drain bolt FORD MUSTANG 1969 Volume One Chassis

04-04-07
Rear Axle — Ford Light-Duty (WER)
04-04-07

RUNOUT CHECK

E 1573-A

FIG. 70—Checking Backlash and Runout—Light-Duty (WER) Axle

All service operations on the differ-

ential case assembly can be performed

with the axle housing in the vehicle.

1.
Raise the vehicle on a hoist.

2.
Position the drain pan under the

axle housing. Loosen the housing

cover attaching bolts. Drain the lubri-

cant from the housing.

3.
Make scribe marks on the drive

shaft end yoke and the rear axle shaft

companion flange to insure proper po-

sition of the drive shaft at assembly.

Disconnect the driveshaft from the

rear axle companion flange. Be care-

ful to avoid dropping the loose univer-

sal joint bearing cups. Hold the cups

on the spider with tape. Mark the

cups so that they will be in their origi-

nal position in relation to the flange

when they are reassembled. Remove

the drive shaft from the transmission

extension housing. Install an oil seal

replacer tool in the transmission ex-

tension housing to prevent transmis-

sion leakage. Refer to the transmis-

sion group for the appropriate tool.

4.
Raise the vehicle and place

jack-type stands under the rear frame

crossmember. Lower the vehicle on a

hoist and allow the axle to lower as

far as possible.

5.
Remove the axle housing cover

and gasket. Discard the gasket.

6. Perform the Inspection Before

Disassembly of Carrier procedure.

Refer to Part 4-1, Section 3 of this

Shop Manual.

7.
Remove the attaching (Tinner-

man) nuts that secure the rear brake

drums to the axle shaft flanges, and

then remove the drums.

8. Working through the differential

case opening, remove the pinion shaft

lock bolt and pinion shaft (Fig. 2).

9. Push the axle shafts inward

toward the center of the axle housing.

Remove the C-locks (Fig. 3) from the

inner ends of the rear axles. Remove

the axle shafts from the housing. Ex-

treme care must be used to avoid con-

tacting the axle shaft seal lip with any
portion of the axle shaft except the

seal journal.

10.
Remove the bearings and oil

seals from the axle housing as shown

in Fig. 4.

11.
Remove the pinion side gears

and the side gear thrust washers.

12.
Remove both side bearing ad-

justing nut locks (bolts).

13.
Install a dial indicator (Fig. 10),

and check and record the backlash

and ring gear runout.

14.
Mark one differential bearing

cap and the case to help in positioning

the parts properly during assembly.

15.
Remove the bearing cap retain-

ing bolts. Remove the bearing caps,

cups,
adjusting nuts and case assem-

bly.

16.
Hold the drive pinion flange

and remove the pinion nut (Fig. 11).

Discard the nut.

17.
Remove the pinion flange (Fig.

12).

18.
Drive the pinion out of the

front bearing cone and remove it from

the carrier housing. Remove and dis-

card the bearing spacer.

19.
With a hammer and drift re-

move the pinion shaft oil seal out

through the front of the carrier hous-

ing.

20.
Remove the pinion rear bearing

from the drive pinion shaft (Fig. 13).

21.
Measure the shim which is

found under the bearing cone with a

Tool-T57L-485T-A

or 4851-K

El 906A
Tool
-
T6SL-485UA
\

E 1574-A

FIG. 12—Drive Pinion Flange

Removal

1575-A

FIG. 13—Pinion Rear Bearing

Removal

00/
- T57L-4220-A

FIG. 11—Typical Drive Pinion

Shaft Nut Removal
E 1576-A

FIG. 14—Differential Bearing

Removal

micrometer. Record the thickness of

the shim.

DISASSEMBLY OF

DIFFERENTIAL CASE

1.
If the 2 differential side bearings

are to be removed from the differen-

tial case, use the tool shown in Fig.

14.procarmanuals.com

04-05-04
Specifications

04-05-04

ATTACHING TORQUE SPECIFICATIONS -(By Axle Ring Gear Diameter)

Description

Differential Bearing Cap Bolt- 7 1/4"

8"

All Others

Differential Bearing Adjusting

Nut Lock Bolts

Carrier
to
Housing Stud Nuts-

8", 8 3/4", 9" 8 3/8"

Pinion Retainer
to
Carrier Bolts-

8", 8 3/4", 9" 9 3/8"

Ring Gear Attaching Bolts-

7 1/4"

All Others

Differential Pinion Shaft

Lock Pin
•
8 1/2" Only
Torque Lbs.
Ft.

40-55

55-70

70-85

12-25

25-40

30-45

40-55

65-80

15-22
Description

Rear Cover Screw and Washer

Assemblies
-8
1/4" &
8
1/2

Only

Oil Filler Plug

Rear Axle Shaft Bearing Retainer

Bolt Nuts:

Falcon,
Fairlane, Montego,

Mustang and Cougar (All)

Ford & Meteor (Exc.
8 1/2" R.G.)

Mercury,
T
Bird

Lincoln Continental (All)

Brake Backing Plate Bolt Nuts-

Ford & Meteor
8
1/2" Only
Torque Lbs.
Ft.

25-35

25-50

20-40

50-75

30-55

20-40

LUBRICANT
CAPACITIES
AND CHECKING PROCEDURES®

Vehicle

Falcon,
Mustang

Cougar, Fairlane, Falcon

Montego, Mustang

Ford,
Meteor

Ford,
Meteor

Cougar, Fairlane, Falcon, Ford,

Mercury, Meteor, Montego, Mustang

Lincoln,
Thunderbird
Engine

(C.I.D.)

170,
200

250,
302

240,
302

240,
302

351,
390,

428,
429

429,
460
Axle

Ratio

All

All

2.80:1,
3.10:1

All Except

2.80:1,
3.10:1

All

All
U.S. Measure

Capacity® (Pints)

2.5

4.0

4.0

5.0

5.0

5.0©
Imperial

Capacity
CD
(Pints)

2

31/5

3 1/5

4.0

4.0

4.0©

©All limited slip and Traction-Lok axles use ESW-M2C-104-A lubricant (C6AZ-19580-C).

All conventional axles use ESW-M2C-105-A lubricant (C6AZ-19580-B).

©Approximate refill capacity-Actual lubricant capacities are determined
by
filling
to
bottom
of
filler hole.

©To check these axles, the plug should be backed
out
slowly.
If
seepage occurs around the threads, the plug should
be
turned back
in

immediately to avoid any drainage. This indicates that the specified amount
of
lubricant
is
present
in
the axle.

SPECIAL TOOLS

FORD,
MERCURY, METEOR

Ford Tool No.

T66L-4204-L

T57L-500-A

T50T-100-A

TOOL-4235-C

T00L-4621-A

TOOL-1225-D

T00L42344

TOOL-1177

TOOL-U75-AB

T57L4220-A

T00L4221-AE

T00L-4221-AF

T66P-4220-P

TOOL-4851-K
Former No.

42211 or

42211-A

6005-M

6005-MS

B-160

4235C

—

—

4234-A

4245-B

1175-AB

—

4221-AF

T57L-4851-A

4851-K
Description

Limited-Slip Differential Check

Bench Fixture

Impact Hammer

Axle Shaft Remover

Drive Pinion Bearing and

Rear Wheel Bear Replacer

Rear Wheel Bearing Remover

Rear Wheel Bearing Installer

Rear Wheel Bearing Oil Seal Installer

Rear Wheel Bearing Oil Seal Remover

Differential Bearing Remover

Differential Bearing Remover

U-Joint
Flange Holder
Ford Tool No.

T53T4851-A

T00L4858-D

T57L4614-A

T00L4621-K

T53L-200-A

T57L-4625-A or

T00L4625-K

T57L4616-A or

T00L4615-D

T58L-101-A

T55P4616-A2

T57L4621-B or

T00L4621-L

T58L4676-A

T00L4858-E
Former No.

4851-A, D

—

4614

4621-K

—

4625-K

—

—

—

—

4676-F

4858-E
Description

U-Joint
Flange Remover

U-Joint
Flange Remover

Drive Pinion Retainer Support

Pinion Rear Bearing Cone Remover

Handle Adapter

Pinion Pilot Bearing Remover and

Installer

Pinion Front Bearing Cup Remover

and Replacer

Puller Attachment—For Bearing

Cup Removal

Pinion Rear Bearing Cup Remover

and Replacer

Pinion Rear Bearing Cone Installer

Drive Pinion Oil Seal Replacer

U-Joint
Flange and Pinion Bearing

Replacerprocarmanuals.com

06-02-04

Ford Design Three Speed Transmission

06-02-04

shift selector, remove
the
shift selector

assembly from
the
extension housing.

6.
On
Ford, Mercury
and
Meteor

vehicles disconnect
the
parking brake

cable from the equalizer lever and sep-

arate
the
lever from
the
crossmember.

7.
On
Ford, Mercury
and
Meteor

models, remove
the
bolts that secure

the extension housing
to the
engine

rear support.

8. Raise
the
rear
of
the engine high

enough
to
remove
the
weight from
the

crossmember.

9. Support
the
transmission with
a

transmission jack
and
remove
the

transmission from
the
flvwheel hous-

ing.

10.
Move
the
transmission and jack

rearward until
the
input shaft
is
clear

of
the
flywheel housing.

11.
Remove
the
transmission from

the jack
and
mount
it in a
holding

fixture.

Do
not
depress
the
clutch pedal

while
the
transmission
is
removed.

INSTALLATION

1.
Make certain that
the
machined

surfaces
of the
transmission case
and

the flywheel housing
are
free
of
dirt,

paint,
and
burrs.
2.
Install
a
guide
pin in
each lower

mounting bolt hole.

3.
Start
the
input shaft through
the

release bearing. Align
the
splines
on

the input shaft with
the
splines
in the

clutch disc. Move
the
transmission

forward
on the
guide pins until
the

input shaft pilot enters
the
bearing
or

bushing
in the
crankshaft.
If the

transmission front bearing retainer

binds
up on the
clutch release bearing

hub,
work
the
release bearing lever

until
the hub
slides onto
the
transmis-

sion front bearing retainer. Install
the

two transmission-to-flywheel housing

upper mounting bolts
and
lockwash-

ers.
Remove
the two
guide pins
and

install
the
lower mounting bolts
and

lock washers.

4.
Raise
the
rear
of the
engine high

enough
to
provide clearance
for in-

stalling
the
crossmember. Bolt
the

crossmember assembly
to the
frame

side supports.

5.
On
Ford, Mercury
and
Meteor

models, lower
the
engine until
the ex-

tension housing just contacts
the
rear

support. Align
the
bolt holes
in the

extension housing with those
in the

support. Then lower
the
engine
and

remove the jack. Install the two exten-

sion housing-to-support attaching
bolts
and
lock washers.

6.
On
Ford, Mercury
and
Meteor

models, insert
the
parking brake front

cable
in the
equalizer
and
install
the

equalizer
in the
bracket
on the

crossmember. Secure
the
parking

brake rear cable
to the
equalizer.

7.
On
vehicles equipped with
a

column-mounted gear shift selector,

secure
the
shift rods
to the
shift levers

at
the
transmission.
On
vehicles

equipped with
a
floor-mounted gear

shift selector, attach
the
shift selector

assembly
to the
extension housing.

8. Insert
the
speedometer cable
and

driven gear
in the
extension housing

and secure
it
with
a cap
screw
and

lock washer.

9. Remove
the
tool shown
in
Fig.
2,

Part 6-1, from
the
extension housing.

Align
the
reference marks
and
slide

the front universal joint yoke onto
the

output shaft
and
into
the
extension

housing. Connect
the
rear universal

joint
to the
axle pinion flange
and tor-

que
the
nuts
to
specifications.

10.
Fill
the
transmission
to the

proper level with
the
approved lubri-

cant.

11.
Adjust
the
clutch pedal free

travel
and the
shift linkage
as re-

quired.

MAJOR REPAIR OPERATIONS

DISASSEMBLY

1.
Mount
the
transmission
in a

holding fixture and drain
the
lubricant

by removing
the
drain plug,
if so

equipped,
or the
lower extension hous-

ing bolt.

2.
Remove
the cap
screws that
at-

tach
the
cover
to
the case. Remove
the

COVER
cover
and the
gasket (Fig.
5)
from
the

case.

3.
Remove
a
long spring that
re-

tains
the
detent plug
in the
case (Fig.

9).
Remove
the
detent plug with
a

small magnet.

4.
Remove
the cap
screws
and
lock

washers that attach
the
extension

housing
to
the case. Remove extension

FRONT

BEARING RETAINER

C2069-A
and gasket from
the
case.

5.
Remove
the cap
screws
and
lock

washers that attach
the
front bearing

retainer
to the
case. Remove
the
front

bearing retainer
and
gasket from
the

case.

6. Remove
the
lubricant filler plug

from
the
right side
of the
case. Work-

ing through
the
plug opening, drive

the roll
pin out of the
case
and
coun-

tershaft with
a
1/4-inch
punch
(Fig.

6).

TERSHAFT'
#

PIN

C 1841-A

FIG. 5—Transmission Case
and
Related Parts—Typical
FIG. 6—Removing Countershaft

Roll
Pinprocarmanuals.com

06-03-03
Ford Design Four-Speed Transmission
06-03-03

cable from the equalizer lever and sep-

arate the lever from the crossmember.

5.
Remove the hairpin retainer se-

curing the cable to the transmission

rear support crossmember, and then

pull the cable assembly forward and

out of the crossmember.

6. Remove the retaining clip, flat

washer, and spring washer that se-

cures the shift rods to the shift levers.

7.
Remove the bolts that attach the

shift linkage control bracket to the ex-

tension housing and position the as-

sembly out of the way.

8. Support the engine with a trans-

mission jack and remove the extension

housing-to-engine rear support attach-

ing bolts.

9. Raise the rear of the engine high

enough to remove the weight from the

crossmember. Remove the bolts re-

taining the crossmember to the frame

side supports and remove the

crossmember.

10.
Support the transmission on a

jack and remove the bolts that attach

the transmission to the flywheel hous-

ing.

11.
Move the transmission and jack

rearward until the transmission input

shaft clears the flywheel housing. If

necessary, lower the engine enough to

obtain clearance for transmission re-

moval.

Do not depress the clutch pedal

while the transmission is removed.
INSTALLATION

1.
Make sure that the mounting

surface of the transmission and the

flywheel housing are free of dirt,

paint, and burrs. Install two guide

pins in the flywheel housing lower

mounting bolt holes. Move the trans-

mission forward on the guide pins

until the input shaft splines enter the

clutch hub splines and the case is posi-

tioned against the flywheel housing.

2.
Install the two upper transmis-

sion to flywheel housing, mounting

bolts snug, and then remove the two

guide pins. Install the two lower

mounting bolts. Torque all mounting

bolts to specifications.

3.
Raise the rear of the engine and

install the crossmember. Install and

torque the crossmember attaching

bolts to specifications, then lower the

engine.

4.
With the transmission extension

housing resting on the engine rear

support, install the transmission ex-

tension housing attaching bolts. Tor-

que the bolts to specifications.

5.
Position the shift linkage control

bracket to the extension housing and

install the attaching bolts.

6. Secure each shift rod to its re-

spective lever with the spring washer,

flat washer, and retaining pin.

7.
Guide the parking brake cable

assembly through the hole in the
transmission rear support crossmemb-

er. Secure the cable assembly to the

crossmember with the hair pin retain-

er.

8. Insert the parking brake front

cable in the equalizer and install the

equalizer in the bracket on the

crossmember. Secure the parking

brake rear cable to the equalizer.

9. Connect the speedometer cable

to the extension housing.

10.
Remove the extension housing

installation tool and slide the forward

end of the drive shaft over the trans-

mission output shaft. Connect the

drive shaft to the rear U-joint flange.

11.
Place both forward gear shift

levers and the reverse shift lever in the

neutral position and insert a 1/4 inch

diameter alignment tool in the shift

linkage alignment hole (Fig. 17). It

may be necessary to loosen the adjust-

ment nuts to install the alignment

tool. Adjust the linkage as necessary

and tighten the adjustment nuts to

specifications. Remove the alignment

tool.

12.
Fill the transmission to the

proper level with the specified lubri-

cant.

13.
Lower the car. Check tne shift

and crossover motion for full shift en-

gagement and smooth crossover oper-

ation.

MAJOR REPAIR OPERATIONS

DISASSEMBLY

1.
Mount the transmission in a

holding fixture and drain the lubri-

cant.

2.
Remove the cover attaching

screws from the case. Lift the cover

and gasket from the case.

3.
Remove the long spring that re-

tains the detent plug in the case (Fig.

4).
Remove the detent plug with a

small magnet.

4.
Remove the extension housing

attaching screws and lock washers.

Remove the housing and the gasket.

5.
Remove the input shaft bearing

retainer attaching screws. Slide the re-

tainer off the input shaft.

6. Support the countershaft gear

with a wire hook. Working from the

front of the case, push the counter-

shaft out the rear of the case as shown

in Fig. 3. Lower the countershaft to

the bottom of the case with the wire

hook. Remove the hook.
Tool-T64P-711hA

COUNTERSHAFT

C2073-A

FIG. 3—Removing Countershaft

From Case

7.
Place the first and second-speed

gear shift lever and the reverse shift

lever in the neutral position. Place the

third and fourth-speed gear shift lever

in the third-speed position.

8. Remove the attaching screw

from the third and fourth-speed shift

fork. Tap on the inner end of the shift

rail to unseal the expansion plug from
the front of the case. Then withdraw

the third and fourth-speed shift rail

from the front of the case. Do not

lose the interlock pin from the shift

rail.

9. Remove the set screw from the

first and second-speed shift fork.

Slide the first and second-speed shift

rail out the rear of the case.

10.
Remove the interlock plug and

the detent plug from the top of the

case (Fig. 4) with a magnet.

11.
On some models, remove the

snap ring that secures the speedometer

drive gear to the output shaft. Slide

the gear off the shaft, then remove the

speedometer gear drive ball. On mod-

els equipped with the new design re-

tainers, depress the tang on the speed-

ometer drive gear retaining clip and

slide the speedometer gear off the

shaft. (Fig. 5).

12.
Remove the snap ring that se-

cures the output shaft bearing to the

shaft.procarmanuals.com

06-03-09
Ford Design Four-Speed Transmission

06-03-09

24.
Place a detent plug (Fig. 5) in

the detent bore. Place the reverse shift

rail into neutral position.

25.
Coat the third and fourth-

speed shift rail interlock pin with

grease and position it in the shift rail.

26.
Align the third and fourth-

speed shift fork with the shift rail

bores and slide the shift rail into place

making sure that the three detents are

facing toward the outside of the case.

Place the front synchronizer into

third-speed position and install the set

screw in the third and fourth-speed

shift fork. Move the synchronizer to

the neutral position. Install the third

and fourth-speed shift rail detent plug,

spring and bolt in the left side of the

transmission case (Fig. 5). Place the

interlock plug (tapered ends) in the

detent case.

27.
Align the first and second-

speed shift fork with the case bores

and slide the shift rail into place. Se-

cure the fork with the set screw.

28.
Coat the input gear bore with a

thin film of grease, then install the 15

roller bearings in the bore. A thick

film of grease could plug the lubricant

holes and restrict lubrication of the

bearings.

29.
Position the front blocking ring

in the third and fourth-speed synchro-

nizer.

Place the input shaft gear in the

transmission case making sure that

the output shaft pilot enters the roller

bearings in the input gear.

30.
Place a new gasket on the input

shaft bearing retainer. Dip the attach-

ing bolts in sealer and install and

tighten them to specifications.

31.
Install the output shaft bearing

as shown in Fig. 21. Install the snap

ring to retain the bearing.

32.
On some transmissions, position

the speedometer gear iometer drive

gear retaining clip on the output shaft

with the lower tang in the retaining

hole.
Align the groove in the gear with

the clip and slide the gear forward

until the upper tang on the clip locks

the gear (Fig. 4).

33.
Place the transmission in a ver-

tical position as shown in Fig. 22.

Align the countershaft gear bore and

thrust washers with the bore in the

case.
Install the countershaft.

34.
Use a new gasket and secure

the extension housing to the case with

the attaching screws. Use a sealer on

the extension housing attaching

screws. Torque the screws to specifica-

tions.

35.
Install the filler plug and drain

plug (if so equipped) in the case if

they were removed. Make sure that
COUNTIERSHAFT

7111

RETAINER WASHER

378559 • S

THRUST WASHER -7119

THRUST

WASHER

7119
ROLLER BEARINGS- 7121(21)

COUNTERSHAFT GEAR - 7113

ROLLER BEARINGS'7121(21)

RETAINER

WASHER

378559 • S

FIG. 17—Countershaft Gear Disassembled
C2081-A

REVERSE IDLER

GEAR SHAFT

7140

ROLLER BEARINGS

7D271 22)

THRUST WASHER

7149

RETAINER

WASHER

351529 - S

REVERSE IDLER GEAR -7142

'REVERSE SLIDING GEAR • 7D223

•THRUST WASHER • 7149

FIG. 78—Reverse Idler Gear Disassembled
C2082-A

the magnetic plug (if so equipped) is

installed in the bottom of the case.

36.
Pour the specified lubricant

over the entire gear train while rotat-

ing the input shaft.

37.
Place each shift fork in all posi-

tions to make sure that they operate

properly.

38.
Install the remaining detent

plug in the case. Install the long

spring (which is retained by the case)
to secure the detent plug.

39.
Use a new cover gasket and in-

stall the cover. Coat the cover attach-

ing screws with sealer and install and

tighten them to specifications.

40.
Coat the third- and fourth-

speed shift rail plug bore with a sealer

and install a new expansion plug.

41.
If the extension housing bush-

ing and seal are to be replaced, refer

to Section 1.procarmanuals.com

06-04-02

Specifications

06-04-02

TORQUE LIMITS(FT-LBS)

Extension Housing Bolts

Input Shaft Bearing Retainer-to-Transmission Case Bolts

Speedometer Cable Retainer-to-Transmission Extension

Transmission-to-Flywheel Housing Bolts

Gearshift Control Levers to Cam and Shaft Assembly Lock Nuts

Transmission Cover Bolts

Filler Plug-to-Case

Drain Plug-to-Case

Shift Fork-to-Shift Rail

Third and Fourth Shift Rail Detent Bolt

Gear Shift Control Assembly
to
Transmission Extension

Shift Selector Levers to Shift Rods

Gear Shift Control Support Bracket
to
Back Plate
3-Speed

Transmissions

42-50

30-36

3.0-4.5

37-42

18-23

14-19

10-20

20-30

10-18

-

8-12

10-20

-
4-Speed

Transmissions

42-50

19-25

3.0-4.5

37-42

18-23

14-19

10-20

20-30

10-18

10-18

8-12

10-20

8-13
® Inch-pounds

SPECIAL TOOLS
SPECIAL TOOLS (Continued)

Tool Numbers

T50T-100A

T59L-100B

Tool-1175AB

T53T-4621-Bor(4621-F)

T57L-4220-A4

T52L-7000-GAE

T63P-7025-A

T64P-7025-B

T53T-4621-C
Description

Impact Hammer-Long

Impact Hammer-Short

Grease Seal Remover

Drive Pinion Bearing Cone

Replacer Front
&
Rear

Differential Side Bearing Cone

Replacer
or
Input Shaft Bearing

Remover

Extension Housing Bushing and

Seal Remover

Output Shaft Bearing Remover

& Replacer

Output Shaft Bearing Remover

& Replacer

Drive Pinion Bearing

Cone Replacer
Tool Numbers

Tool-7025-B

Tool-7025-G

T64P-7111-A

T63P-7111-A

T64P-7140-A

T61L-7657-A

T57P-7697-B

T57P-7657-G

T67P-7341-A
Description

Rear Main Shaft Bearing Removei

Main Shaft Bearing Remover

& Replacer

Cluster Gear Roller Retainer Shaf

Cluster Gear Roller Retainer Shaft

Reverse Idler Shaft Remover

Transmission Extension Housing

Oil Seal Replacer

Extension Housing

Bushing Replacer

Extension Housing

Bushing Replacer

Shift Linkage Grommet

Replacerprocarmanuals.com

07-01-04
General Transmission Service

07-01-04

taching bolts to the proper torque. If

necessary, replace the gasket.

Check the fluid filler tube connec-

tion at the transmission case or pan.

If leakage is found here, install a new

O-ring or tighten the fitting to the

specified torque.

Check the fluid lines and fittings

between the transmission and the

cooler in the radiator tank for loose-

ness,
wear, or damage. If leakage can-

not be stopped by tightening a fitting,

replace the damaged parts.

Check the engine coolant in the ra-

diator. If transmission fluid is present

in the coolant, the cooler in the radia-

tor is probably leaking.

The cooler can be further checked

for leaks by disconnecting the lines

from the cooler fittings and applying

50-75 psi air pressure to the fittings.

Remove the radiator cap to relieve the

pressure build at the exterior of the oil

cooler tank. If the cooler is leaking

and will not hold this pressure the

cooler must be replaced. Cooler re-

placement is described in the Cooling

System Section of Group 11.

If leakage is found at either the

downshift control lever shaft or the

manual lever shaft, replace either or

both seals.

Inspect the pipe plug on the left

side of the transmission case at the

front. If the plug shows leakage, tor-

que the plug to specifications. If tight-

ening does not stop the leaks, replace

the plug. On a C6 transmission, a TV

pressure plug is also provided on the

right rear side of the case.

When converter drain plugs leak,

remove drain plugs with a six-point

wrench. Coat the threads with FoMo-

Co Perfect Seal Sealing Compound or

its equivalent, and install the plugs.

Torque the drain plugs to specifica-

tion. Fluid leakage from the converter

housing may be caused by engine oil

leaking past the rear main bearing or

from oil gallery plugs, or power steer-

ing oil leakage from steering system.

Be sure to determine the exact cause

of the leak before repair procedures

are started.

Oil-soluble aniline or fluorescent dyes

premixed at the rate of 1/2 teaspoon

of dye powder to 1/2 pint of transmis-

sion fluid have proved helpful in locat-

ing the source of the fluid leakage.

Such dyes may be used to determine

whether an engine oil or transmission

fluid leak is present or if the fluid in

the oil cooler leaks into the engine

coolant system. A black light, how-

ever, must be used with the fluorescent

dye solution.
DISHED OR

FLAT WASHER

" O.D.,
a" STEEL PLATE

5/8"X \W,

DRILL TO SUIT
HEX. HEAD SCREW

3/8"-24 X Vl

HEX. NUT W—
24

WELD

TOGETHER

WING
NUT

>/2"_13
THREAD

CHAIN,
10"
LONG
RUBBER PLUG

1
Vi" DIA. X 2"

LONG Vl"

HOLE THRU

APPROXIMATELY

40 DUROMETER
FLAT WASHER

Vs" O.D.

PLUG

VALVE
STANDARD BOLT

W-13
X 4Vl"

LONG SQUARE

THREAD
END

REMOVE HEAD

AND WELD
TO

WASHER

STANDARD 1/8" FITTING-87971-S FOR

RETAPPED DRAIN PLUG THREADS-USE

1/4" OVERSIZE FITTING-87973-S

D 1067-B
WELD TOGETHER

SECURELY—MUST

NOT LEAK

FIG. 2—Converter Leak Checking Tool

CONVERTER LEAKAGE

CHECK

If there are indications that the

welds on the torque converter are

leaking, the converter will have to be

removed and the following check

made before the unit is replaced.

A leak checking tool (Fig. 2) can be

made from standard parts. The tool

can be used to check all converters.

1.
Install the plug in the converter

(Fig. 3) and expand it by tightening

the wing nut. Attach the safety chains.

2.
Install the air valve in one of the

drain plug holes.

3.
Introduce air pressure into the

converter. Check the pressure with a

tire gauge and adjust it to 20 psi.

4.
Place the converter in a tank of

water. Observe the weld areas for

bubbles. If no bubbles are observed, it

may be assumed that the welds are

not leaking.

ENGINE IDLE SPEED CHECK

Check and, if necessary, adjust the

engine idle speed, using the procedure

given in Group 10.

If the idle speed is too low, the en-

gine will run roughly. An idle speed

that is too high will cause the vehicle

to creep, have harsh engagements and

harsh closed-throttle downshifts.
ANTI-STALL DASHPOT

CLEARANCE CHECK

After the engine idle speed has been

properly adjusted, check the anti-stall

dashpot clearance. Follow the proce-

dure given in Group 10 for checking

and adjusting this clearance.

MANUAL LINKAGE CHECKS

Correct manual linkage adjustment

is necessary to position the manual

valve for proper fluid pressure direc-

tion to the different transmission com-

ponents. Improperly adjusted manual

Tire Pressure Gauge

D1921-A

FIG. 3—Converter Leak Checking

Tool Installationprocarmanuals.com

07-01-08
General Transmission Service

07-01-08

3.
Install the bench testing tool on

the transmission.

4.
Remove the
1/8-inch
pipe plug

at the transmission case. Turn the

front pump in a clockwise direction at

75-100 rpm until a regular flow of

transmission fluid leaves the hole in

the transmission case. This operation
bleeds the air from the pump.

5.
Install the pressure gauge (77820

or T57L-77820-A) as shown in Fig.

13.

PRESSURE TESTS

Turn the front pump at 75-100 rpm
and note the gauge readings. The

pressure readings on the bench test

must be within the limits as outlined

in Figure 13, for the engine idle check.

If pressure gauge readings are with-

in limits in all selector lever positions,

install the vacuum diaphragm control

rod unit.

COMMON ADJUSTMENTS AND REPAIRS

TRANSMISSION FLUID DRAIN

AND REFILL

Normal maintenance and lubrica-

tion requirements do not necessitate

periodic automatic transmission fluid

changes.

If a major repair, such as a clutch

band, bearing, etc., is required in the

transmission, it will have to be re-

moved for service. At this time the

converter, transmission cooler and

cooler lines must be thoroughly

flushed to remove any dirt.

When filling a dry transmission and

converter, install five quarts of fluid.

Start the engine, shift the selector

lever as outlined below, and check and

add fluid as necessary.

Following are the procedures for

partial drain and refill due to in-

vehicle repair operation.

C4 TRANSMISSION

1.
On PEA models, disconnect the

fluid filler tube from the transmission

oil pan to drain the fluid.

On PEB and PEE models, loosen

the pan attaching bolts to drain the

fluid from the transmission.

2.
When the fluid has stopped

draining from the transmission, re-

move and thoroughly clean the pan

and the screen. Discard the pan gas-

ket.

3.
Place a new gasket on the pan,

and install the pan on the transmis-

sion.

4.
On PEA models, connect the

filler tube to the pan and tighten the

fitting securely.

5.
Add three quarts of fluid to the

transmission through the filler tube.

6. Run the engine at idle speed for

about two minutes, and then run it at

fast idle speed (about 1200 rpm) until

it reaches it's normal operating temp-

erature. Do not race the engine.

7.
Shift the selector lever through

all the positions, place it at P, and

check the fluid level. The fluid level

should be above the ADD mark. If
necessary, add enough fluid io the

transmission to bring the level be-

tween the ADD and FULL marks on

che dipstick. Do not overfill the trans-

mission.

FMX OK C6

TRANSMISSION

1.
Raise the vehicle on a hoist or

jack stands.

2.
Place a drain pan under the

transmission.

3.
Loosen the pan attaching bolts

to drain the fluid from the transmis-

sion.

4.
After the fluid has drained to the

level of the pan flange, remove the

rest of the pan bolts working from the

rear and both sides of the pan to

allow it to drop and drain slowly.

5.
When the fluid has stopped

draining from the transmission, re-

move and thoroughly clean the pan

and the screen. Discard the pan gas-

ket.

6. Place a new gasket on the pan,

and install the pan on the transmis-

sion.

7.
Add three quarts of fluid to the

transmission through the filler tube.

8. Run the engine at idle speed for

about two minutes, and then run it at

fast idle speed (about 1200 rpm) until

it reaches normal operating tempera-

ture.
Do not race the engine.

9. Shift the selector lever through

all the positions, place it at P, and

check the fluid level. The fluid level

should be above the ADD mark. If

necessary, add enough fluid to the

transmission to bring the level be-

tween the ADD and FULL marks on

the dipstick. Do not overfill the trans-

mission.

OIL COOLER TUBE

REMOVAL AND INSTALLATION

When fluid leakage is found at the

oil cooler, the cooler must be re-

placed. Cooler replacement is de-

scribed in the Cooling System Section

of Group 11.
When one or more of the fluid

cooler steel tubes must be replaced,

each replacement tube must be fabri-

cated from the same size steel tubing

as the original line.

Using the old tube as a guide, bend

the new tube as required. Add the

necessary fittings, and install the tube.

After the fittings have been tight-

ened, add fluid as needed, and check

for fluid leaks.

VACUUM DIAPHRAGM

ADJUSTMENT NON-ALTITUDE

COMPENSATING TYPE

The C4 and C6 transmissions are

equipped with an adjustable vacuum

diaphragm assembly. A similar ad-

justable diaphragm has been released

for service with the FMX transmis-

sion. However, the FMX service dia-

phragm is not interchangeable with

that used on C4 and C6 models.

The vacuum diaphragm assembly

has an adjusting screw in the vacuum

hose connecting tube (Fig. 14).

SPRING

SEAT

THIS CLEARANCE CHANGED

BY ADJUSTING SCREW

D1830-A

FIG. 14—Adjustable Vacuum Unit

The inner end of the screw bears

against a plate which in turn bears

against the vacuum diaphragm spring.

All readings slightly high or all

readings slightly low may indicate the

vacuum unit needs adjustment to cor-

rect a particular shift condition.procarmanuals.com

07-02-09
C4 Automatic Transmission

07-02-09

11.
Remove the handle from the se-

lector lever.

12.
Install the selector housing and

lever assembly as shown in Figure 8.

Torque the attaching bolts 4-6 ft-lbs.

13.
Connect the dial indicator light.

14.
Install the pointer back-up

shield on the housing and lever assem-

bly.

15.
Install the dial housing and

tighten the attaching screws.

16.
Install the selector lever handle

and tighten the attaching screw.

17.
Position the selector lever in the

D position.

18.
Raise the vehicle. Install the

transmission manual lever rod to the

selector lever. Adjust the manual link-

age.

19.
Lower the vehicle and check the

transmission operation in each selo:c-

tor lever detent position.

BAND ADJUSTMENT

INTERMEDIATE BAND

1.
Clean all the dirt from the band

adjusting screw area. Remove and dis-

card the locknut.

2.
Install a new locknut on the ad-

justing screw. With the tool shown in

Fig. 13, tighten the adjusting screw

until the tool handle clicks. The tool is

a pre-set torque wrench which clicks

and overruns when the torque on the

adjusting screw reaches 10 ft-lbs.

I D1854-A

FIG. 13—Adjusting Intermediate

Band

Tool-T59P-77370-B

D1855-A

FIG. 14—Adjusting Low-Reverse

Band
3.
Back off the adjusting screw ex-

actly 1 3/4 turns.

4.
Hold the adjusting screw from

turning and torque the lock nut to

specification.

LOW-REVERSE BAND

1.
Clean all the dirt from the band

adjusting screw area. Remove and dis-

card the locknut.

2.
Install a new locknut on the ad-

justing screw with the tools shown in

Fig. 14, tighten the adjusting screw

until the tool handle clicks. The tool is

a pre-set torque wrench which clicks

and overruns when the torque on the

adjusting screw reaches 10 ft-lbs.

3.
Back off the adjusting screw ex-

actly 3 full turns.

4.
Hold the adjusting screw from

turning and torque the lock nut to

specification.

OIL PAN AND CONTROL

VALVE BODY REPLACEMENT

1.
Raise the vehicle so the trans-

mission oil pan is accessible.

2.
Drain the transmission fluid.

If the same fluid is to be used

again, filter the fluid through a 100

mesh screen. Re-use the fluid only if it

is in good condition.

3.
Remove the transmission fluid

pan attaching bolts, pan and gasket.

4.
Remove the valve body-to-case

attaching bolts (Fig. 25). Remove the

valve body from the case and the

transmission inner control levers.

5.
Refer to the Major Repair Oper-

ation for control valve body repair op-

eration.

6. Thoroughly clean and remove all

the gasket material from the pan and

the pan mounting face of the case. In-

stall the valve body to the case, engag-

ing the transmission inner control le-

vers with the valve body manual and

downshift valves.

7.
Install the eight valve body to

case attaching bolts. Torque the bolts

to specification. Operate the external

manual and downshift levers to check

for proper travel of the valve body

manual and downshift valves.

8. Place a new gasket on the pan.

Install the pan and attaching bolts.

Torque the bolts to specification. In-

stall the fluid filler tube if it was re-

moved. Torque the attaching nut to

specifications.

9. Lower the vehicle and fill the

transmission with fluid. Check the

transmission pan area for fluid leak-

age.
INTERMEDIATE SERVO

REPLACEMENT

1.
Raise the vehicle and remove the

four servo cover-to-case attaching

bolts.

2.
Remove the servo cover, gasket,

piston, and piston return spring. Re-

move the piston from the cover (Fig.

45).

3.
Remove the piston seals and

cover gasket.

4.
Install new piston seals on the

piston. Lubricate the piston seals with

clean transmission fluid. Install the

servo piston in the cover.

5.
Install the piston retvrn spring in

the case. Place a new gasicet on the

cover. Install the piston and cover into

the transmissic se. Use two 5/16

18 x 1 1/4 bolts, 180 degrees apart to

position the cover against the case.

6. Install the two servo cover at-

taching bolts. Remove the two 1 1/4

inch bolts and install two attaching

bolts.
Torque the bolts to specifica-

tion.

7.
Adjust the intermediate band.

Lower the vehicle and check the trans-

mission fluid level.

8. If the band can not be adjusted

properly, the struts are not in posi-

tion. Remove the pan and valve body.

Install the struts, valve body, pan, and

adjust the band. Refill the transmis-

sion with fluid.

LOW-REVERSE SERVO

PISTON REPLACEMENT

1.
Raise the vehicle on a hoist.

2.
Loosen the reverse band adjust-

ing screw lock nut. Tighten the reverse

band adjusting screw to 10 ft-lbs tor-

que.
(Tightening the screw will insure

that the band strut will be held against

the case by the band, preventing it

from falling down when the reverse

servo piston assembly is removed).

3.
Remove the four servo cover to

case attaching bolts. Remove the iden-

tification tag and vent tube retaining

clip.
Remove the servo cover and s»»^

from the case.

4.
Remove the servo piston from

the case. The piston seal cannot be re-

placed, without replacing the piston.

The seal is bonded to the piston.

5. To remove the piston from the

stem, insert a small screw driver in the

hole of the piston (Fig. 44). Remove

the piston attaching nut.

6. Position the accumulator spring

and spacer (Fig. 43) on the piston

stem. Make sure the crowned side of

the spring is facing toward the rod.

Install.a new piston on the piston re-

taining shaft. Install the attaching nut.

Torque the nut to specification.procarmanuals.com

07-02-10
C4 Automatic Transmission

07-02-10

7.
Install
the
piston into
the
case.

Install
a new
seal
on the
cover. Install

the cover
by
using
two
5/16—18 bolts,

1
1/4
inch long,
at
180
degrees apart

to position
the
servo cover
on the

case.
Install
the
vent tube retaining

clip
and
identification
tag.
Install
two

cover attaching bolts. Remove
the two

installing bolts
and
install
the
last
two

attaching bolts. Torque
the
cover-

to-case attaching bolts
to
specifica-

tion.

8. Adjust
the
low-reverse band.

Lower
the
vehicle
and
check
the
trans-

mission fluid level.

9.
If the
band
can not be
adjusted

properly,
the
struts
are not in
posi-

tion. Remove
the
fluid
pan and
valve

body. Install
the
struts, valve body,

pan
and
adjust
the
band. Refill
the

transmission with fluid.

EXTENSION HOUSING

BUSHING
AND
REAR

SEAL REPLACEMENT

1.
Disconnect
the
drive shaft from

the transmission.

2.
When only
the
rear seal needs

replacing, carefully remove
it
with
a

tapered chisel
or the
tools shown
in

Fig.
15.
Remove
the
bushing
as
shown

in
Fig. 16. Use the
bushing remover

carefully
so
that
the
spline- seal
is not

damaged.

3.
When installing
a new
bushing

use
the
special tool shown
in
Fig.
17.

4.
Before installing
a new
seal,
in-

spect
the
sealing surface
of the
univer-

sal joint yoke
for
scores.
If
scores
are

found, replace
the
yoke.

5.
Inspect
the
counterbore
of the

housing
for
burrs
and
remove with

crocus cloth.

6. Install
the
seal into
the
housing

with
the
tool shown
in Fig. 18. The

seal should
be
firmly seated
in the

bore.
Coat
the
inside diameter
of the

fiber portion
of the
seal with
B8A-

19589-A lubricant.

7.
Coat
the
front universal joint

spline with B8A-19589-A lubricant

and install
the
drive shaft.

EXTENSION HOUSING
AND

GOVERNOR REPLACEMENT

1.
Raise
the
vehicle
on the
hoist.

2.
Remove
the
drive shaft. Position

the transmission jack
to
support
the

transmission.

3.
Remove
the
speedometer cable

from
the
extension housing.

4.
Remove
the
extension housing
to

crossmember mount attaching bolts.

Raise
the
transmission
and
remove
the

mounting
pad
between
the
extension

housing
and the
crossmember.
Tool—
I775-AB

Tool—
T50T-100-A

FIG. 15—Removing Extension Housing

EXTENSION HOUSING

rIG. 16—Removing Extension

Housing Bushing

BUSHING

I Tool—T57P-76 7-B

^mmmfm^
0^7000-Ht

EXTENSION HOUSING
D1O26-B

FIG. 17—Installing Extension

Housing Bushing
D 1927-A

5.
Loosen
the
extension housing
at-

taching bolts
to
drain
the
transmission

fluid. Disconnect
the
exhaust inlet

pipes
at the
manifold
and
lower
the

inlet pipes.

6. Remove
the six
extension

housing-to-case attaching bolts
and re-

move
the
extension housing.

7.
Remove
the
governor housing
to

governor distributor attaching bolts

(Fig.
19).
Remove
the
governor hous-

ing from
the
distributor.

8. Refer
to
Major Repair Opera-

tions
for
governor repair operations.

9. Install
the
governor housing
on

the governor distributor
(Fig.
19). In-

stall
the
attaching bolts
and
torque
the

bolts
to
specification.

Tool—
T6
U-7657-A
or B,

7657AA,
or
7657-AB

EXTENSION HOUSING

REAR SEAL

FIG. 18—Installing Extension Housing Seal
D 2042-A

GOVERNOR GOVERNOR GOVERNOR

BOLTS
(4)
DISTRIBUTOR DISTRIBUTOR

SLEEVE

I

D1859-A

FIG. 79—Governor Installed
10.
Install
a new
extension housing

gasket
on the
case. Install
the
exten-

sion housing
and six
attaching bolts.

Torque
the
bolts
to
specification.

11.
Install
the
transmission mount-

ing
pad on the
crossmember. Lower

the transmission
and
install
the
exten-

sion housing
to
crossmember attach-

ing bolts. Torque
the
bolts
to
specifi-

cation. Remove
the
transmission jack.

12.
Install
the
speedometer cable
in

the extension housing. Install
the
drive

shaft.

13.
Install
the
inlet pipes
on the

manifold.

14.
Lower
the
vehicle
and
fill
the

transmission with fluid.

15.
Check
the
extension housing

area
for
fluid leakage.procarmanuals.com