selecto r mechililism -removnl. overhnlll ilud refitting
Apply the hnndbr,lke then Inek up the front of the car ilntl suppo'1
on ilxle stands. 2 Insi(fe the cm. prose off th e selector lever escutcheon. ,md wothrhaw
!he Illumillnt,on 1ll0U1l1l1l\J from the selec tor lever Oeneilth the CM. remove the Spr .1 the selector lever.
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A
6 .33 Checking torque converter engagement with trnnsmission oil pump (Sec 20)
Alle,1S1 100111111 (0.4 ill) 8 O(.1ill (lluy
:-----­
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6 .34 Selector mechanism (Secs 2 1 and 22)
A SclcclOf pawl B SClccrof cabie
C Pusllbu/loll
o Natld/c
f Connccting clip F Shill (od
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12. ) Chapter 6 Manual gearbox lind automatic transmission
6 Remove the l ubbe r 1)lug hom t h e side 01 the sctcctmlcve. housing.
unscrew the nut and prcss the lowe. lever oul of the housing . 7 Unscrew the loc knut on the inhibitor cable alld wit hdraw the pawl. spring ilnd guide bush . a Remove the Allen screw from the T handle ilnd remOve Ill(! hllnd lo. Remove the push button and spring. 9 Using iI pin punch. drive oul the retaining pin ilnd remove thO inhib,jo, mechanism and inhibi tor cab le . 10 Refltling is iI reversa l 01 the above procedure. nOling lhilt lhe
T .handle Allen screw is inserled Irom lhe IrOnt. SO lhilt lhe pus hbtJll0rl rs neareSl the drive r. " Adjust the mechanism liS described In Section 22.
22
Se lector mechanis m -adjustment Fig. 6 .35 Removing the inhibi t o r cable (Se<:: 21)
Almlv the ha ndbtake lhen lack lip the hont 01 the car ;md support on axle stands. A S'NJiyllt IJin 8 Segmen,
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C Gllide piece
T
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Fig. 6.36 Selector mochanism adjustment (Sec 22)
X Locknut y .. 0.' /0 02 mm (0.004 /0 0.008 in)
y
D OpeliJtiflY cable E Rolfer "$SembII'
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Chapter 6 Manual gearbox and automatic transmissio n 127
2 Select position O' th en pri$e off the selector level escutcheon nnd. Irom under th e cnr. re move the plug in the side 01 the selector housing. 3 Adjust the inhibito r cnble locknut X to giv e a dimension of 0.1 to 0.2 mm (0.004 to 0 .008 in) (Fig. 6 .36). 4 Refit the plug nnd escutcheon. S With the trnn smission shih lever and the mnnunl selector lever in '0'. ndJust th e selector rod link until it cnll be reconnected without strain .
23 Downshift cable -removal. refitting and adjustment
Support till! front o f th e cm on Jxle Slng brncke!. pull b~ck the outer sheilth and unhook the c;rble hom the slol. 3 Unsc!Cw the nut at the trnnsrnissiorl rnoun trr\\) hracko::t and unhook the outer she,l th. 4 Unhook the inner callie from the tranSl\\ls s,on lever , 90::1011,n(l ,$ 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 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 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 ,j ,
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