engine FORD CAPRI 1974 Repair 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 lubricatio n
Luh"(. ,rquo wrench settings F(}(If.SI!(',~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 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",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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·06 Chapter 6 Manual gearbox and automatic transmiss io n
disengilge the gearbox inpu t Shill! hom ,ho clutch p,Iot bearing ,111(1 clu tc h friction disc. I, is imporlanllhal,hc engine and transmi ssion <'lre kept in lino while this is being done. 14 When the gearbox shaft is cleDr of the clutch, remove th e
tran smissio n assembly from bCn(!illh the car.
15 When refiuing, ensure 1il1 the clut ch pilot h earing in the end althe tfilnksha h is ill plilce Jncl is scrviceDble. Tic the clutch lever 10 the clutch housing, 1 0 pr(!venllhe release le.rertrolll slipping out while the ,Wnsmission assembly is being lined. 16 Smear some molybdenum-based grease OntO the end and splines 0' the gearbox input s!mh lind refit the gearbox by reversing the fcmovili p.ocedure. 17 II is impO.IMll when offering up the {jOMOO)(. th,lt il is e~ th e clutch ffiction drsc i1nd the Cfankshnft. Ifthe.e.s d.iilcul1y Inlnatinn th e splrnes 01 the gea.box shillt ,1no the frrctio n oisc. select iI \)em to 'CSlrain the movemcnt of the gc,lrbox shillt nnd turn the gearbox
slightly until the splines enter Do not iluempltO lo.ce the tfilllsmisslOn
ontO thO enlJlnO ThiS Illay (i ImpOSSible
'8 Ahe •• el,uinn has been completed. chuck the 011 level Ifl t he .r Gearbox (4 'S II001l) -dismantling
Romoye the lou. bolts hom the 1011 cove. 01 the t.ansm.sslon c~t()"sion housin!J ilnd f.om the lri"'snHs~ir)Ol eo'S<' Ilcmovflthc \:oye. s.
t.1king c from th e seloclOl shalt. 4 Remove tho twO bolts from the selectol sh 5 Remove the Ih.ee bolts from the selector hOUSing COVCI. Remove the cove. with the shaft. then ro tate the selec tor sh th c 15t/2nd. 3!d/top and .cve.se oe,1'5 suiliClently to rele plullger ill th o 3.d/top selecto. '<1'1. Remoy e Iho th.ee selecto. lorks. J Remoye the plug hom the side 01 the c rca •. Allow tho laygeal cluste. to drop into the ho ltom 01 the box. out 0 1 mesh wilh tho lIl<1inshalt gea.s. 15 Withd.aw the mainshalt and elflension assembly from the ge tho '.ont 01 the gembox and slide the retainel 011 the input shalt. 17 Remov e the circlip hom the outside 0 1 the fronl bearing and tap the outer raco of the bearing to d.ive the inpu t shillt and bea.ing assembly into the gea rbox. then lilt them out olthe box . 18 Remoye Ihe laysha lt geaf cluste •. Ihe two th.ust washe.s and any I"'o se needle 'OIiOfS.
R emoYo the .eyerse idle , shah by sc.ewing a suitable bolt into Ihe end of Iho shah and then leye.ing the Sh;'lit Out uSing Iw o open ·ended spanne.s. Fi\)
.
6.6 Removing the seleclor 10lk rolillins (Sec 4)
A CIfC/'11
Fin. 6 .7 Revorso gear interlock nnd light swil c h (Sec 11)
A Ravelse liyh, switch 8 Swing C Plf/ngcr
o h!/ellocl< ball E Sc,ew IJlug
Rct.1ininy bolt F
5 M Remoye 3rd/top gear s yn chron ise. hub ci.clip Ense the hub amf
thud gear lotwald lly lel/erinu the,n gently wrth a p th e mainshah nUl and lemoye it 4 R emove the loc kpli/te . speedometer dfivegem. ilS d.ive ball and Ihen level 011 the reaf bea.ing. complcte With bearing IClaine •. Separate the bea.ing and its lelainel. 5 Remove the 011 scoop ring and lils i gear . 6 Removo 1 sl/2nd gear synchronisc. ci.clip and pull 011 the hub with the bi/ulk .ings and second gear. 7 Check thallhere is a mark to align the selec to. sleeve in .elation to the hub. II no malk can be seen. make one with a dab of paint ~nd then dismantle the synch.oniser hubs. 8 8010/0 sta.ting .eassembly. Clean all parts thoroughly 3nd check
their condition. Smear all Pi/ItS wilh tr3nsmission 011 befo.e fitting .
9 Reassemble the synchroniser sleeve and hub so that the nlafks on thorn align . Inse.t the sliding keys and 1IIIhe shdrn\) key sp"ngs so Ihat Ihei. open ends afe stagge.ed re lat ive 10 each other
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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)
-=<
~:=~~3
-: _~e~~-=--'
Fig . 6.30 V ilCUUI11 line connection to the vilcuum unit ­arrowed (Sec 20)
.... ,' ,',.<.
~
"i'i.
~' ..
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 $llIb ShilfL This should be al leilsl 10 mm (0.4 in) (Fig. 633). Adjust the selector cilble i1nd inhlbilOr switch i1S deSCribed later ill this Chapter. Reftll the 1riln smission unit with lhe specified flu,d before StDrlll1g the ennine i1nd check lhe level i1S describe(f in Section 19.
21 Selecto r mechililism -removnl. overhnlll ilud refitting
Apply the hnndbr,lke then Inek up the front of the car ilntl suppo'1
on ilxle stands. 2 Insi(fe the cm. prose off th e selector lever escutcheon. ,md wothrhaw
!he Illumillnt,on 1ll0U1l1l1l\J from the selec tor lever Oeneilth the CM. remove the Spr .1 the selector lever.
r(
®---i
A
6 .33 Checking torque converter engagement with trnnsmission oil pump (Sec 20)
Alle,1S1 100111111 (0.4 ill) 8 O(.1ill (lluy
:-----­
--
6 .34 Selector mechanism (Secs 2 1 and 22)
A SclcclOf pawl B SClccrof cabie
C Pusllbu/loll
o Natld/c
f Connccting clip F Shill (od
.'
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I
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Chapter 6 Manual gearbox and automatic transmissio n 127
2 Select position O' th en pri$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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