transmission FORD MUSTANG 1969 Volume One Chassis

06-02-06
Ford Design Three Speed Transmission

06-02-06

SPEEDOMETER DRIVE

GEAR

SPRING CLIP

FRONT

C2052-A

FIG. 10—Speedometer Drive Gear Installation—New Design

TOOL-T52T

6500-DJD

C1564-A

FIG. 11—Rotating Second and Third-Speed Shift Rail

PARTS REPAIR
OR

REPLACEMENT

SHIFT LEVERS
AND
SEALS

1.
Remove
the nut,
lock washer,

and flat washer that secure each shift

lever (Fig.
14) to the
lever
and
shaft
in
the transmission case. Lift
the
levers

off
the
shaft. Slide each lever
and

shaft
out of the
case. Discard
the CD-

ring from each shaft.

2.
Lubricate
the new
seals with

transmission lubricant
and
install

them
on the
shafts.

3.
Install
the
lever
and
shafts
in the
case.

4.
Position
a
shift lever
on
each

shaft
and
secure them with
a
flat

washer, lock washer,
and nut.

INPUT SHAFT BEARING

1.
Remove
the
snap ring securing

the input shaft bearing
(Fig. 15), and

press
the
input shaft
out of the
bear-

ing.

2.
Press
the
input shaft bearing

onto
the
input shaft with
the
tool

shown
in Fig. 16, and
install
the
snap

ring
on the
shaft.

SYNCHRONIZERS

1.
Push
the
sychronizer
hub
from

each synchronizer sleeve.

2.
Separate
the
inserts
and
insert

springs from
the
hubs.
Do not mix the

parts from
the
second
and
third-speed

synchronizer with
the
first
and
reverse

synchronizer (Figs.
17 and 18).

3.
Install
the
rear insert spring
in

the groove
of the
first
and
reverse
syn-

SHAFT AND LEVER

0-RING

SHIFT

LEVER

C 1845-A

FIG. 74—Shift Lever and Shafi

Disassembled

REVERSE

IDLER GEAR THRUST

WASHER ROLL
PIN

REVERSE IDLER

GEAR SHAFT

C1799-A

FIG. 72—Reverse Idter Shaft

Disassembled
BLOCKING RING SPEEDOMETER DRIVE GEAR

OUTPUT SHAFT

BLOCKING RINGS

SNAP RING

REAR BEARING

SYNCHRONIZER
THRUST WASHER
REVERSE GEAR

AND SLEEVE
C2072-A

FIG. 13—Output Shaft Disassembledprocarmanuals.com

06-02-07
Ford Design Three Speed Transmission

06-02-07

SNAP RINGS

FIG. 15—Input Shaft Gear Disassembled
C1802-
A

REMOVAL
INSTALLATION

C1O25-B

FIG. 76—Replacing Input Shaft

Bearing
chronizer
hub.
Make sure that
the

spring covers
all
insert grooves. Start

the
hub in the
sleeve making sure that

the alignment marks
are
properly
in-

dexed. Position
the
three inserts
in the

hub making sure that
the
small
end is

over
the
spring
and
that
the
shoulder

is
on the
inside
of the hub.
Slide
the

sleeve
and
reverse gear onto
the hub

until
the
detent
is
engaged. Install
the

front insert spring
in the hub to
hold

the inserts against
the hub. Be
sure

the spring humps
of the
rear spring

cover different inserts than
the
front

spring humps (Fig.
20).

BLOCKING RING

SLEEVE
AND

REVERSE GEAR

C1803-
A

FIG. 17—First
and
Reverse Synchronizer Disassembled

INSERT
HUB AND
SLEEVE ALIGNMENT MARKS

SPRING

BLOCKING m$ERTS

RING
INSERT SPRING

C1804-
A

FIG. 18—Second
and
Third Synchronizer Disassembled
4.
Install
one
insert spring (Fig.
18)

into
a
groove
of the
second
and
third

speed synchronizer
hub,
making sure

that
all
three insert slots
are
fully cov-

ered. With
the
alignment marks
on

the
hub and
sleeve aligned, start
the

hub into
the
sleeve. Place
the
three
in-

serts
on top of the
retaining spring

and push
the
assembly together.
In-

stall
the
remaining insert spring
so

that
the
spring ends cover
the
same

slots
as
does
the
other spring.
Do not

stagger
the
springs. Place
a
synchro-

nizer blocking ring
on
each
end of the

synchronizer sleeve.

COUNTERSHAFT GEAR

BEARINGS

1.
Remove
the
dummy shaft, fifty

roller bearings,
and the two
bearing

retainer washers from
the
countershaft

gear (Fig.
21).

2.
Coat
the
bore
in
each
end of the

countershaft gear with grease.

3.
Hold
the
dummy shaft
in the

gear
and
install
the
twenty-live roller

bearings
and a
retainer washer
in
each

end
of the
gear.

4.
Position
the
countershaft gear,

dummy shaft,
and
roller bearings
in

the case.

5.
Place
the
case
in a
vertical posi-

tion. Align
the
gear bore
and the

thrust washers with
the
bores
in the

case
and
install
the
countershaft.

6. Place
the
case
in a
horizontal

position
and
check
the
countershaft

gear
end
play with
a
feeler gauge.
The

end play should
be
within specifica-

tion.
If not
within specification,
re-

place
the
thrust washers.

7.
After establishing
the
correct end

play, install
the
dummy shaft
in the

countershaft gear
and
allow
the
gear

to remain
at the
bottom
of the
case

until
the
output
and
input shafts have

been installed.

GEAR SHIFT LEVER
AND

CONTROL ASSEMBLY

REMOVAL
AND

INSTALLATION—

FLOOR-MOUNTED

1.
Remove
the
four screws attach-

ing
the
lower boot
to the
floor
pan.

2.
Remove
the two
bolts attaching

the gear shift lever
to the
control
as-

sembly.

3.
Remove
the two
piece lock nuts

that connect
the
shift rods
to the con-

trol assembly.

4.
Remove
the
three bolts retaining

the shift control assembly
to the ex-

tension housing. Allow
the
back-up

light switch
to
hang free.procarmanuals.com

06-02-08
Ford Design Three Speed Transmission

06-02-08

FIRST-REVERSE

SELECTOR LEVER

SELECTOR LEVER

SHAFT

SUPPORT BRACKET

SECOND-THIRD

SELECTOR LEVER

C
2053-A

79—Gear Shift Control Assembly Disassembled—3-Speed
5.
Lower the control assembly from

the vehicle and remove the boot.

6. Remove* the nut from the selec-

tor lever shaft and remove the shaft

from the assembly. Then, llift the se-

lector arm and selector levers out of

the support bracket. Do not lose the

detent spring located between the

first-reverse selector lever and the se-

lector arm (Fig. 19).

7.
Lubricate all mating surfaces

with lithium grease before assembly.

8. Position the detent spring be-

tween the first-reverse selector lever

and the selector arm. Be sure the wide

base of the spring rests against the se-

lector lever. Position the second-third

selector lever against the selector arm

and insert the entire assembly into the

support bracket.

9. Install the selector lever shaft

through the support bracket and selec-

tor lever assembly and install the re-

taining nut.

10.
Slide the control assembly into

the boot and attach the entire assem-

bly to the extension housing. Do not

lose the spacer located inside the as-

sembly. Be sure the back-up light

switch is properly installed.

11.
Install the two bolts securing

the gear shift lever to the shift control

assembly.

12.
Insert a 1/4 inch diameter

alignment pin in the alignment holes

of the control assembly.

13.
Position the shift rods on the

selector levers and install the lock

nuts.

14.
Remove the alignment pin.

15.
Check the operation of the shift

mechanism for smooth cross-over and

adjust as required.

FRONT

REAR

C 1742-A

FIG.
20—First
and
Reverse Speed Synchronizer Insert Spring

Installation

iNEEDLE BEARINGS
(25
EACH
END

\

BEARING

RETAINER ROLL
PIN

. 27—Countershaft Gear Disassembled
BEARING

RETAINER

C1805-
A
ASSEMBLY

1.
Coat the reverse idler gear thrust

surfaces in the case with a thin film of

lubricant and position the two thrust

washers in place.

2.
Position the reverse idler gear

and dummy shaft in place. Align the

gear bore and thrust washers with the

case bores and install the reverse idler

shaft.

3.
Measure the reverse idler gear

end play with a feeler gauge. End play

should be within specification. If the

end play is not within specification,

replace the thrust washers. If the end

play is within limits, leave the reverse

idler gear installed.

4.
Lubricate the output shaft

splines and machined surfaces with

transmission lubricant.procarmanuals.com

06-02-09
Ford Design Three Speed Transmission

06-02-09

PRESS
RAM

OUTPUT SHAFT

SYNCHRONIZER
PRESS
RAM

OUTPUT SHAFT
Tool-T63P7025-A

SYNCHRONIZER

HUB

REMOVAL INSTALLATION c 1718-A

FIG. 22—Removing
and
Installing First
and
Reverse Synchronizer

5.
The
first
and
reverse synchroniz-

er
hub is a
press
fit on the
output

shaft.
To
eliminate
the
possibility
of

damaging
the
sychronizer assembly,

install
the
synchronizer
hub
with
the

teeth
end of the
gear facing toward

the rear
of the
shaft, using
an
arbor

press
as
shown
in Fig. 22. Do not at-

tempt
to
remove
or
install
the hub by

hammering
or
prying.

6. Place
the
blocking ring
on the

tapered machined surface
of the
first

gear.

7.
Slide
the
first gear onto
the out-

put shaft with
the
blocking ring

toward
the
rear
of the
shaft. Rotate

the gear
as
necessary
to
engage
the

three notches
in the
blocking ring with

the synchronizer inserts. Secure
the

first gear with
the
thrust washer
and

snap ring.

8. Slide
the
blocking ring onto
the

tapered machined surface
of the sec-

ond gear. Slide
the
second gear with

blocking ring
and the
second
and
third

gear synchronizer onto
the
mainshaft.

The tapered machined surface
of the

second gear must
be
toward
the
front

of
the
shaft. Make sure that
the

notches
in the
blocking ring engage

the synchronizer inserts. Secure
the

synchronizer with
a
snap ring.

9. Coat
the
bore
of the
input shaft

and gear with
a
thin film
of
grease.
A

thick film
of
grease will plug
the lu-

bricant holes
and
prevent lubrication

to
the
bearings. Install
the 15
bearings

(Fig.
15) in the
bore.

10.
If
working
on a RAT
model

transmission, install
the
input gear

and bearing through
the top of the

case
and
through
the
bore
in
front
of

the case.
On RAN
models,
me
input

shaft
is
installed through
the
front
of

the transmission. Install
the
snap ring

in
the
bearing groove.
11.
Position
the
output shaft
as-

sembly
in the
case. Position
the sec-

ond
and
third-speed shift fork
on the

second
and
third-speed synchronizer.

12.
Place
a
detent plug spring
and

a plug
in the
case
(Fig. 9).
Place
the

second
and
third-speed synchronizer
in

the second speed position (toward rear

of transmission). Align
the
fork
and

install
the
second
and
third-speed shift

rail.
It
will
be
necessary
to
depress
the

detent plug
to
enter
the
rail
in the

bore.
Move
the
rail inward until
the

detent plug engages
the
forward notch

(second-speed position).

13.
Secure
the
fork
to the
shaft

with
the set
screw. Move
the
synchro-

nizer
to the
neutral position.

14.
Install
the
interlock plug
in the

case.
If the
second
and
third-speed

shift rail
is in the
neutral position,
the

top
of the
interlock will
be
slightly

lower than
the
surface
of the
first
and

reverse shift rail bore.

15.
Move
the
first
and
reverse
syn-

chronizer forward
to the
first-speed

position. Place
the
first
and
reverse

shift fork
in the
groove
of the
first

and reverse synchronizer. Rotate
the

fork into position
and
install
the
first

and reverse shift rail. Move
the
rail

inward until
the
center notch (neutral)

is aligned with
the
detent bore. Secure

the fork
to the
shaft with
the set

screw.

16.
Install
a new
shift rail expan-

sion plug
in the
front
of the
case.

17.
Hold
the
input shaft
and
block-

ing ring
in
position. Then move
the

output shaft forward
to
seat
the
pilot

in
the
roller bearings
of the
input

gear.

18.
Tap the
input gear bearing into

place
in the
case while holding
the

output shaft
to
prevent
the
roller bear-

ings from dropping. Install
the
front
C1806-A

FIG. 23—Installing Output Shaft

Rear Bearing

bearing retainer
and new
gasket
mak-

ing sure that
the oil
return slot
is at

the bottom
of the
case. Install
and

torque
the
attaching screws
to
specifi-

cation.

19.
Install
the
large snap ring
on

the rear bearing. Place
the
bearing
on

the output shaft with
the
snap ring

end toward
the
rear
of the
shaft. Press

the bearing into place with
the
tool

shown
in Fig. 23.
Secure
the
bearing

to
the
shaft with
a
snap ring.

20.
On
some models, hold
the

speedometer drive gear lock ball
in

the detent
and
slide
the
speedometer

drive gear into place. Secure
the
gear

with
a
snap ring.
On
models equipped

with
the new
design retainer, install

the speedometer drive gear retaining

clip
on the
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. 9).

21.
Place
the
transmission
in the

vertical position. Working through
the

drain hole
in the
bottom
of the
case,

align
the
bore
of the
countershaft gear

and
the
thrust washers with
the
bore

of
the
case with
a
screwdriver.

22.
Working from
the
rear
of the

case,
push
the
dummy shaft
out of the

countershaft gear with
the
counter-

shaft. Before
the
countershaft
is com-

pletely inserted
in the
bore, make sure

that
the
hole that accommodates
the

roll
pin is
aligned with
the
hole
in the

case.
Drive
the
shaft into place
and in-

stall
the
roll
pin. On all 8
cylinder
ve-

hicles
and
Ford
6
cylinder models,
the

countershaft
is a
press
fit in the
case.

On
6
cylinder models with model

RAN transmissions there
is a
counter-

shaft-to-case clearance
of
0.020 inch

at
the
front bore
and 0.010 at the
rearprocarmanuals.com

06-02-10
Ford Design Three Speed Transmission
06-02-10

bore.
On these 6 cylinder models, in-

stall a new expansion plug in the

countershaft bore at the front of the

case.

23.
Coat a new extension housing

gasket with sealer and position it on

the case.

24.
Install lock washers on the five

attaching screws. Dip the threads of

the cap screws in sealer. Secure the

housing to the case and torque the
cap screws to specification.

25.
Install the filler and drain plugs

(if equipped) in the case. Make sure

that the magnetic plug is installed in

the bottom of the case.

7.6. Place the transmission in gear.

Pour lubricant over the entire gear

train while rotating the input or out-

put shaft.

27.
Install the remaining detent
plug in the case. Install the long

spring (which is retained by the case)

to secure the detent plug.

28.
Coat a new cover gasket (Fig.

5) with sealer. Secure the cover with

cap screws. Torque the screws to spec-

ification.

29.
Check the operation of the

transmission in all of the gear posi-

tions.procarmanuals.com

06-03-01

Ford Design Four-Speed Transmission

06-03-01

PART
6-3
Ford Design Four Speed
Transmission

Trans-

mission

Model

RUG-ADI

RUG-AE1

RUG-AG

RUG-AH

RUG-AJ

RUG-AL

RUG-C2

RUG-D2

RUG-E3

RUG-JZ

RUG-M3

RUG-AK

RUG-VI

® Used with

© Used with
Engine

Model

390-4V-GT

428-4V-CJ

351-2V-4V

351-2V-4V

428-4V

390-4V-GT

390-2V-4V

351-2V-4V

302-2V-4V.351-2V-4V

390-4V-GT

390-4V

351-2V-4V

429-4V

3.75:1
and lower axle ratios

3.50:1
and higher axle ratios
Shift

Lever

Location

Floor

Floor

Floor

Floor

Floor

Floor

Floor

Floor

Floor

Floor

Floor

Floor

Floor
MODEL APPLICATION
All
Models
Ford

X
Mercury
Meteor
Cougar
X

X

X

X

X
Fairlane
X

X

X

X

X

X

X
Falcon
X

X

X

X

X

X

X
Montego
Mustang
X

X

X

X

X
Lincoln-
Continental
Thunderbird
Continental-
Mark
III

COMPONENT INDEX

COUNTERSHAFT GEAR BEARINGS

Removal and Installation

DESCRIPTION

GEAR SHIFT CAMS AND SEALS

Removal and Installation

GEAR SHIFT LINKAGE ADJUSTMENT

GEAR SHIFT CONTROL ASSEMBLY

Removal and Installation

INPUT SHAFT BEARING

Removal and Installation

INPUT SHAFTSEAL

Removal and Installation

REVERSE IDLER GEAR BEARING

Removal and Installation

SYNCHRONIZERS

Disassembly and Assembly

TRANSMISSION (Complete)

Cleaning and Inspection
See
Part 06-01

Disassembly and Overhaul

Removal and Installation

All
Models
03-06

03-02

03-04

03-02

03-05

03-06

03-04

03-06

03-06

03-03

03-02
procarmanuals.com

06-03-02
Ford Design Four-Speed Transmission

06-03-02

1 DESCRIPTION

DESCRIPTION

The Ford designed 4-speed trans-

mission
(Fig. 1) is of the
fully
syn-

chronized type with
all
gears except

the reverse sliding gear being
in con-

stant mesh.
All
forward-speed changes

are accomplished with synchronizer

sleeves.
All forward-speed gears
in the

transmission
are
helical-type, however,

the reverse sliding gear
and the
exter-

ior
of the
first-and second-speed
syn-

chronizer sleeve
are
spur-type gears.

The specifications
of
this section Part

6-4 lists
the
transmission model
num-

bers
and
vehicles
in
which they
are

used.

C 1765-B

FIG. 7—Four-Speed Transmission—Typical
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.

TRANS.
MODEL

O
RUG-C-2

10001
O

SERIAL NO.

C 2088-A

FIG. 2—Transmission

Identification
Tag

IN-VEHICLE ADJUSTMENTS
AND
REPAIRS

SHIFT LINKAGE ADJUSTMENT

1.
Loosen
the
three shift linkage

adjustment nuts. Install
a 1/4
inch
di-

ameter alignment tool through
the

control bracket
and
lever holes
as

shown
in Fig. 13.

An alignment tool
can be
made

from
1/4
inch diameter drill
rod
bent

to
an "L"
shape.
The
extensions
should
be 2 1/2
inch
and 3 3/4
inch

from
the
elbow. Short
end of
align-

ment
pin
should
be
inserted into
con-

trol bracket
and
linkage holes until
it

bottoms.

2.
Disconnect
the
reverse gear shift

rod from
the
shift lever.

3.
Shift
the
transmission into
re-

verse gear.
4.
Tighten
the 1-2 and 3-4
shift
rod

adjustment nuts.

5.
Connect
the
reverse gear shift

rod
to the
shift lever. Shift
the
reverse

lever
to the
neutral position
and
tight-

en
the
adjustment
nut.

6. Remove
the
alignment
pin.

7.
Check
the
gear shift lever
for a

smooth crossover.

REMOVAL
AND
INSTALLATION

REMOVAL

1.
Raise
the
vehicle
on a
hoist.

2.
Mark
the
driveshaft
so
that
it

may
be
installed
in the
same relative
position. Disconnect
the
drive shaft

from
the
rear U-joint flange. Slide
the

drive shaft
off the
transmission output

shaft
and
install
the
extension housing

seal installation tool into the extension
housing
to
prevent lubricant leakage.

See
Fig. 2,
Part
6-1.

3.
Disconnect
the
speedometer

cable from
the
extension housing.

4.
Disconnect
the
parking brakeprocarmanuals.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

06-03-04

Ford Design Four-Speed Transmission
06-03-04

13.
Remove the output shaft bear-

ing as shown in Fig. 6.

14.
Remove the input shaft and

bearing and the blocking ring from

the front of the case.

15.
Move the output shaft to the

right side of the case to provide clear-

ance for the shift forks. Rotate the

forks as shown in Fig. 7, then lift

them from the case.

16.
Support the thrust washer and

first-speed gear to prevent them from

sliding off the shaft, then lift the out-

put shaft assembly from the case as

shown in Fig. 8.

17.
Remove the reverse gear shift

fork set screw. Rotate the reverse shift

rail 90 degrees as shown in Fig. 9.

Slide the shift rail out of the rear of

the case. Lift the reverse shift fork

from the case.

18.
Remove the reverse detent plug

and spring from the case with a mag-

net.

19.
Remove the reverse idler gear

shaft from the case as shown in Fig.

10.

20.
Lift the reverse idler gear and

the thrust washers from the case. Be

careful not to drop the bearings and

the dummy shaft from the gear.

21.
Lift the countershaft gear and

the thrust washers from the case. Be

careful not to drop the bearings or the

dummy shaft from the counter-shaft

gear.

22.
Remove the snap ring from the

front of the output shaft. Slide the

third and fourth-speed synchronizer

(Fig. 11) blocking ring and the third-

speed gear off the shaft.

23.
Remove the next snap ring and

the second-speed gear thrust washer

from the shaft. Slide the second-speed

gear and the blocking ring off the

shaft.

24.
Remove the next snap ring.

25.
Remove the thrust washer, first

speed gear and blocking ring from the

rear of the shaft. The first and second

synchronizer hub is a press fit on the

output shaft. To eliminate the possi-

bility of damaging the synchronizer

assembly, remove the synchronizer

hub using an arbor press as shown in

Part 6-2, Fig. 20. Do not attempt to

remove or install the hub by hammer-

ing or prying.

PARTS REPAIR OR

REPLACEMENT

CAM AND

SHAFT SEALS

1.
Remove the attaching nut, lock

washer and the flat washer from each

shift lever and remove the three levers.

2.
Remove the three cam and shafts

from inside the case.
jjL
-SPRING
•
7234

if

Q-* 'DETENT PtUG 7C316

THIRD AND FOURTH

SPEED SHIFT FORK- 7230

SCREW. 377886 - S

DETENT PLUG-fr-fl

7C316 **

INTERLOCK PIN

7235
FIRST AND SECOND SPEED SHIFT RAIL

7240

fl-«-—
SCREW - 377386 • S

FIRST AND SECOND

SPEED SHIFT FORK • 7230

THIRD AND FOU

SPEED SHIFT RAIL

7241

EXPANSION

PLUG-74112-S

MAGNETIC DRAIN PLUG -373719-S

FIG. 4—Shift Rails and Forks Disassembled
C2074-A

SPEEDOMETER DRIVE

GEAR

SPRING CLIP

FRONT

C2052-A

# 5—Speedometer Drive Gear Installationprocarmanuals.com

06-03-05
Ford Design Four-Speed Transmission

06-03-05

DETAIL
4

FORD
AND
MERCURY

DETAIL
5

COUGAR. FAIRLANE,

FALCON,
MONTEGO,

AND MUSTANG
REVERSE SHIFT

RAIL

C1533-B

FIG. 6—Removing Output Shaft Bearing

3.
Remove
and
discard
the
O-ring

from each
cam and
shaft (Fig.
12).

4.
Dip the new
Orings
in
gear
lu-

bricant
and
install them
on the cam

and shafts.

5.
Slide each cam
and
shaft into
its

respective bore
in the
transmission

case.

6. Secure each shaft lever with
a

flat washer, lock washer
and nut.

GEAR SHIFT CONTROL

ASSEMBLY

1.
Remove
the
four screws attach-

ing
the
lower boot
to the
floor
pan.

2.
Remove the two bolts that secure

the gear shift lever
to
the shift control

assembly.

THIRD AND,

FOURTH

SPEED

SHIFT

FORK

FIRST
AND

REVERSE

SPEED

SHIFT

FORK
3.
Remove
the two
piece lock nuts

that secure
the
shift rods
to the
shift

levers.

4.
Remove
the
three bolts attaching

the control assembly
to the
extension

housing. Lower
the
control assembly

and boot
and
remove
the
control
as-

sembly from
the
boot.

5.
Remove the back-up light switch.

6. Remove
the
outer
nut
from
the

selector lever shaft
and
slide
the
shaft

from
the
control assembly.

7.
Lift
the
outer support bracket,

rubber washer, first-second,
and

third-fourth selector levers
off the as-

sembly (Fig.
13).

8. Remove
the two
bolts retaining

the inner support bracket
to the
back

THIRD
AND
FOURTH

SPEED SYNCHRONIZER

OUTPUT SHAFT MOVED

TO RIGHT SIDE
OF
CASE

C2075-A
C2077-A
Tool-T52T-

C2076-A

FIG. 9—Rotating Reverse

Shift Rail

plate. Lift
the
inner support bracket,

selector arm, and reverse selector lever

from
the
back plate.

9. Lubricate
all
mating surfaces

with lithium grease before assembly.

10.
Position
the
reverse gear selec-

tor lever, selector
arm and the
inner

support bracket
on the
back plate.

The reverse gear selector lever will

have
a
flat spot
on the
top
of
the lever

to distinguish
it
from
the
third-fourth

selector lever. Install the two retaining

bolts finger tight.

11.
Insert
a 1/4
inch gauge
pin

through
the
alignment holes
of the se-

lector levers
and
support brackets.

Line
up the
gauge
pin
perpendicular

to the back plate. Torque the two sup-

port bracket-to-back plate retaining

nuts
to
specification
and
remove
the

gauge
pin.

12.
Position
the
rubber washer,

first-second
and
third-fourth selector

levers
in the
outer support bracket.

Position this assembly against
the

inner support
so
that the selector lever

shaft holes
in the
selector levers
and

support brackets
are
aligned.

13.
Install
the
selector lever shaft

"~ REVERSE IDLER

GEAR SHAFT

Tool-T64P-7140

C2078-A

FIG. 7—Removing Shift Fork

From Case
FIG. 8—Removing Output

Shaft Assembly
FIG. TO—Removing Reverse Idler

Gear Shaftprocarmanuals.com