transmission FORD MUSTANG 1969 Volume One Chassis

05-04-01
Specifications

05-04-01

PART
5-4
Specifications

CLUTCH IDENTIFICATION

Car Line

Ford

Meteor

Ford

Ford

Meteor

Ford

Meteor

Mercury

Ford

Falcon

Fairlane

Falcon

Montego

Fairlane

Montego

Falcon

Mustang

Mustang

Cougar

Fairlane

Montego

Fairlane

Montego

Mustang

Cougar

Fairlane

Montego

Mustang

Cougar

Fairlane

Montego

Mustang

Cougar
Engine

240-IV

240-IV

302-2V

390-2V,

4V

429-4V

170-1V

200-IV

250-1V

302-2V

200-IV

250-1V

302-2V

390-2V,

4V

390-4V GT

351-2V,

4V

428-4V
Transmission

3-Speed

3-Speed

Heavy Duty

3-Speed

3-Speed

4-Speed

4-Speed

3-Speed

3-Speed

3-Speed

4-Speed

3-Speed

3-Speed

4-Speed

3-Speed

4-Speed

3-Speed

4-Speed

3-Speed

4-Speed

4-Speed
Pressure Plate

Diameter

(Inches)

9.5

11

10

11

11.5

9

9

10

9

10

11

11.5

11

11.5
No.
of

Springs

6

9

9

9

12

6

6

9

6

9

9

12

9

12
Color Identification

(Paint Daub)

Pressure Plate-No Color

Cover—Green

Springs—Aluminum

Pressure Plate-White

Cover-Pink and Blue

Springs
8-Green

Pressure Plate-Green

Cover-White

Springs-White
on
Bronze

Pressure Plate—Orange

Cover-Black

Springs-Aluminum

Pressure Plate-Yellow

Cover-Black

Springs-Green

Pressure Plate-Orange

Cover—Purple

Springs-Aluminum Stripe

Pressure Plate-Orange

Cover-Purple

Springs-Aluminum Stripe

Pressure Plate—Green

Cover-White

Springs-Bronze

Pressure Plate—Orange

Cover—Purple

Springs—Aluminum Stripe

Pressure Plate-Blue

Cover—Purple

Springs—Bronze

Pressure Plate-Green

Cover-Purple

Springs-Purple

Pressure Plate-Green

Cover-Purple

Springs-Purple

Pressure Plate-Blue

Cover-Yellow

Springs-Silver

Pressure Plate-Yellow

Cover-Black

Springs—Green
Disc

Diameter

(Inches)

9.5

11

10

11

11.5

9

9

10

9

10

11

11.5

11

11.5
No.
of

Springs

6

8

12

12

10

6

6

12

6

6

8

8

8

10
Color Identification

(Paint Daub)

Clutch-Yellow

Springs—2 Purple (Small)

4 Aluminum (Large)

Clutch-No Color

Springs—4 Aluminum

4 Pink

Clutch-Blue

Springs-6 Orange (Small)

6 Pink (Large)

Clutch-Pink

Springs-6 Green (Small)

6 Orange (Large)

Clutch-Gray

Springs—5
Red
Stripe (Small)

5
No
Color (Large)

Clutch-Pink

Springs—Blue

Clutch-Pink

Springs-Blue

Clutch-Blue

Springs-6 Pink

6 Orange

Clutch-Blue

Springs—Blue

Clutch-Green

Springs-Orange

Clutch-Pink
and
Orange

Springs—Aluminum

Clutch-Pink and Orange

Springs—Aluminum

Clutch—Pink and Orange

Springs—Aluminum

Clutch-Gray

Springs-Red Stripe

CLUTCH-DRIVELINE ADJUSTMENTS (INCHES)

Release Lever
Rod
Adjusting
Nut to
Swivel Sleeve

Ford,
Mercury Meteor
0.194

Fairlane, Montego, Falcon, Mustang, Cougar
ex.
with

390,
428
engine
0.136

390,
428
Engines
0.178
*

Clutch Pedal Free Travel (Engine Running)
7/8"-l
1/8"

Clutch Housing Alignment
If
Dia-L-lgner reading
0.014

is greater than that indicated,
the
clutch

housing alignment
is
unacceptable.

Maximum Shim to Correct Alignment
0.010procarmanuals.com

05-04-02

Specifications

05-04-02

TORQUE LIMITS (FT-LBS)

Description

Lower Access Clutch Cover Pan to Flywheel Housing Bolts (Cast Iron Housing)

Transmission Assembly to Flywheel Housing Bolts

Pressure Plate and Cover Assembly to Flywheel Attaching Bolts

Clutch Release Equalizer Frame Bracket Bolts

Clutch Pedal Free Travel Adjustment Nut

Flywheel Housing to Cylinder Block Bolts
6-Cylinder

8-Cylinder

Clutch Pedal Assist Spring Bracket to Brake Pedal Support Bracket
Meteor

Ford,
Mercury

17-20

37-42

12-20

15-24

15-20

_

12-17
Mustang,
Cougar

Fairlane, Montego, Falcon

-

-

12-20

15-24

15-20

23-33

40-50

12-17

SPECIAL TOOLS

Tool No.

A-37H

T61L-7657-Aor B

T57L-7657-A

T64P-7657-A
Description

Clutch Disc Aligner-Universal

Transmission Extension Housing Oil Seal

Replacer
Tool No.

CJ91B

T64L-6392-A

T49P-7580-A
Description

Universal Joint Bearing Replacer

Dia-L-lgner Gauge

Clutch Release Bearing Replacerprocarmanuals.com

06-01-01

06-01-01

ual Shift
GROUP

6

PART
6-1
PAGE

General Transmission Service
06-01-01

PART 6-2

Ford Design Three-Speed

Transmission
06-02-01
PART 6-3

Ford Design Four-Speed

Transmission

PART
6-4

Specifications
PAGE

.06-03-01

.06-04-01

Part 6-1 General
Transmission
Service

COMPONENT INDEX

REAR SEAL

Removal and Installation

REAR BUSHING AND SEAL

Removal and Installation

TRANSMISSION

Cleaning

Inspection

Lubrication
MODEL APPLICATION
All
Models
Ford

01-02

01-02

01-02

01-02

01-02
Mercury
01-02

01-02

01-02

01-02

01-02
Meteor
01-02

01-02

01-02

01-02

01-02
Cougar
01-02

01-02

01-02

01-02

01-02
Fairlane
01-02

01-02

01-02

01-02

01-02
Falcon
01-02

01-02

01-02

01-02

01-02
Montego
01-02

01-02

01-02

01-02

01-02
Mustang
01-02

01-02

01-02

01-02

01-02
Lincoln-
Continental
N/A

N/A

N/A

N/A

N/A
Thunderbird
N/A

N/A

N/A

N/A

N/A
Continental-
Mark
III
N/A

N/A

N/A

N/A

N/A

A page number indicates that the item
is for
the vehicle listed
at
the head
of
the column.

N/A indicates that the item
is
not applicable
to
the vehicle listed.

COMMON ADJUSTMENTS
AND
REPAIRS

54E
M IB I2H 33
CODE

1

5

6
TRANSMISSION

THREE-SPEED

FOUR-SPEED (WIDE RATIO)

FOUR-SPEED (CLOSE RATIO)

C2086-A

FIG.
1—Typical
Warranty Plate—Transmission Identification
procarmanuals.com

06-01-02
General Transmission Service

06-01-02

REAR SEAL REPLACEMENT

1.
Remove the drive shaft.

2.
Remove the seal from the exten-

sion housing with the tool shown in

Fig. 2.

3.
Install the new seal in the exten-

sion housing with the tool shown in

Fig. 3.

4.
Install the drive shaft.

.REAR OIL SEAL

Tool-T61L-7657-A

EXTENSION HOUSING

C 1830.A

FIG. 3—Installing Extension

Housing Seal
Too/-7J75-AB

Tool-TSOT-lOO-A

FIG. 2—Removing Extension Housing Seal

EXTENSION HOUSING

Tool-T52L-7000-GAE

or 7000-G

C1O28-D

FIG. 4—Removing Extension

Housing Bushing and Seal
EXTENSION HOUSING
D
1927. A

Tool—T57P-7697-B

57-G

BUSHING

C 1832.A

FIG. 5—Installing Extension

Housing Bushing

REAR BUSHING AND SEAL

REMOVAL AND INSTALLATION

1.
Remove the drive shaft from the

vehicle.

2.
Insert the tool shown in Fig. 4

into the extension housing until it

grips on ihe front side of the bushing.
3.
Turn the screw clockwise until

the seal and the bushing are free of

the housing.

4.
Drive a new bushing into the ex-

tension housing with the tool shown in

Fig. 5.

5.
Install a new seal in the housing

as shown in Fig. 3.

6. Install the drive shaft.
LUBRICATION

Lubricant level should be even with

the bottom of the filler hole at the

right side of the transmission case.

CLEANING AND INSPECTION

CLEANING

1.
Wash all parts, except the ball

bearings and seals in a suitable clean-

ing solvent. Brush or scrape all foreign

matter from the parts. Be careful not

to damage any parts with the scraper.

Do not clean, wash or soak transmis-

sion seals in cleaning solvents. Dry all

parts with compressed air.

2.
Rotate the ball bearings in a

cleaning solvent until all lubricant is

removed. Hold the bearing assembly

to prevent it from rotating and dry it

with compressed air.

3.
Lubricate the bearings with ap-

proved transmission lubricant and

wrap them in a clean, lint-free cloth

or paper until ready for use.

4.
Clean the magnet welded to the

bottom of the case with kerosene or

mineral spirits.
INSPECTION

1.
Inspect the transmission case for

cracks, worn or damaged bearings

bores,
damaged threads or any other

damage that could affect the opera-

tion of the transmission.

2.
Inspect the front face of the case

for small nicks or burrs that could

cause misalignment of the transmis-

sion with the flywheel housing. Re-

move all small nicks or burrs with a

fine stone.

3.
Replace a cover that is bent or

distorted. Make sure that the vent

hole in the cover is open.

4.
Check the condition of the shift

levers, forks, shift rails and the lever

and shafts.

5.
Examine the ball bearing races

for cracks, wear or roughness. Inspect

the balls for looseness, wear, end play
or other damage. Check the bearings

for looseness in the bores. If any of

these conditions exist, replace the

bearings.

6. Replace roller bearings that are

broken, worn or rough.

7.
Replace the countershaft (clust-

er) gear if the teeth are chipped, brok-

en or worn. Replace the countershaft

if it is bent, scored or worn.

8. Replace the reverse idler gear or

sliding gear if the teeth are chipped,

worn or broken. Replace the idler

gear shaft if bent, worn or scored.

9. Replace the input shaft and gear

if the splines are damaged or if the

teeth are chipped, worn or broken. If

the roller bearing surface in the bore

of the gear is worn or rough, or if the

cone surface is damaged, replace the

gear and the gear rollers.

10.
Replace all other gears that areprocarmanuals.com

06-01-03

General Transmission Service

06-01-03

chipped, broken or worn.

11.
Check the synchronizer sleeves

for free movement on their hubs.

Make sure that the alignment marks

(etched marks) are properly indexed.

12.
Inspect the synchronizer block-

ing rings for widened index slots,

rounded clutch teeth and smooth in-

ternal surfaces (must have machined

grooves). With the blocker ring on the
cone,
the distance between the face of

the blocker ring and the clutch teeth

on the gear must not be less than

0.010 inches.

13.
Replace the speedometer drive

gear if the teeth are stripped or dam-

aged. Make certain to install the cor-

rect size replacement gear.

14.
Replace the output shaft if

there is any evidence of wear or if any
of the splines are damaged.

15.
Inspect the bushing and the seal

in the extension housing. Replace

them if they are worn or damaged.

The bushing and/or seal should be re-

placed after the extension housing has

been installed on the transmission.

16.
Replace the seal in the input

shaft bearing retainer.

17.
Replace the seals on the cam

and shafts.procarmanuals.com

06-02-01
Ford Design Three Speed Transmission

06-02-01

PART 6-2 Ford Design Three Speed
Transmission

Trans-

mission

Model

RAN-AL

RAN-AM

RAN-AN

RAN-AZ

RAT-AJ

RAT-AM

RAT-A2

RAT-B2

RAT-C2

RAT-N2

RAT-SI

RAT-T

RAT-U1
Engine

Model

200-IV, 250-IV

200-IV, 250-IV

170-1V

240-IV

351-2V-4V

351-2V-4V

390-2V-4V

390-4V-GT

390-4V-GT

390-4V

302-2V

302-2V-4V

302-2V
Shift

Lever

Location

Column

Floor

Column

Column

Column

Floor

Column

Floor

Column

Floor

Column

Column

Floor
MODEL APPLICATION
All
Models
Ford

X

X

X
Mercury
X

X
Meteor
X
Cougar
X

X
Fairiane
X

X

X

X

X
Falcon
X

X

X
Montego
X

X

X

X

X
Mustang
X

X

X
Lincoln-
Continental
Thunderbird
Continental-
Mark
III

COMPONENT INDEX

COUNTERSHAFT GEAR BEARINGS

Removal and Installation

DESCRIPTION

GEAR SHIFT CONTROL ASSEMBLY—

Floor Mounted

Removal and Installation

GEAR SHIFT LEVERS AND SEALS

Removal and Installation

GEAR SHIFT LINKAGE ADJUSTMENT

Column Mounted

Floor Mounted

INPUT SHAFT BEARING

Removal and Installation

SYNCHRONIZERS

Disassembly and Assembly

TRANSMISSION (Complete)

Cleaning and Inspection See Part 06-01

Disassembly and Overhaul

Removal and Installation

AH
Models
02-07

02-02

02-07

02-06

02-02

02-03

02-06

02-06

02-04

02-03
procarmanuals.com

06-02-02
Ford Design Three Speed Transmission

06-02-02

DESCRIPTION

DESCRIPTION

The RAN and RAT Model three-

speed transmission (Fig. 1) are used

on models having 170, 200, 240, 250,

302,
351 and 390 C.I.D. engines. The

specifications of this section, Part 6-4,

lists the transmission model numbers

and vehicles in which they are used.

A transmission service identification
tag is located on the right side of the

case at the front (Fig. 2). The first

line on the tag will show the transmis-

sion model and service identification

code when required. The second line

will show the transmission serial num-

ber. Additionally, a driveline compo-

nent identification tag is attached to

the upper right side of the transmis-

sion case.
This transmission is of the fully

synchronized type, with all gears ex-

cept the reverse gear and sleeve being

in constant mesh. All forward-speed

changes are accomplished with syn-

chronizer sleeves.

The forward-speed gears are

helical-cut and are in constant mesh.

Gears used in the reverse gear train

are spur-cut and are not synchronized.

C2O87-A

FIG.
1—Three-Speed
Transmission—Typical
TRANS.
MODEL

SERIAL
NO.

C 2089-A

FIG.
2—Transmission
Identification

Tag

IN-VEHICLE ADJUSTMENTS
AND
REPAIRS

GEAR SHIFT LINKAGE

ADJUSTMENT—COLUMN

MOUNTED

1. Place the gear shift lever in the

neutral position.

2.
Loosen the two gear shift rod

adjustment nuts.

3.
Check shift levers on transmis-

sion to be in neutral position.

4.
Insert a 3/16-inch diameter

alignment tool through the first and

reverse gear shift lever, the second and

third gear shift lever and both holes

in the lower casting (Fig. 3). An align-

ment tool can be made from 3/16

inch drill rod bent to an L shape.

The extensions should be 1 inch and 2

inches from the elbow. The short end

of the tool should be inserted into the

alignment holes.

5.
Tighten the two gear shift rod

adjustment nuts.

6. Remove the alignment tool from

the levers.

7.
Start the engine and shift the se-

lector lever to each position to make

sure it operates freely.
FIG.
3—Gearshift
Linkage Adjustment—Typicalprocarmanuals.com

06-02-03
Ford Design Three Speed Transmission

06-02-03

STOP
PIN

GROMMET

Tool -
T67P.7347.A

GROMMET

LEVER

CONTROL ROD REMOVAL
^S.
GROMMET INSTALLATION

SET STOP PIN SO THAT THE GROMMET

Tool
-
T67P.734LA
AND
SHIFT ROD ARE PROPERLY SEATED
OMMET—^

SEATED
\

CONTROL ROD INSTALLATION

CONTROL ROD

STOP
PIN

FIG. 4—Removing
or
Installing Shift Linkage Grommet

GEAR SHIFT LINKAGE

ADJUSTMENT—FLOOR MOUNTED

1.
Loosen
the
three shift linkage

adjustment nuts. Install
a 1/4
inch
di-

ameter alignment pin through the con-

trol bracket and lever alignment holes

shown
in Fig. 18.

2.
Tighten
the
three linkage adjust-

ment nuts
and
then remove
the
align-

ment
pin.

3.
Check
the
gear shift lever
for a

smooth crossover.

COLUMN-MOUNTED

SHIFT LINKAGE

GROMMET REMOVAL
AND

INSTALLATION

The column-mounted shift lever
as-
sembly incorporates
an oil
impregnat-

ed plastic grommet
in the
end
of
each

lever
arm. A
special tool T67P-

7341-A
is
required
to
install the grom-

met
in the
shift lever,
and to
install

the shift linkage
rod
into
the
grom-

met. Remove
and
install
the
grommet

as follows:

1.
Place
the
lower
jaw of the
tool

between
the
shift lever
and the
shift

rod.
Position
the
stop
pin
against
the

end
of the
shift
rod
(Fig.
4)
and force

the
rod out of the
grommet. Remove

the grommet from
the
shift lever
by

cutting
off the
large shoulder with
a

sharp knife. The groin met must
be re-

moved from
the
shift lever
and a new

one installed each rime
'he rod is
dis-

connected.

2.
Before installing
a
new grommet,
C 2090-A

adjust
the
stop
pin as
necessary
to

properly install
the
grommet and coat

the outside
of
the grommet with lubri-

cant. Then, place
the
grommet
on the

stop
pin and
force
it
into
the
shift

lever hole. Turn
the
grommeit several

times
to be
sure
it is
properly seated.

3.
Readjust
the
stop
pin to a
length

which
is
sufficient
to
install
the
shift

rod into
the
grommet
(Fig.
4).
If
the

pin height
is not
adjusted,
the
shift

rod
may be
pushed
too far
through

the grommet causing damage
to the

grommet retaining
lip.

4.
With
the pin
height properly
ad-

justed, position
the
shift
rod on the

tool
and
force
the rod
into
the
grom-

met until
the
groove
in the rod
seats

on
the
inner retaining
lip of
the grom-

met.

REMOVAL AND INSTALLATION

REMOVAL

1.
Raise
the
vehicle
on a
hoist.

2.
Mark
the
drive shaft
so
that
it

may
be
installed
in the
same relative

position. Disconnect
the
drive shaft

from
the
rear U-joint flange.

3.
Slide
the
front
of the
drive shaft
out
of the
transmission extension

housing
and off the
output shaft
In-

sert
the
tool shown
in (Fig. 2),
Part

6-1 into the extension housing
to
pre-

vent
the
lubricant from leaking
out of

the transmission.

4.
Remove
the cap
screw
and
lock

washer that secures
the
speedometer
cable retainer
to the
extension hous-

ing. Pull
the
speedometer cable
out of

the extension housing.

5.
On
vehicles equipped with
a

column-mounted gear shift selector,

remove
the
shift rods from
the
shift

levers
at
the transmission. On vehicles

equipped with
a
floor-mounted gearprocarmanuals.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

06-02-05

Ford Design Three Speed Transmission

06-02-05

Dummy

Shaft

FIG. 7—Removing Countershaft

7.
On 6-cylinder vehicles with a

model RAN transmission except

Ford, tap the countershaft from the

rear of the case with a dummy shaft

to remove the expansion plug from

the countershaft bore at the front of

the case.

8. Hold the countershaft gear with

a hook and with the tool shown in

Fig. 7, push the countershaft out the

rear of the case.

The countershaft (cluster) gear and

thrust washers (Fig. 21) can be low-

ered to the bottom of the case. Re-

move the countershaft from the rear

of the case.

9. On some models, remove the

snap ring that secures the speedometer

drive gear on the output shaft. Slide

the speedometer drive gear off the

shaft. Remove the speedometer drive

gear lock ball from the shaft. If the

vehicle is equipped with the new de-

sign retainer, depress the tang on the

speedometer drive gear retaining clip

and slide the gear off the output shaft

(Fig. 10).

10.
Remove the snap ring that re-

tains the output shaft bearing on the
C2070 A

shaft. Remove the bearing from the

case and shaft as shown in Fig. 8.

11.
Place both shift levers in the

neutral (center) position.

12.
Remove the set screw that se-

cures the first and reverse shift fork to

the shift rail. Slide the first and rev-

erse shift rail out through the rear of

the case.

13.
Slide the first and reverse syn-

chronizer forward as far as possible,

and rotate the first and reverse shift

fork upward. Then lift it from the

case.

14.
Move the second and third-

speed shift fork to the second-speed

position to gain access to the set

screw. Remove the set screw from the

fork. Rotate the shift rail 90 degrees

as shown in Fig. 11.

15.
Lift the interlock plug (Fig. 9)

from the case with a magnet.

16.
Tap on the inner end of the sec-

ond and third-speed shift rail to re-

move the expansion plug (Fig. 9) from

the front of the case. Remove the shift

rail.

17.
Remove the second and third-

speed shift rail detent plug and spring

from the detent bore.
18.
Pull the input gear and shaft

forward until the gear contacts the

case,
and then remove the large snap

ring. It is necessary to move the gear

forward to provide clearance when re-

moving the output shaft assembly

from RAT model transmissions. On

all other models, the input shaft and

gear is removed from the front of the

case at this time.

19.
Rotate the second and third-

speed shift fork upward, and lift it

from the case.

20.
Carefully lift the output shaft

assembly out through the top of the

case.

21.
On an RAT model, work the

input shaft bearing and gear back

through the bore in the case and out

through the top. Remove idler gear

shaft, driving from the front of the

case.

22.
Lift the reverse idler gear and

two thrust washer (Fig. 12) from the

case.
Lift the countershaft gear, thrust

washer, and dummy shaft from the

case.

23.
Remove the snap ring from the

front of the output shaft, and slide the

synchronizer and the second-speed

gear (Fig. 13) off the shaft.

24.
Remove the next snap ring and

tabbed thrust washer from the output

shaft. Then slide the first gear and

blocking ring off the shaft.

25.
Remove the next snap ring

from the output shaft. The first and

reverse synchronizer hub is a press fit

on the output shaft. To eliminate the

possibility of damaging the synchro-

nizer assembly, remove the synchro-

nizer hub using an arbor press as

shown in Fig. 21. Do not attempt to

remove or install the hub by hammer-

ing or prying.

C2071-A

FIG. 8—Removing Output Shaft

Bearing
SET SCREW
SCREW

MACHINED SURFACE

2ND AND 3RD SHIFT FORK

EXPANSION PLUG

1ST AND REVERSE

SHIFT RAIL

FIG. 9—Shift Rails and Forks Disassembled
C1798-Aprocarmanuals.com