Werkstatthandbuch Book 1 · Seiten 501–600

16-01-5 General Clutch Service 16-01-5 cantsto the release bearing, release bearing hub and the release lever fork, as excessive lubricant would PRESSURE PLATE AND COVER contaminate the clutch disc. Hold the bearing inner race and rotate the outer race while applying pressure. If rotation is rough or noisy, replace the bearing. Undue bearing wear is usually caused by an improper clutch linkage free play setting or where the clutch pedal does not return against rubber stop. If the clutch linkage does not have enough free travel, the release bearing will constantly touch the release fingers and spin whenever the engine is running. Misalignment between the engine and transmission can also cause release bearing wear and damage. Pressure Plate and Cove

16-01-6 General Clutch Service 16-01-6 NORMAL FINGER WEAR ExCESSIVE FINGER WEAR SLIGHT CHATTER MARKS ExCEIVE BLUEING AND CHATTER ExcESSIVE WARPAGE WEAR PATTERN FROM WARPED PRESSURE PLATE 025 19-2A FIG. 6 Clutch Inspection "This publicati

16-01-7 General Clutch Service 16-01-7 REMOVAL AND INSTALLATION DOWELS-FLYWHEEL AND ENGINE Removal NEEDLE ROLLER Dowels can be removed by using a drift pin where the dowel is installed in a drilled hole and vise grip pliers where the dowel is installed in a blind hole. They should be pulled or driven from their seat, taking care not to damage the surface area around the dowel during removal. Installation C2998.1 A 1. Solid Type Dowels All solid.type dowels can be installed by driving them into place using a brass or plastic mallet. Again, care should be exercis

16-01-8 General Clutch Service 16-01-8 Clutch Pilot Bearing Installation-Mustang II 5.OL 302 CID, Monarch, Granada, Fairmont and Zephyr 3.3L 200 CID Removal-All Models 1. Coat the pilot bearing bore in the crankshaft with 1. Remove the transmission, clutch pressure plate and a small quantity of lithium base grease. Avoid using disc following procedures described in the pertinent too much lubricant as it may be thrown on the clutch sections of the Shop Manual. disc when the clutch revolves. 2. Pull the bearing from the crankshaft using a slide-

16-02-1 Clutch 16-02- 1 PART Clutch 16-02 Applies To Pinto/Bobcat Mustang II. Fairmont/Zephyr, Granada/Monarch SUBJECT PACE SUBJECT PAGE DESCRIPTION REMOVAL AND INSTALLATION Cont’d.} Granada/Monarch 02-1 Fairmont/Zephyr 02-1 Pinto/Bobcat/Mustang II - Fairmont/ Mustang II 2.3L and 5.OL [302 CID] 02-6 Zephyr 02-1 Mustang II 2.3L V-6 02-6 REMOVAL AND INSTALLAT

16-02-2 Clutch 16-02-2 Installation 5. Disengage the clutch cable from the flywheel housing. Install the clutch release lever if it was removed. 6. Remove the starter electrical cable, then the starter2. Position the clutch disc and pressure plate assembly motor from the flywheel housing. on the flywheel. The three 3 dowl pins on the flywheel must be properly aligned with the pressure 7. Remove the bolts that secure the engine rear plate plate. Bent, damaged o

16-02-3 Clutch 16-02-3 8. Install the transmission following instructions fork and anti-rattle spring where they contact contained Part 161 1, Ford Three-Speed the release bearing hub, 3 to the release Transmission. bearing surfaces that contact the pressure plate 9. Adjust the clutch pedal free travel following release fingers, and 4 to the release lever instructions given in Part 16-03. pivot. Then, fill the grease groove of the release bearing with the same lubricant Clean GRANADA AND MONARCH REFER TO FIG. 4 all excess lubricant from insi

C LUBRICATE LOVER CROWN U SPRING RE IEPFTION CR058. 0 SEE LUBRICATIOR CHART 2.31.2.8 LITER ENCS. REAR FACE OF BLOCK SPRIPIG 54857 RE POSITIGREO 34092-530 RET & FLYWHEEL REF. HEITRIN SEARING GROOVE SECTION A 57

16-02-5 Clutch 16-02-5 14303 - CABLE ASSY. 3179 1D’S36M 34793-S36M I RBQ’D. I REaD.

16-02-6 Clutch 16-02-6 MUSTANG II 2.3 LITRE AND 5.0L 302 CID REFER 5. Install the clutch release bearing to the release TO FIG. 5 lever. Removal 6. Attach the release lever and release bearing to the flywheel housing. 1. Remove the clutch cable retaining clip and loosen the clutch cable adjusting nut to provide slack in 7. Make certain that the flywheel housing and the the cable. cylinder block mounting surfaces are clean and that

RELEASE LEVER -7591 HOUSING 6394 .1 L.EVERCROWN RELEASE LEVER ANOSPRING RETENTION CROWN ASSEMBLY-. 7515

16-02-8 Clutch 16-02-8 15. Remove the pressure plate and clutch disc fram the 3. Pull back the rubber dust cover and disengage the flywheell. clutch cable from the release lever. Installation 4. Disconnect the clutch cable from the flywheel housing.1. If the clutch release lever was removed, install it by placing it in position and sliding the lever and shaft 5. Remove the starter electrical’ cable and the starter motor from the flywheel housing. assembly through the hous

16-02-9 Clutch 16-02-9 11. Connect the clutch cable to the flywheel housing. 12. Install the starter motor and starter electrical cable. 13. Connect the clutch cable to the release lever and reinstall the rubber dust cover. 14. Adjust the clutch pedal free travel following instructions in Part 1 6-03. "This publication contains material that is reproduced and distributed under a license to Detroit Iron from Ford Motor Company. No further reproduction or distribution of the Ford Motor Company material is allowed without the express written permission of Ford Motor Company."

16-02-10 Clutch 16-02-10 REAR FACE OF BLOCK & FLYWHEEL DOWELS 1K518 3 REQUIRED DOWELS 2 REQUIRED PILOT BEARING 7120 INSTALL WITH SEAL N800054-S51 M

16-02-11 Clutch 16-02-11 SPECIFICATIONS CLUTCH IDENTIFICATION Car Line Engine Transmission Pressure-Plate Disc Diameter No. of Color Identification Diameter No. of Color Identification Inches Springs Paint Daub llnches Springs hint Daub Pinto/Bobcat 2.3L 4-Speed 8.5 N/A None 8.5 6 Disc - Pink

16-02-12 Clutch 16-02-12 TORQUE SPECIFICATIONS - CLUTCH - GRANADA/MONARCH Component Torque FT-La Component Torque FT-LB Bolt - Flywheel Housing to Engine Bolt - Pressure Plate to Flywheel 1220 38-61 -4.1 L 250 610, 5.OL 302 GIn TORQUE SPECIFICATIONS - PINTO/BOBCAT/MUSTANG II Component Torque FT-LB Component Torque FT-La Bolt - Flywheel Housing 28-35

16-03-1 Mechanical Clutch Linkage 16-03-1 PART Mechanical Clutch Unkage 16-03 Applies To Pinto/Bobcat/Mustang II, Fairmont/Zephyr, Granada/Monarch SUBJECT PAGE SUBJECT PAGE ADJUSTMENTS REMOVAL AND INSTALLATION Cont’d. Clutch Free Travel 03-1 Clutch Equalizer Bar or Bushing 03-8 Clutch Pedal 03-1 Clutch Pedal O37 REMOVAL AND INSTALLATION SPECIFICATIONS 0310 Clutch Cable 03-8

16-03-2 Mechanical Clutch Linkage 16-03-2 BRAKE SUPPORT RETAINING CLIP 74275-s 2 CLEVIS PIN PLATE ASSEMBLY 38463 2-52 /85.1 /

MANUAL BRAKE AND/OR 2-3 LITRE CLUTCH CABLE RETAINING CLIP 70590 POWER BRAKE ONLY V6 CLUTCH ONLY CLUTCH CABLE 3DBB2 1-4 HUMMERI BRAKE SUPPORT 7L523 11-4 LIMA I MUST BE INSERTED INTHIS NUT 3828O2-S1OD

16-03-4 Mechanical Clutch Linkage 16-03-4 BUSHING 24612 REQUIRED BUMPER 7583 97414 ‘‘LIIUJJJIIIflhIjjJJJJJIJJ2 =.1 VIEW IN CIRCLE X VIEW ‘V 18517 PLATE BRAKE SUPPORT

16-03-5 Mechanical Clutch Unkage 16-03-5 Fairmont/Zephyr 3.3L 200 CID Engine 2.3 Litre Engine Refer to Fig. 4 Refer to Fig. 4 Pull the clutch cable toward the front of the car until the adjusting nut can be rotated. Rotate the 1. From Under the car, remove the release lever return adjusting nut away from the rubber insulator spring and dust shield. approximately 0.30". Do not try to rotate the nylon nut until it is free of the rubber insulator. If required.2. Loosen

16-03-6 Mechanical Clutch Linkage 16-03-6 2.2L 200 OlD ENC. FREE PLAY ADJ. BRAKE PEDAL VIEW Y SUPPORT REF. 366531 BUMPER 6362 ASSY. REP. 7K553 ASSY.

16-03-7 Mechanical Clutch Linkage 16-03-7 REMOVAL AND INSTALLATION CLUTCH PEDAL Installation Pinto/Bobcat Refer to Fig. 1 1. Apply a coating of SAE 10 engine oil to the Removal bushings and locate the bushings in their proper place on the clutch and brake assemblies. 1. Disconnect the negative battery cable. 2. Install the clutch pedal to the pivot bolt and spacer 2. Working from under the car, loosen the clutch cable and install th

16-03-8 Mechanical Clutch Linkage 16-034 Fairmont/Zephyr 2. Position the equalizer bar over the bushing an the engine bracket.Refer to Fig. 4 3. Install the wire retaining clip to the equalizer bar. Removal Be sure that the clip seats in the bushing groove. 1. Disconnect the negative battery cable. 4. Position the outer bushing on the frame bracket 2. Loosen the clutch cable adjusting nuts; on the 2.3L, pivot and install ‘‘C" clip. Then position the working under the car, remove the r

16-03-9 Mechanical Clutch Linkage 16-03-9 Mustang 11-2.3 Litre and 5.0 Litre 302 CIO V.8 Installation Refer to Fig. 2 1. Insert the clutch cable in the flywheel housing boss and secure with locknut. Place the clevis over the 1. At the dash panel, remove the cable retaining clip end of the cable and attach the cable to the release and pull the cable toward the front of the car until lever shaft assembly with the clevis pin and the adjusting nut can be rotated. Rotate the nut

16-03-10 Mechanical Clutch Linkage 16-03-10 SPECIFICATIONS CLUTCH - ADJUSTMENTS INCHES Free Play Adjustment Dimension Granada/Monarch else Fairmont/Zephyr 0.30 Pinto/Bobcat Built-in Adjusting Nut Mustang II Built-in Adjusting Nut Clutch Pedal Free Trav

16-10-1 General Manual Transmission Service 16-10-1 General Manual Ibo Transmission Service Applies to All Models SUBJECT PAGE SUBJECT PAGE CLEANING AND INSPECTION REMOVAL AND INSTALLATION Manual Transmission 10-7 Sub-Assemblies 10-5 Aluminum Case Repair 10-9 DIAGNOSIS SPECIALTOOLS 10-9 Manual Transmission 10-2 CC3O1 8-2B MFD. BY FOR

16-10-2 General Manual Transmission Service 16-10-2 DIAGNOSIS CONDITION POSSIBLE CAUSE RESOLUTION * Transmission shifts hard * Improper clutch pedal free travel * Adjust. Assure complete clutch re lease. Part 16-03. * Manual shift linkage binding * Free up linkage. * Internal shift mechanism binding * Remove transmission and free up shift

16-10-3 General Manual Transmission Service 16-10-3 CONDITION POSSIBLE CAUSE RESOLUTION * Transmission jumps out of gear * Manual - shift linkage out of adjustment * Adjust linkage. Align steering column to car body. * Floor shift - stiff shift boot * Verify jump-out with boot removed. Replace boot if necessary. * Floor shift - interference between shift * Adjust console to eliminate inter-

16-10-4 General Manual Transmission Service 16-10-4 CONDITION POSSIBLE CAUSE RESOLUTION * Transmission leaks * Excessive amount of lubricant in trans * Check level and type. Fill to bottom mission - wrong type of filler plug hole. * Other component leaking * Identify leaking fluid at engine, power steering or trensni i

16-10-5 General Manual Transmission Service 16-10-5 CONDITION POSSIBLE CAUSE RESOLUTION * Transmission locked in one gear Can- * Neutral sensing switch If so equipped * Replace switch. not be shifted out of year Four- for detent ball frozen in extended speed models position * On RUG models, disconnect shift rods from levers. Try to

16-10-6 General Manual Trarsmission Service 16-10-6 TOOL - 1t75.AC TOOt. - T5OT-100-A 01921-28 FIG. 6 Removing Extension Housng Seal EXTENSION HOUSING TOOL -Tb? P-i697 -8 USHiNG clan-lA

16-10-7 General Manual Transmission Service 16-10-7 AoAPTcn TOOL-T71 P7095-A -v SHOULDER AWAY FROM SEALI N C2564-lB FIG. 11 Installing Extension Housing Seal- Pinto/Bobcat/Mustang I l-Fairmont/ Zephyr CLEANING AND INSPECTION TRANSMISSION 8. Replace the reverse idler gear or sliding gear if the

16- 10-8 General Manual Transmission Service 16- 10-8 13. Replace the speedometer drive gear if the teeth are Bearing External Surfaces stripped or damaged, Make certain to install the The bearing must be replaced if damage is found in correct size replacement gear. any of the following areas: 1. Radial cracks on front and rear faces of the outer 14. Replace the output shaft if there is any evidence of wear or if any of the splines are damaged. or inner rings. 2. Cracks on outside diameter or outer ring 15. Inspect the bushin

16-10-9 General Manual Transmission Service 16-10-9 inspection and spin tests, it should be reinstalled in the insert on the tool and adjust the sleeve to the the transmission. length of the insert being used. Press the insert against the face of the tapped hole. Turn the tool ALUMINUM TRANSMISSION CASE REPAIR clockwise and wind the insert into the hole until the insert is 1/2 turn below the face. If an aluminum transmission case thread is damaged, 4. Working through the insert, bend the insert tang service kits may be purchased from local jobbers. To

16-11-1 Ford Three-Speed Transmission 16-11-1 PART Ford Three-Speed Transmission 16-11 Applies To Fairmont/Zephyr SUBJECT PAGE SUBJECT PAGE ADJUSTMENTS DISASSEMBLY AND ASSEMBLY Cont’d.J Gear Shift Linkage 11-1 Transmission 11-4 DESCRIPTION REMOVAL AND INSTALLATION Transmission 11-1 Floor-mounted Shift Control 11-3 Transmission

16-11-2 Ford Three-Speed Transmission 16-11-2 7213 INSTALLATION OF SHIFT KNOB 1. WITH LEVER IN NEUTRAL POSITION, INSTALL LOCKING NUT 70404 HAND- TIGHT, 2. INSTALL KNOB 7213 HAND-TIGHT. 3, BACK SHIFT KNOB OFF UNTIL PATTERN ALIGNS WITH URIVE LINE CENTERLINE,

16-11-3 Ford Three-Speed Transmission t6-I I-S REMOVAL AND INSTALLATION GEAR SHIFT LEVER AND CONTROL 37961 B-SE 8-12 FT’LB ASSEMBLY-FLOOR-MOUNTED REMOVAL Refer to Figs. 2 and 3 379999-52 1. Remove the four screws attaching the lever boot to the floor pan. 7400 ASSY. 2. Remove the two bolts attaching the gear shift lever

16-11-4 Ford Three-Speed Transmission 16-11-4 attaching bolts. Secure each shift rod to its front universal joint yoke onto the output shaft and respective lever with the spring washer, flat washer, into the extension housing. Connect the rear and retaining pin, universal joint to the axle pinion flange and torque 6. Insert the speedometer cable and driven gear in the the nuts to specifications. extension housing and secure it with a capscrew 8. Fill the transmission to the proper level with the and lockwasher. approved lubricant. 7. Remove tool To] L-7o57-A from the extension 9. Adjust the clutch pedal free trave

16-11-5 Ford Three-Speed Transmission 16-11-5 COUNTERSHAFT DUMMY SHAFT c2070’iB FIG. 6 Removing Countershaft 16. Pull the input gear and shaft forward to separate the input shaft and gear from the front of the case. 17. Rotate the second- and third-speed shift fork upward, and lift it from the case. 18. Carefully lift the output shaft assembly out through the top of the case. C3023-lB 19. Remove idler gear shaft, driving from the front of FIG. 7 Removing Input or Output Shaft Bearing the case. 20. Lif

16-11-6 Ford Three-Speed Transmission 16-11-6 the gear as necessary to engage the three notches speed position toward rear of transmission, and in the blocking ring with the synchronizer inserts. secure the fork to the rail with the set screw. Secure the first gear with the thrust washer and 13. Move the synchronizer to the neutral position. snap ring. 14. Install the interlock pin in the case. If the second- 8. Slide the blocking ring onto the tapered machined and third-speed. shift rail is in neutral position, the surface of the second gear. Slide the second gear top of the interlock pin will be slightly lower than with blocking ring, and

16-11-7 Ford Three-Speed Transmission 16-11-7 PRESS RAM PRESS RAM TOOL - TISL-7025.P SYNCHRONIZER GUT PUTA’ OUTPUT SHAFT SHAFT / SYNCHRONIZER SYNCHRONIZER HUB NUT REMOVAL INSTALLATION Cilia-iA FIG. 12 Removing and Installing First and Reverse Synchronizer

16-11-8 Ford Three-Speed Transmission 16-V 1-8 AUGMENT 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 INSERTS- 7A044 synchronizer Figs. 16 and 17. MARKSH 3. Install the insert spring in the hub of the first and reverse synchronizer. Make sure that the spring

16-11-9 Ford Three-Speed Transmission 16-i 1-9 7. After establishing the correct end play, install the gear to remain at the bottom of the case until the dummy shaft in the countershaft gear and allow the output and input shafts have been installed. SPECIFICATIONS 3 SPEED TRANSMISSIONS - TRANSMISSION COMPONENT END PLAY LUBRICANT REFILL CAPACITY TO BOTTOM OF FILLER HOLE

16-28-1 Model RAD Four-Speed Transmission 16-28-1 Model RAD Four-Speed 1rT8 - Transmission Applies To Mustang II SUBJECT PAGE SUBJECT PAGE DESCRIPTION AND OPERATION REMOVAL AND INSTALLATION Transmission 28-1 Shift tever 28-2 Transmission 28-3 DISASSEMBLY AND ASSEMBLY Transmission - Assembly

16-28-2 Model RAD Four-Speed Transmission 16-28-2 0 PAD MAINSHAFT SNAP LOCATION INPUT OUTPUT 2ND GEAR C2410-IA FIG. 2 Gear Shift Lever Positions SNAP-RINGS PART NUMBERS & LOCATIONS

16-28-3 Model RAD Four-Speed Transmission 16-28-3 Installation 1. Make sure the shift lever insulator is in a straight downward position on the shift rail. 2. Position the shift lever in the extension housing so that the forked ends engage in the insulator properly Fig. 5. 3. Install the three attaching metric MB bolts. 4. Install the boot and attaching screws. SHIFT LEVER 5. Position the carpet or floor mat arid install the step plates and screws. 6. Install the two kick pads. 7. Install the locknut and shift knob. 8. Check to make sure that the transmission lever is operating properly. TR

16-28-4 Model RAD Four-Speed Transmission 16-28-4 DISASSEMBLY AND ASSEMBLY TRANSMISSION REFER TO FIG. 11 6. Remove the spring clip retaining the reverse lever assembly to pivot bolt. Remove the pivot bolt, andDisassembly the reverse lever assembly. 1. Mount the transmission in a holding fixture Fig. 8 7. Remove the snap ring securing the input bearing to and drain the lubricant by removing the lower the input shaft. Remove the outer snap ring from extension housing bolt.

16-28-5 Model RAD Four-Speed Transmission 76-28-5 80 82 is 2 3 2Og 21 ITEM PART NAME REaD. ITEM PART NAME REaD. CASE ASSY. - TRANS. 47. LEVER-TRANS. REV. GEAR SHIFT RELAY CASE - TRANS. 48. FORK-TRANS. REVERSE GEAR SHIFT 3. MAGNET ‘TRANS. CASE CHIP

16-28-6 Model RAD Four-Speed Transmission 16-28-6 ASSEMBLY BOL BOLT SCREW SHAF E ‘FORK PLATE NYLON INSERT LEVER -PORK INSERT FORK 02740-10

____________ 16-28-7 Model RAD Four-Speed Transmission 16-28-7 2. Remove the next snap ring and the second-speed gear thrust washer from the shaft. Slide the second- speed gear and blocker ring off the shaft. Take HUB iNSERTS 3RD AND 4TH SYNCHRONIZER SPRINGS 1109 care not to lose the sliding gear from first- and 7116 second-speed synchronizer assembly. The first- and second-speed synchronizer hub cannot be removed from the output shaft. 3. From rear of output shaft, remove the first gear thrust washer oil slinger. Remove the spring pin

16-28-8 Model RAD Four-Speed Transmission 16-28-8 EXTENSION HOUSING TOOL-T6OK’7697-A SEAL /WOL_T7 1 P7657-A ClOfl-I E FIG. 18 Removing Extension Housing Bushing and Seal C2416-1C

16-28-9 Model RAD Four-Speed Transmission 16-28-9 10. Install the reverse idler gear lever assembly, making 13. Insert the speedometer drive gear lock ball into the sure the fork is positioned in the reverse idler gear hole. Holding the ball, slide the speedometer drive groove. gear into place and secure with a snap ring. 11. Use a sealer on the reverse lever pivot bolt threads, 14. Using a new gasket, install the extension housing and install the bolt into the case. Align the lever to the case. Use a sealer on the attaching bolts and on the pivot bolt and torque bolt 15 to 25 ft-lb. torque 18 to 27 ft-lb. Caution should be taken so Install reverse lever retaining spring clip t

16-29-1 Model 7SET Four-Speed Transmission 16-29-1 Model 78ET Four-Speed 1t9 Transmission Applies to Pinto/Bobcat, Fairmont/Zephyr SUBJECT PAGE SUBJECT PAGE DESCRIPTION AND OPERATION SPECIFICATIONS AND SPLCIAL Transmission 29-1 SERVICE TOOLS 29-15 DISASSEMBLY AND ASSEMBLY Transmission 29-7 REMOVAL AND INSTALLATION Shift Lever 29-3 Transmission 29-5 CC 332

16-29-2 Model 78ET Four-Speed Transmission 16-29-2 7E391 COIN TRAY ASSY. VIEW SHOWING COIN TRAY FILLER PLUG

16-29-3 Model 7SET Four-Speed Transmission 16-29-3 C24 10-lA FIG. 3 Gear Shift Lever Positions C2206-2A FIG. 4 Snap Ring Locations REMOVAL AND INSTALLATION SHIFT LEVER 3. Lower the vehicle. 4. Loosen the gearshift lever knob locknut and removePINTO/BOBCAT the knob and locknut. Removal

16-29-4 Model 78ET Four-Speed Transmission 16-29-4 7. Working from the front, fold the carpet or floor mat Installation up against the shift lever Fig. 6. Remove the four 1. Make sure that the shift lever insulator is in a shift lever boot retaining ring screws. Remove the straight downward position on the shift rail. boot through the opening in the floor mat. 2. Position the shift lever in the extension housing so 8. Compress the corrugated rubber spring Fig. 7 then that the forked end engages the insulator properly. remove the retaining snap ring and slide the spring 3. Carefully t

16-29-5 Model 78E1 Four-Speed Transmission 16-29-5 GEAR SHIFT LEVER LEVER -- 7K3E] PLASTIC NUT LOCK TA B S C24lA FIG. 8 Removing or Installing Shift Lever- Pinto/Bobcat

16-29-6 Model 7BET Four-Speed Transmission 16-29-6 11. Lower the engine as required to permit removal of bolts that attach the flywheel housing to the engine. 7K327REF. Slide the transmission away from the engine and from under the vehicle. NOTE: On Fairmont/Zephyr vehicles, it may be necessary to slide the mounting bracket forward from the catalytic converter heat shield in order to move the transmission rearward far enough to remove it. 12. Remove the cover attaching bolts and drain the lubricant into a container. INSTALLATION OF SHIFT KNOB 13. Remove the bolts that attach flywheel housing- to WITHNIJT 7C404LEVERUNTILIN NEUFHALHAND TIGH

16-29-7 Model 78ET Four-Speed Transmission 16-29-7 13. Install the driveshaft, making sure that it is 15. Install the back-up lamp switch a nd connect the connected to the pinion flange in its original wire to the switch. position. 16. Lower the vehicle to the ground. 14. Fill the transmission with the specified lubricant until 17. Check the transmission for proper operation. it appears at the bottom of the filler plug hole. Install the filler plug and torque to specification. DISASSEMBLY AND ASSEMBLY TRANSMISSION Disassembly 1. Remove the clutch release bearing and lever. Remove the clutch housing attaching bolts and

16-29-8 Model 78ET Four-Speed Transmission 16-29-8 SHIFT LEVER INSULATOR SHIFT RAIL C 2466-2A FIG. 16 Removing or Installing Shift Rail MAINSHA F / -....REVERSE IDLER GEAR SHAFT INPUT SHAFT

16-29-9 Model 78ET Four-Speed Transmission 16-29-9 THRUST wASHER BEARING RETAINING WASHER THICK THRUST WAR BEARING RETAINING WASHER THIGK.._ BEARINGS LONG-1121 BEARING RETAINING WASHER THIN BEARINGS SHORT-Il 21

16-29-10 Model 78ET Four-Speed Transmission 16-29-10 Assembly of the synchronizer unit, being sure that the spring 1. Seat the new shift rail seal in the rear of the tab locates in the same insert as the spring just transmission case as shown in Fig. 23. installed and is in the opposite rotational direction Fig. 24.2. If the shift rail bushing was removed from the extension housing, drive a new one into place with 4. Assemble a blocker ring on the first gear side of a 9/16-inch socket wrench and extension. the first- and second.speed synchronizer Fig. 22.

16-29-li Model 78ET Four-Speed Transmission 16-29-11 the output shaft gear journals prior to installa tion of all gears. 9. Position the third-fourth synchronizer assembly on the output shaft with the hub boss small diameter facing forward. 10. Retain the third-fourth synchronizer assembly to the output shaft with a snap ring. Pull up on th

16-29-12 Model 78ET Four-Speed Transmission 16-29-12 TOOL TilE 1111-B 3RD AND 4TH SPEED SYNCHRONIZER 1ST AND 2ND SPEED SYNCHRONIZER .71 BEAM flU /0 SHORT

16-29-13 Model 78ET Four-Speed Transmission 16-29-13 BEARING RETAINER INPUT SHAFT TOOL T1IP-7OSO.4 LUBRICANT RETURN C2482 IA FIG. 33 Installing Input Shaft Gear INPUT SHAFT BEARING RETAINER

16-29-14 Model 78ET Four-Speed Transmission 16-29-14 26. Position a new oil seal on Tool T71 P-7050-A Fig. 32 so that the tension spring and the lip of the sealing element face in the direction of the EXTENSION HOUSING transmission case. 27. Drive the seal into the retainer until it bottoms. Tool -TTOP-E01’-A 28. Position a new 0-ring in the groove in the face I Fig. 33 of the transmission case. Apply C3RZ-19C547-B lubricant or equivalent to input shaft seal journal area. Exercise care / when installing the retainer to prevent damage to the seal lip. Position the input shaft bearing retainer

16-29-15 Model 78ET Four-Speed Transmission 16-29- 15 SPECIFICATIONS MODEL 1BET TRANSMISSION Transmission Component End Play Component In Inches Transmission Lubricant I Cluster Gear To Case .006-018 Type Level Capacity ESW-M2C83-C To Bottom 2.8 Pts. U.S. SPECIAL SERVICE TOOLS - of Filler Hole 2.3 Pts. IMP.

16-30-1 Four-Speed Overdrive Transmission 16-30-1 Four-Speed Overdrive Transmission Applies Ta Granada/Monarch SUBJECT PAGE SUBJECT PAGE ADJUSTMENTS REMOVAL AND INSTALLATION Shift Linkage 30-1 Floor-Mounted Shift Control 30-3 Transmission 30-4 DESCRIPTION Transmission 30-1 SPECIFICATIONS ANO SPECIAL SERVICETOOLS 30-12 DISASSEMBLY AND ASSEMBLY Sub-Assem

16-30-2 Four-Speed Overdrive Transmission 16-30-2 7K329 .ASSY 7C305 A5SY ?C404 13-IS FT- LB 383184-52 INSTALLATION FOR MODELS WITH CONSOLE

16-30-3 Four-Speed Overdrive Transmission 16-30-3 LLAEION OF SHIFT KN WITH LEVER IN NEUTRAL POSITION, INSTALL LUCKINU NUT 7C4D4 UNTIL HAND TIGHT. THEN INSTALL KNOB 7K327 UNTIL HAND TIGHT. BACK KNOB OFF UNTIL SHIFT PATTERN ALIGNS WITH G OF DRIVE LINE TIGHTEN LOCKING NUT 13-lB FT-LB. NO THREAD SHALL BE VISIBLE AFTER NUT HAS BEEN TIGHTENED. PATTERN ALIGNMENT MUST BE WITHIN * 15° OF QOF DRIVELINE. 379818-SE 37999952

16-30-4 Four-Speed Overdrive Transmission 16-30-4 9. Lubricate all connections with chassis lube, as 9. Move the transmission and jack rearward until the required, and shift the transmission back to neutral. transmission input shaft clears the flywheel housing. 10. Install back-up lamp switch connector on switch. If necessary, lower the engine enough to obtain clearance for transmission removal. Do not 11. Lower the vehicle. Position the shift lever to the shift depress the clutch pedal while the control and install the two attaching bolts. Torque transmission is removed. the bolt

16-30-5 Four-Speed Overdrive Transmission - 1640-5 5. Remove the input shaft bearing retainer attaching 10. Remove the interlock plug from the top of the case screws. Slide the retainer off the input shaft. with a magnet. 6. Support the countershaft gear with a wire hook. 11. Remove the snap ring that secures the speedometer Working from the front of the case, push the drive gear to the output shaft. Slide the gear off countershaft out the rear of the case with a dummy the shaft, then remove the speedometer gear drive shaft T64p-71 1 lÀ as shown in Fig. 4. Lower the ball. countershaft to the bottom of the case with the wire 12. Remove the snap ring that secures the output shaft

16-30-6 Four-Speed Overdrive Transmission 16-30-6 THIRD AND OVERDRIVE SYNCHRONIZER T75L-7025. 1J- T75L 7075 E.-- 117 L-7025.A T751-7O,5.H C300B-1B FIG. 9 Removing and Installing Output Shaft FIG. 7 Removing Input Shaft Bearing Assembly THIRD

16-30-7 Four-Speed Overdrive Transmission 16-30-7 in place on the reverse idler sliding gear and install the shift rail from the rear of the case. Secure the REVERSESHIFT RAIL fork to the rail with the Allen head set screw. 11. Install the first and second-speed synchronizer Fig. 19 into the front of the output shaft, making sure that the shift fork groove is toward the rear of the shaft. The first and reverse synchronizer hub is a slip fit on the output shaft. Install the synchronizer hub with the teeth end of the gear facing toward the rear of the shaft. 12. Position the blocking ring on the second-speed gear. 13. Slide the second-speed gear onto the front of the shaft, ma

_______ 1640-8 Four-Speed Overdrive Transmission 16-30-8 SPEEDOMETER DRIVE GEAR I 1285 7065 SNAP RING RING 7026

16-30-9 Four-Speed Overdrive Transmission 16-30-9 Ti? L-’{LTh-U COUNTERSHAFT T7IL-7D25.D / ASSEMBLED TD SHAFT INSIDE T75L-7025-B C3009-1A FIG. 14 Installing Input Shaft Bearing 1OOL - T751-7025-P FIG. 16 Installing Countershaft TOOL - T751.7025-K 7/ THIRD AND OVERDRIVE CAM AN

16-30-10 Four-Speed Overdrive Transmission 16-30-10 7064 7026 INPUT SNAFT ROLLER AND GEAR-701 7 RETAINER WASHER-378559-5 THRUST WASHER 7119 SNAP RINGS FRONT EEARING-7025 BLOCKING N C1802-lB THRUST ROLLER EEARING$-71 21 211

16-30-11 Four-Speed Overdrive Transmission 16-30-11 Installation - SEAL TOOL-T50T-l00-A LI 1. Coat the bore in each end of the reverse idler gear A with grease. 2. Hold the dummy shaft in the gear and install the 22 roller bearings and the retainer washer in each end of the gear. TOOL-T58L-10l-A 3. Install the reverse idler sliding gear on the

16-30-12 Four-Speed Overdrive Transmission 16-30-12 SPECIFICATIONS 4-SPEED OVERDRIVE TRANSMISSION Gear Ratios Car Model Engine Transmission Model 1st 2nd 3rd Overdrive Reverse 1 Granada/Monarch 4.1L 250 dO 4.1L 250 dID SQL 302 dO RUG-BP 3.29 1.84 1.0 0.81 3.29 SQL 302 dO LU8RICANT REFILL CAPACITY TRANSMISSION COMPONENT END PLAY Transmission Lubricant Capacity Type Application Spe

17-00-1 Automatic Transmission 17-00-1 GROUP AUTOMATIC TRANSMISSION 17 PART TITLE PART NO. PART TITLE PART NO. 03 Automatic Transmission 17-03 [MX Automatic Transmission 17-15 04 Automatic Transmission - 17-05 General Transmission Service 17-01 JATCO Automatic Transmission 17-08 Shift Control Linkage 17-02 CS Automatic Transmission 17-10 CD2880*2B "This publication cont

17-01-2 General Automatic Transmission Service 17-01-2 . PART General Automatic . 17-01 Transmissions Service Applies To All Cars SUBJECT !Aq! SUBJECT PAGE CLEANING AND INSPECTION DIAGNOSIS AND TESTING Case 01-28 Air Pressure Checks 01-11 Control Valve Body 01-22 Anti-Stall Dashpot Cle

_______ 17-01-3 General Transmission Service 17-01-3 GENERAL INFORMATION TRANSMISSION IDENTIFICATION All vehicles are equipped with a Vehicle Certification and to Fig. 1 below for proper transmission label, affixed to the left driver’s side door lock post. identification. Refer to the stamped code in the spoce marked Trans. MFD, BY FORD MOTOR CO. IN USA. DA FE, S 7" U,R 65,5 TRANSMISSION TRANSMISSION GR. FRO - lI’ R J.C5 CODE TYPE ‘tHIS VI-UI LI: ONFORIS lu ALL AI’P[,I’ BI_l- FFII’R,I 1OIOR S AUTOMATIC JATCO Vt-HICL,L SAil’ Ii St .NIARIS

_________j8 ______ 17-01-4 General Transmission Service 17-01-4 Before adding fluid, be sure that the correct type will FLUID LEVEL HIGH BEFORE STARTING be used. If in doubt, check the Vehicle Certification ENGINE-OK DURING NORMAL CHECKLabel affixed to the left front door lock face panel or door pillar for the Transmission Code. FMX The C-3 Automatic Transmission Transmission Code 1. Recheck fluid level after 6 hour soak. V, C-4 Automatic Transmission Code W and the FMX 2. Check for correct indicator, Automatic Transmission Code X use transmission fluid 3, Remove transmission meeting Ford Specification ESW-M2C33-F Type F,

17-01-5 General Transmission Service 17-01-5 If leakage is found at either the downshift control transmission from the vehicle. The paths which the lever shaft or the manual lever shaft, replace either or fluid takes to reach the bottom of the converter both seals. housing are shown in Fig. 2. Inspect the pipe plug on the left side of the 1. Fluid leaking by the front pump seal lip will tend transmission case at the front. If the plug shows to move along the drive hub and onto the back of leakage, torque the plug to specifications, using the impeller housing. Except in the case of a total seal failure

17-01-6 General Transmission Service 17-01-6 a.Leakage at the racker arm cover may allow oil to N. 5, flow over the converter housing or seep down between the converter housing and cylinder block causing oil to be present in or at the bottom of the converter housing. b.Oil gallery plug leaks will allow oil to flow down the rear face of the block to the bottom of the converter housing. c. Leakage at the crankshaft seal will work back to the flywheel, and then into the converter housing. 7. Fluid leakage from other areas, such as the power steering system forward of the transmission, could cause fluid to be present around the

17-01-7 General Transmission Service 17-01-7 source such as the one provided in the distributor tester 3. Firmly apply the parking brake and start the or a hand operated vacuum pump. engine. ENGINE VACUUM PRESSURE On a vehicle equipped with a vacuum brake release, apply the service brakes, The parking When the vacuum diaphragm unit is operating brake cannot be used because the brake properly and the down shift linkage is adjusted automatically releases when the transmission properly, all the transmission shifts automatic and selector lever is moved to a drive position. kickdown should occur within the road speed limits

17-01-8 General Transmission Service 17-01-8 VACUUM SUPPLY TEST The vacuum supply to the vacuum diaphragm unit and the diaphragm itself must be checked. To check the supply, disconnect the vacuum line at the diaphragm unit and connect it to a vacuum gauge. With the engine idling, the gauge must have a steady acceptable vacuum reading for the altitude at which the test is

_______ _ 17-01-9 General Transmission Service 17-01-9 CONTROL PRESSURE TEIII L LOIN Al IDLE HIGH AT IDLE DK AT IDLE IN ALL RANGES IN ALL RANGES IN ALL RANGE CHECK ENGINE FUR CHECK ENGINE EGR SYSTEM, LOIN FLUID SYSTEM, VACUUM DIA PHRAGM LEVEL. RESTRICTED UNIT,

S S________ ________ _____________________________________ 17-01-10 General Transmission Service 17-01-10 TRANSMISSION FLUID COOLER FLOW transmission should shift from third to second or third CHECK to first, depending an vehicle speed. Check the closed throttle down shift from third to first The linkage, fluid and control pressure must be within by coasting dawn from about 30 mph in third gear. The specifications before performing this flow check, shift should occur within the limits given in the Remove the transmission dipstick from th

17-01-11 General Transmission Service 17-01-11 Connect the line from the distributor tester vacuum Forward Clutch C3, C4, C6 and JATCO ar Front pump to the vacuum diaphragm unit. Clutch FMX CAUTION: NEVER EXCEED 60 MPH Apply air pressure to the transmission case forward SPEEDOMETER SPEED clutch or front clutch passages Figs. 1 3, 14, 15, 10 and 17. A dull thud can be head when the clutch piston is 1. Ta check the shift valves and governor circuits, applied. If no noise is heard, place the fingertips an the apply 18 inches of vacuum to the transmission

17-01.12 General Transmission Service 17-01-12 MAIN PRESSURE TO THROTTLE VALVE LOAn SInE FRONT SERVO FICTON H EL IS F SLOE - H HON SERVO PISTON THROJTLE PRESSURE 1Lt1 RETURN THROTTLE PRESSURE TO CONTROL BLOCK - MAIN PRESSURE TO COVERNOR GOVERNOR PRESSURE

___ 17-01-13 General Transmission Service 17-01-13 SERVO APPLY FRONT PUMP DISCHARGE cONVEATER CHANGE GOVERNOR ouTpuT SERVO RELEASE PItflO SUCTION / REVERSE.HIGH APPLY TO CONVERTER J I.RQNT PUMP INTAKE - 71:::

17-01-14 General Transmission Service 17-01-14 DIAGNOSIS - AUTOMATIC TRANSMISSION CONDITION POSSIBLE CAUSE RESOLUTION * Slow Initial engaqenlellt. * Improper fluid levpl. * Add fluid as required. * Damaged Or improperly ad1usled * Repair or ad1ijat linkage. linkage. * Contaminated fluid. * Perfoun tluid level check.

17-01-15 General Transmission Service 17-01-15 DIAGNOSIS - AUTOMATIC TRANSMISSION CONDITION POSSIBLE CAUSE RESOLUTION * No drive, slips or chatters in first * Damaged or worn one-way clutch. * Repair or replace one-way clutch. gear in U. All other gears normal. * No drive, slips or chatters in second * Improper fluid level. * Perform fluid level check. gear. * Damaged or improperly adjusted * Repair or adjust linkage. linkage. * Intermediate band out of adjustment.

17-01-16 General Transmission Service 17-01-16 DIAGNOSIS - AUTOMATIC TRANSMISSION CONDITION POSSIBLE CAUSE RESOLUTION * Shift points incorrect, * Improper fluid level. -- * Perform fluid level check. * Improper vacuum hose routing or * Correct hose routing. leaks. * Improper operation of CR system. * Repair or replace as required. * Linkage out of adjustment. * Repair or adjust lin kage.

17-01-17 General Transmission Service 17-01-17 DIAGNOSIS - AUTOMATIC TRANSMISSION CONDITION POSSIBLE CAUSE RESOLUTION * Mushy 1-2 shift. a Improper fluid level * Perform fluid level check, * Incorrect engine performance. * Tone adjust engine idle as required a Improper linkage adjustment. * Repair or adjust linkage. a Intermediate band out of adjustment.

17-01-18 General Transmission Service 17-01-18 DIAGNOSIS - AUTOMATIC TRANSMISSION CONDITION POSSIBLE CAUSE RESOLUTION a No forced downshifts. a Improper fluid level, a Perform fluid level check. a Linkage out of adjustment. a Repair or adjust linkage. * Improper clutch or hand application, a Perform control pressure test. or oil pressure control system.

__ 17-01-19 General Transmission Service 17-01-19 TRANSMISSION NOISY - OTHER THAN VALVE RESONANCE - ---- -_ CHECK FOR GEAR_____J__NOISE iN LOW AND SECONJ1 TO VERIFY IF WITHIN NORMAL RANGE J OK 4 PERFORM FLUID C

17-01-20 General Transmission Service 17-01-20 DIAGNOSIS - AUTOMATIC TRANSMISSION CONDITION POSSIBLE CAUSE RESOLUTION a No engine braking in manual a Improper fluid level, a Perform fluId level check. second gear. a Linkage out of adjustment a Repair or adjust In kage. a Intermediate band out of adjustment. a Adjust intermediate band. a