key FORD CAPRI 1974 Workshop Manual

\.
50 C hapter 1 Engine
51 T llp pcts -removat
Remove the 1 !.111m "' thell bores.
5 2 Crnnksh Prel/cntlho CJ,lIlkshilf l hom 'Ot:ll111(J. by lillllmUl!J the flywheel,' the (jl1nin.! 'S 0111 01 the C;1I, o' hy 10ckll1\1 Ihe transmIssion ,I the cnOllle IS 51,11 III the Cill . 2 Rclcilsc the p"lIny boll hy l,oUlU 1l '111\1 511.11111C. ;'Ind rapptl1\J the sp,lnnc. ShiH ply, thon remove Iho holl ;1I\d washer 3 Usc il S I).ockcl pllile. 10 (h"w the pulley olllhe Cfilnkshall. Do not ilUOl1lpl 10 lever II oH, bC(:.lIlSl; the engllle [,onl COV(II IS j,aulle ;111(1 Icvcrn'H ilU1l1l1S1 11 Ill;)y (11510'1. or even InC.11; II.
4 Wilhdraw Ih~ Wood'uH key hom the end of th(! CllInk5hah and pl,lC,(! " w'lh Ihe pulley. til(! holl alld its washer 5 The C'.1nk~h;)h p"lIey m;oy he ICliloved wilh Ihe eno,,,e III Ihe C:\I. hilt ,I 'S IIIsl tU!Ccss;o,y 10 ,emove Ihe ',ld'illO' :lI1d thc rh'vehelts
53 Flyw heel -remov[ll
P,even llhe flywhcel hum 101m",!) by FHlHllln\J Ihe lin!) !lcal ;ollain~1 ;In imp.ovised SIOI). 2 On nlodels willi nl;lnu:ol 1I;o"$""S5'01i. Icmove Ihe Clulch plessure 1)1;lle and disc :os described in Ch:op!Cr 5. 3 Rele.lse Ihe s,~ bolts secu.in!1 Ihe flywheel 10 Ihe CllInksh;oll .lnd lefl\OVC I,ve of Ihenl.
4 Whilc supporling Ihe tJywheel III pl;ll':e .• emove Ihc Sixlh hoi' ,'11d Iolt Ihe lIywheel otl c;o,elully. so 111:01 Ihe m;lllllg su.lilccs of flywheel [lild c.;onksh;oit ;o.e 1101 dllm,'ged
5 4 Sump -removal
W"h lhe '''1(1'''') oul fli the e,". CII~"'C Ihal Ihe sump has 1o('CIl d,amvd ;ond then lilln the engll1C ()VCI so tl1011 Ihe sump's U l)I)ClmOSI F" wOOr1CII bloc"s tn Slll)lmrl tim en!l'ne 'n Ih,s POSIIiOIl . 2 Remove 11m h()IIS seCUlln( J the oil Sump 10 Ihe CI.1nkColSe o1nd rClllOVO Ihe SUll1p_ 11 the sump IS stuck 10 the c r;ollkcasc . II should be reh;lIsctl hy 1"'SII1\1 olle SIde wllh 11 sClcw drover. 3 To !Cn,ovtl .Ile sump wllh Ihc CIIU"HJ Hl tloe eM. 11151 IcnlUVC Ihe
d'l)S llck :ond d'SCOIlII(!Ct Ihe hatlery 4 Remove Ihe luur holts ;ond lou. Ch,)S ;ond dCI.leh Ihe OIl splash
shIeld.
5 Pl;oce a Con'"lIlcr 01 at lellst 6lttre (106 JlIllI) cal,,-.elly heneath Ihe SUml). remove Ihe d,ain pl\l(l ;ond d,aln Iha sump. Reflilhe d.am plull and (11)hlen II 10 Ihe 10lqUO wrench seilIng gtven In the SIXlClflC;JIIons G Del:och the engme fubl)CI mounllngs, by lemovlng the" nuts an(1 w:oshe!s. 7 Romove the ciampinI) bolt hom the tal) ;oml bOIlOI11 endS 01 the Steellll!.) intellnediate sh(lil. rush Ihe lap end 0 1 Ihe shlilt upwollds unlll Ihe lowcr ell(1 Clin be dlsenga\led 8 PI 9 Remolle I he Inur boilS securing Ihe fronl anlj·roll har to the Slde·membei (lnd the l()ul boilS securing each engHle mounling blllckel to .lIe sidenlCmber. 10 Remove the 011 sump Imlts lind I I the sump hns sluck to the crilnkc;ose .• elellse the sump by press ing 'I sideways wilh a screwdriver.
55 FrOllt cover -removlll
If Ihe engHle IS In the CM. II wllllnSI he necessaly 10 dlsc()nneC lthe l!allefY. drll'" 11m coolll1\) sys tem ;ond lel110lle Iho radiillor. 2 loosen the alternalol mounllrlg bOilS. SWlrlg the aitemalor downwilids .0w:Olds the cyltnder block and lemove Ihe drive belt
3 Remove the bolt Irom the cenlro of Ihe cooling Ian .. nd pull (
Ian and clutch assembly. 4 Remove Ihc boil an d wilsher from Ihe centre of the cran pulley .. nd I hen use ., claw puller 10 drilw Ihe I)ulley ofllhe sha nOI anempllO lelle, Ihe pulley ott. t)Ccause Ihis may .esull in dllm. t he Irani covcr.
5 Rcmove the si~ bolts secuung Ihe sump 1 0 Ihe honl cover an, t he cleven bolts securing Ihe I ront cover 10 the Cylllldcl block . G lIlt Ihe cover ott ;ond remove Ihe g;oskel.
5 6 Tillling gears -relllov;ol
1 Remove the honl cover 10 e xpose Ihe IImlnu ueo1/S 2 Removc Ihe bolt and washer sccu"I1IJ Ihe fat!Je gear I,
cn,nsIl1'll t. IhCIi pull.he geill ol! and Icmovc tho Woodllll! key. 3 Dlllw the ileal hOI11 Ihe cr;onk!;h:oh am! remove Ihe Wood'utl
57 Carllshaft -r erllov;ol
The camsh:olt nwy be rCUlovfld wllh the cll!JlIle 1<1 Ihe car •• lollowlng p!Cpol.aloIY wo,k IS co1med out. 2 0,,,,,. Ihe cootong syStelll nnd .emove Ihe .ad,mOl 3 Dlsconneci the ballery. 1 Remove Iho sp.1lk pili!! IC.1ds 1,om Ihe spalk 11lugs. 5 D,s':Ol
eCI the le;ods I,ull' Ihe :l lt'!11\.110r. remove Ihc allelllalo·
l i S (hivebell. G Undo "nd rem ovC tho screws S()CIIIII1U Ihe .0dcl covers and It Ihe rocke. covels and Iheir ilaskcls 7 Sincken lhe nulS secullnu the rocker ~"ns unlollhe locke' arm, he swung aside . 8 Remove the pushrods. idenlllylllg each one as .. IS lemoved. so 1 Ciln be rell1l ed in Ihe same position 9 Remove the cylmde. heads, screws. These cannOt be removed wI,h an oldm;OlY screwdliver ,lily nllempt 1 0 do so WIll resull OIl Ihe sc,ews bemU d",na\.l<:d. I Impact SCfeW(!IIver is nOI ilva,lnl)lo. the SCIOWS m;o¥ he Icmoved w sui l:oblc key lInd the urace 01 a sockel scI 12 Remove t he c.1m5ho1ll IhllJS I !)lolW 011\(1 the space. hclund II 13 Pull the c;omsh;oll lo.ward to wllhdl,1W 'I. 100f 111\1 Cil!e 10 ~ee" Sh,'lllfl Ime. 50 Ih;ollhe edges ullhe cams do nOl rt,1mnge Ihe cam~ beilllllUs_
58 O il pump -r e m oval
Remove Ihe crill1kc:ose sump as ;olleady dcsc"hed 1 2 Remove Ihe boll aUJchmg the 011 scrcen 10 the Illalll 00111.119 (
/ /

Fig. 1.11 Oil pump o n tho 3.0 f itre efluill(l (Se c 58)
F
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Chapter 3 Fuel and exhilust sys tems 81
1 8 Disco"nect the hllllmy 1 9 Relc,,~e tl", .. ,e5~II.e In t he system "s described in palaglaph 3 22 P lace some cluth hcnc,llh the luel flhel then disconnect the mlet ilnd outlet ", lions 2 1 Rcmollc tht) mOIlI1lIlI11 sc.cws ,1od withl1,,,w Lhe fuel f,ltc ,. Remove
the bl:lclwt II 'ltICIlS$:I'y 22 RchulI1U IS a .ellcls:l1 01 ,emoval. but m"ke sure tha t the 1,ltel is
pQs. t.onnd thll I:Olfe ct W,ly 10un(l. "n(1 Locate tile OUIICI plj'JC:I~ snown
io FiH. 33!)
Fucl tlisfllbu{(}r 23 The f""t d'~L"I"'lor .~ IOr.i'to(1 on top 0 1 the "" flltl'!'. 24 DISCOnl"" .t thu !o:m",y 25 n,;L""~,,, thO! L''''',~II''~ III (hI'! system:ls d"sl:"lmd in piull u,a"h :I"" t compL"L"ly 11,111"11" tho I,,,, d 111111 ",Hon 26 DI~r."'UII". t tl,,, """,11'1'1111 f,,(:II'"C$ 1,<)ul til(! llis t,d,utOI 27 UIIS'~":W ,I", nll"l1 """m'"'n sc",ws alld hit Ihe IIISIIIIJlIIOI away 28 RHhll""1 ".,' ",v':I~,,1 "I rr""OvilIIJlJ IIISC a IIIiW coppe, w"~.h,,, r:ach ~,de of Iht: '1',"'1" IIIIIW'~ ",,(I dO not OVf!rI'UII1I:rllhe llIliol Imils 9 Hall" Ih" :.y·.1t:1I1 I""",u'li t: heckr.d by yo"r dllatCr: 30 I\dl"~t th" "II" "I~:I"t :II\l IIIHXIIlIfl as ,leScII",,1I III SectIons 73 ,IIld 26.
W"",,·/I/I/I.'ylll;/fOf 31 The w."'" "I' "'!I"I"tl1l 's loc ;llt,d on till! hunt of the ""!I"'" ""xtlO t he c(X,l"'H ~y~t"l11 nuth, t I:lhow 32 D,sco",,, • .: ! tl", lhlllCI" 33 Flcleasc Ihe prcssllfc In the sySlcm as desc"hed in parag'''I)h 3 34 Discount: GI Ihc lIacuum hose ilud wi"uy plllg (photo) 35 D'SCOI1"I:CI the fuel hiles (l)holO) 36 Unsc,ew the Iwo sockcl·he;lded uolts ;lnll wllhd';lw thll 'C!jUI;ltol . 37 Ref,(lln\1 IS ,1 ,cve.sa' o t ,emOIl"' . hut lise a new copp .. " wa~hcr eilch Si(lc 01 tim h,ll1l0 \llllons (phOIO) 00 nOl ove,l>ghtcil lh" I"'''on cenlre hol ts
Fuel S f"ff v:llvc 38 T hc luel stMI 1I:llve is located on thc ligl1l ·hand s,de of the lIir ch"mhel. 39 DIsconnect the bmlory . 40 Disconnect the elcctlic p lug and fuel supply pipc from th e lIalve (pholo) 41 Unscrew tho twO socke t·headed mount,ng bolts uSlllg an Allen
key .
42 Ref,,,,,,!) IS .1 'ellcrS:l1 of ,ernOllal. but u~e II ncw moullting flange !lasket Use" new copper w"shel all each SIde of the """10 union lind do nOI ovnlllllhien the Centrc holt.
A!lxih~1I"Y "i,. r/(!vicc 1\3 Thc i",x,h.n y "" rlcvice is 10C"II,1I On the IIU"t hal1d flOllI of thu lIir cha",!,,", 1\4 O lsc0I1"", .1 Ihe hallerI'. 1\5 D.scr"'''.,ct tl,(, eleCt,ic p l11\1 ;,ml IWO illf hoses IrOI11 the ""vice (phoIOS) 116 Unsc",w tl", two 'UO"nIl119 holts .11,,1 hit tl"l ;rss",,,t,ly i!Wlly. 1 7 Fl"f,It'''H .s ;1 HIIIC,s,,1 of 'elllolllli
Foel injocrurs 48 D, sclI"""'.t Ihe h;lll",y. 1\9 O, sr. 25.3 4 D,sconncct'no Ihe wII'no plug . 25.35 ... "nd fuel hncs from the W""'H'P !egulato! 25.37 Re new tho copper wilshcrs each side 01 the banjo union
25 .4 0 A DisconnectIng Iho tuel slart valve
wiring plug
, "-
2 5 .4 06 ... and fuel supply pipe
•
25.4 5A Au xilia,y air dcvice w ifin g plug.
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,
~ Chilpter 3 Fuel and exhaust systems
~5 4513 ,111<1 "'f hose s 2550A D",conneclinu the maUl "" supply t.unkul!! 1.011 the 1111~hue cont.ol 111111 25501l mid th'OI1I C houslIlU
"",'
25 53A UnsCII)w the holts. 255311 ,,,"U)IIC the ~'" chal11bcr ~5 53C ;11111 'cmoY(: the Haskct
,
25 5 4A UlIsc'ew the 11101l1lt;IIU bolts. 2554 U ,lIld remove the UIIL'CtOrs 2556 The "'Jecto, Q·rinU seal (a"owed)
56 Rcl,llll.g IS 11 reve rsal 01 rcmoval. hut mtlke SUiO Iha l til.., "l)OC Iors .IIC clea n and III new O'lIng seals (pholo). Also rencw the;IU chamber gtlskel.
26 I( H o mixture -adjustment
Noto: 11!e miJllllfe s"/liIl9 is preset during (!for/actiOIl of II", eM ,'nd shOll1ll 1101 "ofllwll~ require "djIISlment. If I!~'W r:QfIIl'O"Cllf.~ l)f 'he sys({)m ""VI! bccn flllCd. IlOwever. tile mix/IIII! (;,1/1 be mi,l/steil as lollows "Silly /II) cxlwlls/ y,l$ Slandard equlplllcnt) III iI(;COnlDncc with tIn: nH!llul;I(;WH"'s 111-SIIUCllons
3 Incroase the enyulC speed 10 3000 'pm and hold it the,e 10' 30 seconds to Sl Idle speed .
5 Break oft the lalllpl:q)lOol cap 110111 the mj~ture conlrol screw on lap 01 Ihe fuel uistllbulOi. 6 S tabilise the cxhausl Ua ses as dcscllhc·d ,n paragraph 3. 7 In sert 11 3 r1\I AUcn key onto Ihe heau 01 the mixture SCfew and tum the SCfew urlld the COlfeCI CO re -
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Chapte r 4 Ig nitio n sys te m
6,SA Unsc rew the clamp bolt, 680 ... and remove the (tistJlbu to. 68C Rotor nnn alignmen t ;]lter re movnl Irorn engine
~ I
~.

F ig . 4.3 IU "i\iol1 timinu ma,ks o n the 3,0 lit.e e:1Uine (Sec 6)
Allow ;//(lic<1leS din'cliu" 0' !(JIM;oll
7 Distributor (3.0 litre engine) -overhaul
W,th the diMJlhuto. removed from the entl,ne. 'emove the rotor arm and the cont.1CI breaker assembly . 2 Prose Ihe small Clfclll} I'om the v"cuum u,,,t p,vo l IXJSt. 3 flemove th e two sc,ews wh,ch sucure the hfllaker pl,lI!! to Ihe d,slJlbu tor body and hit the ,}I'rte orl.
" Slacken Ihe self'lappmg SCfew which SC<:UlCS the condense, and low tenSion leads 10 Ihe contact l .. eaker a ssembly and shde OUI Ihe lo.ked ca ble terminations, 5 Undo imd remove Ihe condenser rCI.1,nlfl!.l screw and remove the condense •. 6 Remove the c" chp. lIiJt washer and wavy wash er from the pivot post. Se parat e the two plates by h,ingmu the holding down se,ew Ihrough Ihe keyhole sial in Ihe lowe. 1)late , Ta ke care not 10 lose the e.Jrt h spring on the prvo t flOst. 7 Remove the two se,ews seeu"n\) Ihe vilCuum un,t to the d IS t"lHIIO' hotly .Jntl remove the vacuum uni t. S To d,snl.JllIle Ihe vacuum unll, remove the plug I.om the end 01 the
unit (md withdraw the spring. vacuum stOp and shims 9 Oelo,e disll1<1ntling th e centJllugal .Jtlvance mech.Jnism. note thM th e tw O spri ngs arc d.lle.ent and ma,k them so th.Jtlh ey .Jre ref'tled in th ei r OJlgHlall}lilces . Remove the sp. ings. pJlse all the circ lil)S securong the cenlJlluga i weights. nl.J.k the weight s 10 'dent'fy their o"ginal positions and then remove them ,
1 0 M3 lages w llh the s tol) m Ihl! ;]C hOn I)I"le II II" s IS not dono. II rs ~ s, llle to h.Jve th e ,oto, ,'Jln 180' from 'I S COf/,-ct pOSition. 11 Remove the lelt pad 1 10m t h e centre 01 the C.JIll. e~pand the circhp
x - ------:::-.
z
y -
Fig . 4.4 Distrihutor lilting position on the 2.8litrc e ngine (Sec 6)
XX Re.1r "U;,.' of ellgmc yy V,1CI/(JIII flllil Mas Z = 0 '10 11/'
A Triggcr (lffll U Slillor l!fII!
whICh'S Ihen exposed Ilntl ,emove ,I L,lt all Ihe Ci"n and 1l(IV3ncc plJle ;Issemul y,
12 Do nOI .cmove t he d,stJluutor Sl)indle unless II 's necess.l'y to "1 a new ge.n. 0' S I)iJldle To remove Ihe uear . usc <1 IlUnch Ilnt! hJmmer t o dJlve outlhc lock P'" and Ihon pull tl)() !.Ic", frO'11 Ihe sprndle T"ke cn,e
1 0 rOIil'" ilny slums, 0' wllshe,s wh,ch fll.Jy be In led . W,t h the ueJ' lell'Ov\:(\. the sl)lIldle .Jsscmbly can be withd,awn hom the d ,s'Jlhu tor 13 Belore reassembhng. ca,elully clc.J1l the body 01 th e d,s lnbulOr and "II a s CO'llpo llent p"'ts. II th e sp,n(!ie has been .emoved. lulmenlC II w'lh e'lu",e oil h efor e ,ellssemhly. 14 Reassenlbly.s <1 SUa'ghtIOrw<1Jd ,eve'SilI 01 d,sman tling bUI t he,e Inc several pointS which shoold be noted.
15 Lut)JJc;]te th e ce Jltlil ugnl weights and otho. p3rtS ol the cenlrifugal
advnnce mechanism. the diSlrrbutor shah a nd Ihe pa'l 01 the spindle wh,eh c.l"'es Ihe cam assembly. using engine all. Do not orl excess,vely. 16 " Ih e dr'veshnlt hilS heen .emoved. firSt re fi t th e thru st wash ers below tho action plnte. bolore "'se,ting the S h .l h into thc disl. ih llto,
hody . FII the w3vy washer .Jnd IhrUSI washcr to the lowe! end 01 the shah and then relilthe ge.Jr. secuJlnU it with a new spring p in. II a now gear. or a ne w u"ves hnfL h,15 been fllt ed . a n\lW hole should be d"lIed .1t 90' 1 0 Ihe e~is'U1g hole 17 Alte • .Jssemhhng the centJll ug.J 1 weIgh ts .Jnd sprrngs. check that Ihl!Y movo hccly. w,thout I)inding, 18 8clOle assemblmg Ihe breaker pla tcs . make sure thill the three nylon bearing slUds a.e located "1 tht) h oles ,n the uPllC' uearinU plale and Ih3tthe e.Jrth,ng sprrng ,s foiled to the p,vOt post 19 On complet'on of assemlJly. adlust the conlnCl b'eake , gilp to the spc cified selling
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104 Chapter 6 Manual g earbox and autom ati c transmission )
PART 1, MANUAL GEARBOX
Gener"l description
The nl 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 Ge;u$ "re ell!J 2 ROlltine Illainten,lIlce
At the "It,,"v "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"'~J ,I s\III, II,le SqLl,lIU key. un~r:",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: 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(;"'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'("ltI~1 h" ""'w""" 1 0 0 ""d 150 """ (0 <1 alld 0 G 'n) 1,,;low 110" I)()UDl Il "d~I'! of Ihe I'lu~1 hoi,!
G WI",,,! "'";"s~.,,y top "I' l h " lev,,! with II", ~1'(!<: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.11le. 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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·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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~10 Chap ter 6 Manual gearbo)( an d automatic transm iss io n
operlltlon. looseness between the inner ;mel oulC. ';)ces. imd 10f genera' wear. NOfIll.llly they should be .enewed on a gearbox lh<11 IS being .ebuil l. 8 II Clther 0' the synchrOnise. unllS ;nc WOUl II w Ill be ncccssmy 10 buy" complete assembly as the Pill ts ,lIC not sold individually. Also check the sliding keys 10' we;'!. 9 Examine tho ends 0' IhO scl(!C I(ll' lor ks where they rub "g.1In51 the channels in the peJiphery of the synchrOntSfl f units_If I)()Ss,ble cOIllp.."e the sclecw. lorks with new Units to hell) dC1Crminc the weill lh,,1 h,IS occtJUcd Renew thelll " worn. 10 If the bCilring bUSh ,n Ihe CXI(mSlon is b;uliy worn II,s OOS110 [ J Ge1Hbox (4·speed) -reassembly
When any hOlt screws "110 a throuUh hor". JOllll11\!J COlllpnulI/t Should hc nj)lllted to I he lhwads 011l11! holl helorc It ," InS/"h~1 2 Fit Ihe /cve.so Idle. He"r WIlli Ihc It,oolle on the !le;1I tuw;IId,. Ih,' lenr.lnsel! Ihe .dle, s h ah nnll dlllle 11111 with .1 pla~t.c·IIIl:IIIt].1 h;""""" unllllhc OOltOnl ollhe Slel) on the end ollhe shalt.s IIIIsh WIth lhl! ,,11.1 0 1 the gCJloox. Thc mIlled " t he OIl lellHn horo 01 Ihe Ui ls k e l ,1nd tW:illnlJ IfJlilinur .lte ah\jl1fJd as III
FlU. 6 13 Apply 101ll1lng compoullll to the threilds 0 1 Ihe bolts. lIl~e SpecIIIC(ltIOns .
0,1
the new IIlput sh,ll! ncedle rollel heilrlllg ilnd push I t 11)10 tllC oJorc 01 the input sha ft Slide the lOP gC(lr synchroniser baulk IInu on to the cone olthe IIlJ)u I sha h 8 FIt the extension houSll19 gnske!. lhen InSerl the ,1s~",hlcd mainsha/t into Ihe rca. 01 the box anll (frille II III untIl the nose 01 Ihe Illalnsh~h is fully engaucd in I he II1PUI shilh necdle l>c,l11nU 9 Carefully lu.n the ge;ubox upSIde down. so thilt the layshalt \}e,lr elusler dIOI)S mto engJgelllenl with the malnshillt Jnd IIlpIII shalt Check thilt the gear and the two lluust wilshe.s il.e III line and then c,l.elully push in the layshalt from thc leal. If necessary till) Ihe S h ,ll! In with the p lasuc·headed IHI/llmer. bllt take grC;lI CJre not to dlslodUe Ihe thruSI washels or needle .olle.s . When fully home. the h Ollom of Ihe slep on the .dlel shalt shOuld be In hnc with Ihe face 01 the box and Ihe mIlled flats should be in IIno wllh the Idler shalt oo.e. 10 Turn the geilrbo~ the lighl w;ly UI) Jnd align the hole in the 1>.111 bemll1g SUpj)Orl WIth the dowcl on Ihc cxtcnsion housing. Fit the eXlenSlon housing. Apply jOlllllnu coml)ound to the ttlle<1ds of Ihe bolts. InSClt them and tightcn 10 thO torQuc wrench seHlng gillen In the SpeCll l
C3tions . 11 1/ a new cxtension bush has been fllle(1. check Ih~t the notch 01 011 groolle III II ilhgns wllh lhe o ll,elurn grOOlle In thoJ extension housing. If thc now exlension housinU 011 senl hilS not illready been filled. slide It Ollel the extension Shill t and enrelully tap it in wilh n h~nllller and n
b lock 01 wood.
1 2 FIt J ncw O ·ring to the spcedomeler pll110n assembly. relit the ~Sembly and f it the C llcli l) to socure i1. ,3 Inser t the r(,lIerse gear interlock plungel. ball and spring. Fllihe boll with aloek plate and lIl$crl tI,c l.Iol t. TIghten the boll and bend Ihe lock plilles to seCure ,to
Fig. 6.1 3 Posilionin g of Iront hearin\} .e lainer oil return \}Ioove (Sec 9)
=-*.------t---.---- ---
FiU . 6.14 R olitting the Inyshaft (Sec 9 )
A hlSC//ing /,1vs/!I!f/ B ClJflec / lIi1:qlll!!efl/ of /,J)'$/I,III illld 'fJve.se IdlfJf sl!,lfl
1/1 Insert ~II Ihrce selecto, 10l~s Into Ihcn I)ositlons 111 lhe gearl)o~ 15 Shllc 1~1/2n(1 \le,1r selector ,,111 through Ihe r,ghl-hilll(1 bo.e mille
I:ilse. Ihell tluead ,t through the 1 S I/2nd gCM selector lo.k Align Ihe holes 111 tile lo.k and r~11 ,111(/ t<1l) in the 101l1)ln. Insert the plunUe/ into thc c,lse 16 FIt Ihe pltlllgc/ '1110 Iho 3rd /lOI) ge,ll selecto. lad. inscrt lhe 'illl
t h .ough Ihe ccnHe hore III the C,lse ;lnd Ihread the raIl Ihrough Ihe 3rd 101) gea. sel()(: tor lo.k. Fit the clfchp to Ihe groolle ;n the se lecta' lilll Ahon Ihe holcS III the selectol 100k and ,;lil. insert the loll pIn and lal) .t home. 17 PUSh lellerSC gc,'1 seleelo, r;llt Ih/ough Ihe lelt·hand bore in the hou$"'g. and then thread 11 through the rellerse gear seleclol fork. Align Ihe holes III Iho IOrk and 101.1. inserl a roll pin and tap it home. 18 FIt Ihe interlock plungC/< apply sealing compound to the plug and dfille In Ihe plug 19 Inse!! ICllerSe ueJI ,clay lever and secu/c it wilh a roll pin. 20 Inse't thO sCleCtOr shalt ItHough the selcctol housing COllel and fit the co~er using a new gaskel Insert the COlier rewining bolts and screw them in Iingel lIghl. 21 FII the sel/lCIO' sh:lh b'lIcket 22 Shdo lhe S(lIOClOr flnge. onto the selec tol shalt. Eng~gc the strew III the ,ece~~ in th O shaft ~nd tIghten the sc rew. 23 0101) lhe Ihloo dctent ba lls 1I1tO thcir bores in t he casc. g1Case the thleo sprinus alld Ilise rt thcm Into the recesses 01 tile yeJ.1>ox COllel. FII
a new COlier gasket and positIon Ihe COllcr onto II Insert the COllel holtS and tlghtcn Ihem to tho 10Ique wrench suiting (Jillen III lhO SpeClf,callons
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