wheel bolt torque FORD MUSTANG 1969 Volume One Chassis

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

05-01-01
05-01-01

Clutch
GROUP

5

PART
5-1
PAGE

Drive Shaft 05-01-01

PART
5-2

General Clutch Service 05-02-01
PART
5-3

Clutch

PART
5-4

Specifications
PAGE

05-03-01

05-04-01

PART
5-1
Drive Shaft

COMPONENT INDEX

DESCRIPTION

DRIVE SHAFT ANGLE CHECK

DRIVE SHAFT BALANCE CHECK

DRIVE SHAFT BALANCING

(Single Universal Joint)

DRIVE SHAFT DISASSEMBLY
AND

OVERHAUL

Single Universal Joint — Ford Design

Double Cardan Joint — Dana Design

Double Cardan Joint — Saginaw Design

DRIVE SHAFT REMOVAL
AND

INSTALLATION

DRIVE SHAFT RUNOUT CHECK
MODEL APPLICATION
All
Models

01-01

01-01

01-01

01-02

01-01
Ford
01-04

01-04

N/A

N/A
Mercury
01-04

01-04

N/A

N/A
Meteor
01-04

01-04

N/A

N/A
Cougar
01-04

01-04

N/A

N/A
Fairlane
01-04

01-04

N/A

N/A
Falcon
01-04

01-04

N/A

N/A
Montego
01-04

01-04

N/A

N/A
Mustang
01-04

01-04

N/A

N/A
Lincoln-
Continental
N/A

N/A

01-04

N/A
Thunderbird
N/A

N/A

N/A

01-05
Continental-
Mark
III
N/A

N/A

N/A

01-05

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.

DRIVE SHAFT TESTS

DRIVE LINE BALANCE CHECK

If detailed parts
of the
drive shaft

are replaced
and
shaft vibration
is en-

countered after installation, disconnect

the shaft
at the
slip yoke. Rotate
the

slip yoke
180
degrees; then, reconnect

the shaft
to the
slip yoke.
If the
vibra-

tion persists, disconnect
the
shaft
at

the rear axle companion flange.
Ro-

tate
the
companion flange
180
degrees

and reconnect
the
shaft
to the
flange.
DRIVE LINE ANGLE CHECK

Vibration
or
"shudder" which
is no-

ticeable either
on
fast acceleration
or

when coasting, using
the
engine
for a

brake,
may be
caused
by the
rear axle

housing being loose
on the
rear

springs
or by
improper pinion angle.

Refer
to
Group
3,
Part
2 for
pinion

angle checking procedures.
If the
rear

axle U-bolts (Fairlane, Montego,

Mustang, Cougar, Falcon models
only)
are
loose, torque
the
nuts
to

specification.

DRIVE SHAFT RUNOUT CHECK

Using
a
dial indicator, check
the

runout
at
each
end and in the
middle

of
the
driveshaft.
The
rear check

should
be
made
on the
small tube
sec-

tion
of the
shaft between
the
balance

weights
and the
yoke welds. Drive-

shaft runout should
not
exceed 0.035

inch
at any one
point.

DESCRIPTION

The drive shaft
is the
means
of

transferring power from
the
engine,

through
the
transmission,
to the dif-
ferential
in the
rear axle,
and
then
to

the rear wheels.
The
drive shaft incor-

porates
two
universal joints
and a
slip
yoke
(Fig. 1) or two
double cardan

universal joints,
one at
each
end of the

shaft (Figs.
2 and 3).
Each double
procarmanuals.com

05-01-04
Drive Shaft

05-01-04

tralizing.
If a
vibration exists,
the

drive shaft should
be
disconnected

from
the
axle, rotated 180 degrees
and

reinstalled.

3.
Install
the
U-blots
and
nuts that

attach
the
U-joint
to the
drive pinion

flange. Torque
the
U-bolt nuts
to

specification.
On
vehicles equipped

with
a
double cardan joint, install
the

rear joint-to-drive pinion flange
at-

taching bolts. Torque
the
bolts
to spe-

cification.

YOKE

C1773-A

FIG. 5—Output Shaft Spline Seal
—

Continental Mark
III
and Thunderbird

IN-VEHICLE REPAIR

USE SUPPORT STAND

AS
A
STEADY REST

E 1685-A

FIG. 6—Marking Driveshaft
CHALK MARK

CLAMPS 18d*FR0M CHALK MARK
*« >

E 1686-A

FIG. 7—Installing Whittek Clamps
E
1687-
A

. 8—Rotating Whittek Clamps

DRIVESHAFT BALANCING

(SINGLE UNIVERSAL JOINT)

If rotating
the
driveshaft
180 de-

grees does
not
eliminate vibration,
the

driveshaft
may be
balanced using
the

following procedure:

1.
Place
the
vehicle
on a
twin post

hoist
so
that
the
rear
of the
vehicle
is

supported
on the
rear axle housing

with
the
wheels free
to
rotate.

2.
With
the
driveshaft rotating
at a

speedometer speed
of
40-50
mph,
carefully bring
a
crayon
or
colored

pencil
up
until
it
just barely contacts

the rearward
end of
driveshaft
(Fig.

6).
The
mark made
by the
crayon
or

pencil will indicate
the
heavy side
of

the shaft. Care should
be
exercised

when working near
the
balance

weights
to
prevent injury
to the
hands.

3.
Install
two
Whittek type hose

clamps
on the
driveshaft
so
that
the

heads
are
located
180
degrees from

the crayon marking
(Fig. 7).
Tighten

the clamps.
4.
Run the
vehicle
up to
65-70
mph

speedometer speed.
If no
vibration
is

felt, lower
the
vehicle
and
road test.
If

unbalance still exists rotate
the
clamp

heads approximately
45
degrees away

from each other
and
test
for
vibration

(Fig.
8).

5.
Continue
to
rotate
the
clamp

heads apart
in
smaller amounts until

vibration
is
eliminated.
To
prevent

overheating,
do not run the
vehicle

on
the
hoist
for an
extended period.

6. Road test
the
vehicle.procarmanuals.com

05-02-03
General Clutch Service
05-02-03

in the direction of the face runout

arrow and its center line is parallel to

the center line of the face runout

arrow.

18.
Determine the amount of the

face runout on the B arrow scale.

19.
The value of the circular line

beneath the amount of face runout

will be the desired reading. If the

reading is in excess of 0.014 inch the

housing alignment is unacceptable.

20.
Remove the Dia-L-lgner gauge

from the flywheel housing.

21.
Install the spark plugs and con-

nect the wires.

ENGINE IN VEHICLE

Since any change in face alignment

will change bore alignment, it may be

possible to correct bore alignment by

changing face alignment. Face align-

ment can be changed by shimming be-

tween the flywheel housing and en-

gine.
Fig. 4 shows the type of shim

which can be fabricated.

Not more than 0.010 inch thickness

shims may be used between the fly-

wheel housing and engine. If a 0.010-

inch shim will not bring face and bore

alignment within limits, replace the

flywheel housing.

The shim required is one half the

maximum (—) indicator reading, and

should be located at the point of max-

imum minus (—) indicator reading.

If both the bore and face alignment

are out of limits, shim between the

flywheel housing and engine to bring

face alignment within limits. Check

the bore alignment.

If the bore alignment is out of lim-

its and the face alignment is within

limits,
shim the flywheel housing to

the limit of face misalignment and

check the bore alignment. If it is not

within limits, replace the housing.

ENGINE OUT OF VEHICLE

The same procedure to correct

alignment may be used with the en-

gine out of the vehicle or in the vehi-

cle,
up to the point of replacing the

flywheel housing. If the bore align-

ment cannot be brought within limits

by shimming, follow this procedure:

dure:

1.
Remove the flywheel housing

from the engine and remove the dowel

pins.
Install the flywheel housing and

tighten the attaching bolts.

2.
Install the dial indicator (Fig. 1).

Check the face alignment, and shim as
C2068-A

. 3—Dia-L-lgner Gauge Installed

required to bring face alignment with-

in limits.

3.
Position the indicator to check

the bore alignment. If the bore align-

ment is not within limits, reduce the

tension on the flywheel housing at-

taching bolts so that the housing can

be moved by striking it with a lead

hammer or a block of wood and a

steel hammer.

4.
The lateral alignment should be

brought within limits so that an indi-

cator reading is within limits between

the 9 o'clock and the 3 o'clock posi-

tions on the bore circle. When the lat-

eral alignment is within limits the

housing usually can be moved straight

up or down without disturbing the lat-

eral alignment. When alignment is

within limits, torque the housing bolts

and recheck bore alignment.

5.
If the flywheel housing cannot be

moved enough to bring the alignment

within limits, mark the holes restrict-

ing movement, and then remove the

housing and drill the marked bolt

holes 1/32 inch larger.

6. When the flywheel housing bore

alignment is within limits and the at-

taching bolts are at normal torque,
C 178 4-A

FIG. 4— Fabricated Flywheel

Housing Shim

hand ream the dowel pin holes 1/32

inch larger. Use a straight reamer and

ream from the flywheel housing side.

Oversize dowel pins can be made from

drill rod stock.

7.
Remove the flywheel housing

and then install the oversize dowel

pins in the cylinder block. Complete

the assembly in the usual way.

8. Recheck the flywheel housing

with the Dia-L-lgner gauge to make

sure that the housing is within the spe-

cified limits.procarmanuals.com

05-03-05
Clutch

05-03-05

4.
Remove the bolt that secures the

left air vent control cable bracket to

the instrument panel. Position the

control cable to one side.

5.
Remove the retaining clip and

flat washer from the clutch pedal

shaft. Then, remove the shaft, bush-

ing, clutch pedal and brake pedal

from the support.

6. Remove the bushings from the

pedal shaft, and transfer the pedal

pad.

7.
Lubricate the clutch pedal shaft

bushings and position them on the

shaft. Then, position the brake pedal

and clutch pedal in the pedal support.

8. Install the flat washer and re-

taining clip on the pedal shaft.

9. Position the assist spring to the

pedal and bracket. Pry the bracket

forward and install the lower bolt.

Torque the bolts to specifications.

10.
Position the master cylinder

push rod, bushing, and washers on the

brake pedal and secure with a retain-

ing clip.

11.
Connect the equalizer rod to

the clutch pedal and secure it in place

with a retaining clip.

12.
Position the air vent control

cable bracket to the instrument panel

and secure with the attaching bolt.

13.
Adjust the clutch pedal free

travel.

EQUALIZER BAR AND/OR

BUSHING REMOVAL AND

INSTALLATION

FORD, MERCURY

AND METEOR

1.
Raise the vehicle and disconnect

the clutch pedal-to-equalizer rod at

the equalizer bar (Fig. 1).

2.
Disconnect the return spring and

retaining spring at the release lever.

Separate the release lever rod from

the release lever.

3.
Remove the equalizer bar frame

bracket from the frame.

4.
Remove the equalizer bar from

the pivot on the flywheel housing.

5.
Remove the wire clip to replace

the outer bushing and the snap ring
from the inner pivot stud to replace

the inner bushing.

6. Position the flat washer, felt

washer and bushing on the inner and

outer pivots. Secure these parts with

the snap ring.

7.
Position the equalizer bar on the

inner pivot and bolt the equalizer bar

frame bracket to the frame. Torque

the attaching bolts to specification.

8. Install the clutch release rod, re-

turn spring and retaining spring.

9. Connect the clutch pedal rod to

the equalizer bar.

10.
Adjust the clutch pedal free

travel.

MUSTANG, COUGAR,

MONTEGO, FALCON,

FAIRLANE (EXCEPT

MONTEGO AND FAIRLANE

WITH 390 V-8)

1.
Disconnect the clutch pedal

equalizer rod at the equalizer bar

(Figs.
2 and 3).

2.
Raise the vehicle and disconnect

the release lever, return spring at the

lever.

3.
Remove the equalizer bar outer

bracket and bushing assembly.

4.
Remove the release rod from the

equalizer bar, and then remove the

equalizer bar. Remove the bushing

and washers from the inner mounting

stud.

5.
Position the equalizer bar, wash-

ers,
inner bushing, and retainer on the

inner stud.

6. After positioning the outer bush-

ing, install the outer bracket (with the

equalizer bar in place).

7.
Connect the release rod and the

release lever return spring.

8. Lower the vehicle. Connect the

clutch pedal equalizer rod to the

equalizer baY and secure with the re-

taining pin.

9. Adjust the clutch pedal free trav-

el as required.

MONTEGO AND

FAIRLANE—390 V-8

1.
Disconnect the clutch pedal
equalizer rod at the equalizer bar (Fig.

2).

2.
Raise the vehicle and disconnect

the return spring at the release lever.

Disconnect the release lever rod from

the equalizer lever.

3.
Remove the equalizer bar center

bolt.

4.
Separate the equalizer bar and

remove both sections from the vehicle.

5.
Remove the bolts retaining the

equalizer bar inner bracket to the fly-

wheel housing and remove the bracket

and bushing assembly.

6. Remove the equalizer bar outer

bracket and bushing assembly.

7.
Remove the snap ring, bushing,

and felt washer from each bracket as-

sembly.

8. Position a felt washer, and bush-

ing on each bracket assembly and se-

cure with the snap ring.

9. Install the outer bracket and

bushing assembly to the frame (Fig.

2).
Torque the bracket attaching bolts

to specifications.

10.
Position the outer section of the

equalizer bar on the outer bracket

pivot.

11.
Connect the two sections of the

equalizer bar. Insert the inner bracket

pivot into the equalizer bar and install

the assembly to the flywheel housing.

Torque the attaching bolts to specifi-

cations.

12.
Install the equalizer bar center

bolt and torque to specifications.

Make sure that both ends of the

equalizer bar are against the felt

washers.

13.
Connect the release rod and the

release lever return spring.

14.
Adjust the clutch pedal free

travel.

15.
Lower the vehicle. Connect the

clutch pedal equalizer rod to the

equalizer bar and secure with the re-

taining clip.

16.
Check the free travel at the

pedal for conformance to specifica-

tions.
Readjust if necessary.

REMOVAL AND INSTALLATION

CLUTCH REMOVAL

1.
Raise the vehicle on a hoist.

2.
Disconnect the drive shaft from

the rear U-joint flange. Then, slide the

drive shaft off the transmission output

shaft. Insert the appropriate tool over

the output shaft and into the extension

housing oil seal.
3.
Disconnect the speedometer

cable from the extension housing.

4.
Disconnect the gear shift rods

from the transmission. If the vehicle is

equipped with a four-speed transmis-

sion, remove the bolts that secure the

four-speed transmission, disconnect

the front brake cable from the cross-

member and remove the crossmem-
member from the vehicle.

5.
Remove the bolts that attach the

transmission to the flywheel housing.

6. Move the transmission rearward

until the input shaft clears the fly-

wheel housing, then remove it from

the vehicle.

7.
Disconnect the clutch release

lever retaining spring from the release

lever.procarmanuals.com

05-03-06
Clutch

05-03-06

8. Remove the starter cable then

remove the starter motor from the fly-

wheel housing.

9. Remove the bolts that secure the

engine rear plate to the front lower

part of the flywheel housing.

10.
Remove the flywheel housing

lower cover (390 CID housing only).

11.
Remove the bolts that attach

the housing to the cylinder block.

12.
Move the housing back just far

enough to clear the pressure plate,

then move it to the right to free the

pivot from the clutch equalizer bar. Be

careful not to disturb the linkage and

assist spring.

13.
Loosen the six pressure plate

cover attaching bolts evenly to release

the spring tension. If the same pres-

sure plate and cover is to be installed

after the clutch is overhauled, mark

the cover and flywheel so that the

pressure plate can be installed in the

same position.

14.
Remove the pressure plate and

the clutch disc from the flywheel.

CLUTCH INSTALLATION

1.
Install the clutch release lever if

it was removed.

2.
Place the clutch disc, and pres-

sure plate assembly in position on the

flywheel. Start the cover attaching

bolts to hold the pieces in place, but

do not tighten them. Avoid touching

the clutch disc facing, dropping the

parts or contaminating them with oil

or grease as clutch chatter may result.

3.
Align the clutch disc with the

tool shown in Fig. 7, and alternately

tighten the bolts a few turns at a time

until they are all tight. Then torque

the six pressure plate cover attaching

bolts to specification before removing

the tool.
4.
Apply a light film of grease

(C3VY-19586-A) to the outside diam-

eter of the transmission front bearing

retainer. Apply a light film of grease

(C3VY-19586-A) to both sides of the

release lever fork where it contacts the

release bearing bore spring clips.

Apply a light film of grease to the re-

lease bearing surface that contacts the

pressure plate release fingers. Fill the

grease groove of the release bearing

hub with lithium base grease (C3VY-

19586-A). Clean all excess grease

from inside the bore of bearing hub.

Excess grease will be forced onto the

spline by the transmission input shaft

bearing retainer and will contaminate

the clutch disc. Also, place the release

bearing and hub on the release lever.

5.
Make certain that the flywheel

housing and the cylinder block mount-

ing surfaces are clean. Position the

felt washer on the pivot in the fly-

wheel housing. Slip the pivot into the

clutch equalizer shaft being careful

not to disturb the linkage and at the

same time position the housing on the

dowels in the cylinder block. Install

and torque the attaching bolts to spec-

ification.

6. Install the starting motor and

connect the cable.

7.
The mounting surfaces of the

transmission and the flywheel housing

must be free of dirt, paint, and burrs.

Install two guide pins in the flywheel

housing lower mounting bolt holes.

Move the transmission forward on the

guide pins until it is tightly positioned

against the flywheel housing.

8. Install the two upper mounting

bolts.
Then, remove the guide pins

and install the two lower mounting

bolts.
Torque all the bolts to specifica-

tion.

9. Raise the rear of the engine and
install the crossmember. Install and

torque the crossmember attaching

bolts to specifications, then lower the

engine.

10.
Install the extension housing-

to-engine rear support attaching bolts.

Torque the bolts to specification.

11.
Remove the transmission jack

and connect the parking brake cable.

12.
If the vehicle is equipped with a

four-speed transmission, connect the

gear shift linkage control bracket to

the extension housing.

13.
Connect the gear shift rods to

the transmission. Adjust the shift link-

age as required.

14.
Connect the release lever retain-

ing spring. Install the flywheel housing

cover (390 CID housing only).

15.
Remove the tool from the

transmission output shaft and install

the drive shaft.

16.
Check the clutch pedal free

travel.

CLUTCH ARBOR CLUTCH DISC

PRESSURE PLATE

C 1788-A

FIG. 7—Installing Clutch Disc —

Typicalprocarmanuals.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

06-03-03
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

06-04-02

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

07-02-11
C4 Automatic Transmission
07-02-11

REMOVAL AND INSTALLATION

An oil impregnated plastic grommet

is incorporated in the end of the man-

ual shift linkage lever arm on all col-

umn shift vehicles. A special tool

T67P-7341-A is required to install the

grommet in the manual lever, and to

install the manual linkage rod into the

grommet. Refer to Part 7-1, Section

2,
for the grommet replacement pro-

cedures.

TRANSMISSION REMOVAL

1.
Raise the vehicle and remove the

converter cover attaching bolts, at the

lower front side of the converter hous-

ing. Remove the cover.

2.
Remove the two conveter drain

plugs (Fig. 20). Drain the fluid from

the converter. Install the two convert-

er drain plugs.

3.
Remove the drive shaft and in-

stall the extension housing seal repla-

cer tool in the extension housing.

4.
Remove the vacuum line hose

from the transmission vacuum unit.

Disconnect the vacuum line from the

retaining clip.

5.
Remove the two extension

housing-to-crossmember attaching

bolts.

6. Remove the speedometer cable

from the extension housing.

7.
Disconnect the exhaust pipe

flange from the manifolds.

8. Remove the parking brake cable

from the equalizer lever.

9. Remove the fluid filler tube from

the pan and drain the transmission

fluid on PEA models. On PEB and

PEE models, loosen the transmission

CONVERTER A
ATT,
pan bolts and drain the fluid at one

corner of the pan. Tighten the attach-

ing bolts after the fluid has drained.

10.
Disconnect the fluid cooler lines

from the transmission case.

11.
Remove the manual and kick-

down linkage rods from the transmis-

sion control levers.

On vehicles equipped with a column

shift, use tool T67P-7341-A to remove

the selector rod from the manual

lever.

12.
On a Mustang, disconnect the

neutral start switch wires from the re-

taining clamps and connectors.

13.
Disconnect the starter cable.

Remove the starter attaching bolts

and remove the starter from the con-

verter housing.

14.
On PEB and PEE models, lift

the fluid filler tube from the case.

15.
Remove the four converter-

to-flywheel attaching nuts.

16.
Position the transmission jack

to support the transmission and secure

the transmission to the jack with a

safety chain.

17.
Remove the four crossmember

attaching bolts and lower the

crossmember.

18.
Remove the five converter

housing-to-engine attaching bolts.

Lower the transmission (Fig. 21) and

remove it from under the vehicle.

TRANSMISSION

INSTALLATION

1.
With the converter properly in-

D 2043-A

FIG. 20—Converter Drain Plug

Location
FIG. 21—Transmission Mounted

on Jack
stalled, place the transmission on the

jack (Fig. 21). Secure the transmission

to the jack with the safety chain.

2.
Raise the transmission into posi-

tion and install the five converter

housing-to-engine attaching bolts.

Torque the bolts to specification. Re-

move the safety chain from the trans-

mission.

3.
Position the crossmember and

install the four attaching bolts. Torque

the bolts to specifications.

4.
Lower the transmission and in-

stall the extension housing and

crossmember attaching bolts. Torque

the bolts to specification.

5.
Install the four flywheel to con-

verter attaching nuts. Torque the nuts

to specification.

6. Remove the transmission jack.

Install the fluid filler tube in the

transmission case or pan. Install the

vacuum hose on the transmission vac-

uum unit. Install the vacuum line re-

taining clip.

7.
Connect the fluid cooling lines to

the transmission case.

8. On a Mustang, connect the neu-

tral start switch wires to their respec-

tive connectors and secure the harness

in the retaining clamps.

9. Install the linkage rods on the

transmission downshift and manual

control levers.

On vehicles equipped with a column

shift, use tool T67P-7341-A to install

a new grommet in the manual lever,

and to install the manual linkage rod

into the grommet.

10.
Connect the speedometer cable

to the extension housing.

11.
Connect the exhaust inlet pipes

to the manifolds.

12.
Install and adjust the parking

brake cable at the equalizer lever.

13.
Install the converter housing

cover and torque the attaching bolts

to specification.

14.
Install the starter and torque

the attaching bolts to specification.

Connect the starter cable.

15.
Install the drive shaft. Torque

the companion flange U-bolts attach-

ing nuts to specification.

16.
Lower the vehicle. Fill the

transmission to the proper level with

the specified fluid. Adjust the manual

and downshift linkage.procarmanuals.com