Werkstatthandbuch Book 1 · Seiten 701–800

17.06-16 JATCO Automatic Transmission 17-06-16 FORWARD CLUTCH ASSEMBLY /FORWARD CLUTCH HUB INPUT SHELL AND ‘SUN GEAR ASSEMBLY 02960-lA 529M-IA FIG. 17 Installing Forward Clutch Assembly FIG. 15 Installing One-Way Clutch

17-06-17 JATCO Automatic Transmission 17-06-17 THROTTLE VALVE FULLY OEPRESSED a 029624 A DEPTH FIG. 19 Checking Total End Play VACUUM THROTTLE VALVE

17-06-18 JATCO Automatic Transmission 17-06-18 PRESSURE REGULATOR SECOND LOCK VALVE PLATE LATOR PLUG 2-3 SHIFT VALVE S PLATE SPRING SEAT VALVE LOWER VALVE BOOY OILSCREEN - 7A095

17-06-19 JATCO Automatic Transmission 17-06-19 TV BLCV/OFF CHECK VALVE & SPRING lIE COILSI LNTERMEDIATE SERVO CHECK VALVE & SPRING 113 COILSI 02965-lA FIG. 22 Location of Check Valves and Springs-Control Valve Body "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 Compan

17-06-20 JATCO Automatic Transmission 17-06-20 SECONDARY GOVERNOR VALVE OIL DISTRI 70220 SPRING SEAL RINGS -70011 SPRING

17-06-21 JATCO Automatic Transmission 17-06-21 T73J-77248 SHAFT 02971-lA FIG. 28 Installing Seal Using Tool T73J-77248 PUMP COVER C 1CE 02970-1 A FIG- 27 Using OH Pump Aligning Tool T73J- 77108

17-06-22 JATCO Automatic Transmission 17-06-22 EH6SSUIIL PLATE - ThOSE DISHED PLATE - 7CSS SPR IN C INNER SEAL-- 700i1g SNAP RING - 7D483 STEEL PLATES - 78442 SNAP RINC SPRING RETAINER - 7A521

17-06-23 JATCO Automatic Transmission 17-06-23 FRICTION PLATES - 78164 41 DISHED PLATE - 7EO85 SNAP RING SPRING - 78488 PISTON 7A262 INNER SEAL - 7C099 REAR CLUTCH DRUM-7A360 SNAP RING -70483 STEEL PLATES - 79422 141 SPRING RETAINER - 7A527 OUTER SEAL - 7A548

-‘Ia ‘3 In 0 0< >1Inn Inc 00 w r tfl00 <33 *0 0 a. 3a C=09 I I.>

17-06-25 JATCO Automatic Transmission 17-06-25 SPECIFICATIONS MAINTENANCE SCHEDULE The scheduled maintenance requirements for the Jatco automatic If ii is neceary to add or replace fluid, use only fluids which have been transmission are as follows: cerlified by the supplier as meeting Ford Motor Company specification ESP.M2C138-CJ. This fluid is the 1918 C*B transmission fluid. A. Fluid Level Check at predelivery and when performing other required maintenance service and add if necessary. GENERAL SPECIFICATIONS B. Intermediate Band Adjustment

17-06-26 JATCO Automatic Transmission 17-06-26 Operation Specifications Total Gear Train End Play 0.010-0.020 Selective Bearing Race Thickness 0.047, 0.055, 0.063, 0.071, 0.079, 0.087 Reverse and High Clutch Pressure 0.062-0.071 Plate-To.Snap Fling Clearance Low and Reverse Clutch Pressure Plate

17-06-27 .JATCO Automatic Transmission 17-06-27 GOVERNOR PRESSURE GOV. PSI. END PLAY SPECIFICATION MPH 2.41:1 Axle Ratio 2.50:1 Axle Ratio Oil Pump Cover to Front Clutch Drum Total End Play 20 19-25 19*25 0.020-0.032 0.010-0.020 35 32-39 33-40 50 62-60 63-61 CLUTCH PLATE USAGE Forward Clutch High Clutch Model Steel Friction Clearance Steel Friction Cle

17-06-28 JATCO Automatic Transmission 17-06-28 FLYWHEEL ASSEMBLY Number of Teeth & 0.0. Used with Transmiuion Model Engine Vehicle 157 Teeth, 13.3 0.0. PLA-A1 4.1 L 250.IV Granada/Monarch OIL FILLER TUBE AND INDICATOR ASSEMBLY Indicator Full Mark to lop of Cap Identification thed with Transmission Model Engine. Vehicle 19.71" Yellow Paint on Cap PLA-Al 4.1 L 25O1V Granada/Monarch FILLER TUBE Filler Tube Color t.D. Used with Trinimission Model Engine

17-06-29 JATCO Automatic Transmission 17-06-29 TORQUE SPECIFICATIONS Item Ft-Lbs Flywheel to crankshatt 100-115 Flywheel to torque converter 29-36 Converter housing to engine 29-36 Converter housing to transmission case 23-24 ® Extension housing to transmission case

17-10-1 Co Automatic Transmission 17-10-1 PART C6 Automatic Transmission 17-10 Applies To All Cars Except Pinto/Bobcat/Mustang II, Granada/Monarch/Versailles, Fairmont/Zephyr SUBJECT PAGE SUBJECT PAGE ADJUSTMENTS DISASSEMBLY AND ASSEMBLY Cont’d. Intermediate Band Adjustment 10-4 Reverse-High Clutch 10-20 Servo Apply Lever 10-18 DESCRIPTION 10-1 Transmission 10-11 DISASSEMBLY AND AS

___ 17-10-2 C6 Automatic Transmission 17-10-2 EXTENSION HOUSING SEAL REVERSE PLANET CARRIER FRONT PLANET

-ft VACUUM 0181 6-211 FIG. 3 Hydraulic Control System "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 Compan

17-10-4 Co Automatic Transmission 17-10-4 TOOL_T7IP.77310B. -COR -DADJUSTMENTS The only adjustment on the transmission is the intermediate band. To prevent damage to the transmission and to assure proper bond adjustment, it is essential that the tools and procedures described here ore used whenever the bond is odjusted. INTERMEDIATE BAND ADJUSTMENT 1. Raise the vehicle on o hoist or jack stands. 2. Clean all the dirt from the bond adjusting screw orea. Remove and discord the lock nut. 3. Install a new lock nut and tighten the adjusting screw. 4. Back off the adjusting screw exactly 1-1/2 turns. 5. Hold the adjusting screw from turning and torque the

17-10-5 CO Automatic Transmission 17-70-5 2. Position the converter on the transmission, making LTD II. Cougar. Thunderbird and Continental Mark sure the converter drive flats are fully engaged in V the pump gear by rotating the converter. Removal 3. With the converter properly installed, place the 1. Working from the engine compartment, remove the transmission on the jack. Secure the transmission to two bolts retaining the fan shroud to the radiator. the jack with a chain. 2. Disconnect the battery 4. Rotate the converter until the studs and drain plug 3

17-10-6 C6 Automatic Transmission 17-10-6 21. Remove the bolt that secures the transmission filler 15. Connect the vacuum lines to the vacuum diaphragm tube to the cylinder block. Lift the filter tube and makng sure that the metal tube is secured in the dipstick from the transmission, retaining clip. 22. Move the transmission away from the cylinder 16. Position the starter motor to the converter housing block, and secure it with the attaching bolts. 23. Lower and remove the transmission and converter 17. Install torque converter-to-flywheel attaching nuts. assembly from under the vehicle. Torque nuts to specification. 24. Remove the conv

17-10-7 C6 Automatic Transmission 17-10-7 drain pan under the converter to catch the fluid. To maintain initial engine/transmission balance, With fluid drained, reinstall the plug. assemble the converter to the flywheel so that the 9. Remove the two front support bracket bolts at the orange-dyed converter drive stud is installed converter housing. through the orange-painted hole in the flywheel. 10. Lift the fluid filler tube from the transmission case. 4. Move the converter and transmission assembly forward into position, using care not to damage the11, Remove the two idler arm bracket bolts from the

17-10-8 C6 Automatic Transmission 17-10-8 27. lower the vehicle. TRANSMISSION CASE 28. Fill the transmission to the correct level with the specified fluid. Refer to Part 17-01. 29. Adjust the manual and throttle linkage as required. COVER-70027 Refer to Part 17-02. CONTROL VALVE BODY Removal 1. Raise the vehicle an a hoist or jack stands. 2. Place a drain pan under the transmission and loosen SEAL-70024 the bolts to drain the fluid from the transmission. D

17-10-9 Co Automatic Transmission 17-10-9 8. Remove the servo cover, piston, spring and gasket 12. Lower the vehicle and replenish the fluid as from the case, turning the band adjusting screw required. inward as the piston is removed. This places enough tension on the band to keep the struts properly EXTENSION HOUSING BUSHING AND REAR engaged in the band end notches while the piston SEAL is removed. Removal 9. Apply air pressure to the port in the servo cover to remove the piston and rod assembly. If the piston 1. Raise the vehicle and disconnect the drive shaft at or piston sealing lips are damaged, the complete the transmission. piston and rod assembly must

17-10-10 C6 Automatic Transmission 17-10-10 TOOL-T75P-7697-A 01600-lA FIG. 7 Removing Extension Housing Bushing TOOL-TS7P-7697B !ct FIG. 10 Governor Installed BUSHING 01601-IA Installation 1. Clean the mounting surface on the transmission and FIG. 8 Installing Extension Housing Bushing on the extension housing. Position a new gasket on the transm

17-10-11 Co Automatic Transmission 17-10-Ti 4. Refer to the Disassembly and Assembly Section of 2. Reinstall the extension housing as outlined in this this Part for governor repair operations. Part of the manual. Installation 1. Secure the governor Fig. 10 to the distributor flange with the attaching bolts. Torque the bolts to specification. DISASSEMBLY AND ASSEMBLY TRANSMISSION Before removing any of the subassemblies, 11. Remove the forward part of the gear train as on thoroughly clean the outside of the transmission to assembly as shown in Fig. 16. prevent dirt from entering the mechanical parts.

17-10-12 CO Automatic Transmission 17-10-12 FRONT PUMP - TOOL-T59P 77067 INPUT SHAFT TOOL-4201 -c 01605-18 FIG. 15 Removing or Installing Band FIG. 13 Checking Gear Train End Play /1’ FIG. 14 Removing Front Pump 01608-lA 13. Remove the cover, piston, spring and gasket from the case. FIG. 16 Removing or Installing Forward Part of 14. Remove the large sn

17-10-13 Co Automatic Transmission 17-10-13 LOW-REVERSE OUTPUT SNAP the low-reverse clutch hub clockwise while applying CLUTCH DRUM SHAFT RING pressure to seat it on the inner race. 18. Install the law-reverse clutch plates, starting with the wave plate next to the piston and following with steel and friction plates alternately. Retain them with petroleum jelly. Five 5 steel and five 5

17-10-14 C6 Automatic Transmission - 17-10-14 28. Install tool 4201-C at the seventh pump mounting bolt Fig. 13 and check the transmission end play. See Specification at end of this Port. Remove the tool. Install the seventh mounting bolt and torque to specifications. 29. Install the main control on the case, making sure that the levers engage the valves properly. Install the primary throttle valve, rod, and the vacuum diaphragm in the case. 30. Install a new pan gasket and the pan. Torque the bolts to specifications. 31. Install the converter assembly. 32. Install the transmission in the vehicle as detailed IUOL T6s - A 01610-18 under Removal and Installation.

17-10-15 C6 Automatic Transmission 17-10.. ‘IS 3. Place the valve body on o clean surface with the 5. Place the lower body and plate assembly on the passage side facing up. Place the converter relief upper valve body Fig. 20, and install the attaching valve spring in its bore Fig. 23. Coat the converter screws finger tight. relief valve check valve with petroleum jelly and place it on top of the spring. Place the 2-3 shift 6. Install the oil screen screws loosely, without the screen, to properly align the upper and lower valve check valve ball in its cavity. Place the throttle

17-10-16 C6 Automatic Transmission 17-10-16 10, Place the cutback valve Fig. 22 and coasting 2. Working from the front end of the output shaft, regulator valve in the valve body. slide the governor distributor into place on the 11. Place the spring DR-2 shift valve and the 1-2 shift shaft. Install the snap ring to secure it. Make sure valve in the body. that the snap ring is seated in the groove. 12. Place the throttle modulator valve and spring and 3. Position the governor on the distributor Fig. 25 the 2-3 shift valve in the valve body. and secure with the attaching screws. 13. Place the spring and the 2-3 backout valve

/ 17-10-17 C6 Automatic Transmission 17-10-17 tI 4 PLATE 2-a SHIFT -2-aBAcK.ouTvALvr ,._ ,a- 3.2 SIIIFT TIMING VALVE PLUG t - INTERMEDIATE SERVO MODULATOR VALVE CUT.SACK VALVE p

17-10-18 Co Automatic Transmission 17-10-18 3. Install the parking pawl shaft in the case. Slip the parking pawl and spring into place on the shaft. 4. Position the guide plate on the case, making sure that the actuating rod is seated in the slot of the plate. Secure the plate with two bolts and lockwashers. SERVO APPLY LEVER

____ 5 17-10-19 Co Automatic Transmission 17-10-19 14-20 11/4 INCH BOLT OUTER MANUAL LEVER OR #8-32 1 V4 INCH BOLT AND SHAFT INNER MANUAL LEVER PARKING PAWL ACTUATING ROD DETENT SPRING ATTACHING SCREW INC D2330-1A FIG. 26 Downshift and Manual Linkage

17-10-20 C6 Automatic Transmission 17-10-20 4 Install the selective thrust washer. Make sure that 7. After all clutch plates have been installed, pasition the correct thickness selective washer is being used the pressure plate in the clutch drum. Install the to obtain the specified end play. Refer to pressure plate snap ring. Specifications at end of this Part. 8. With a feeler gauge, check the clearance between 5. Place the pump on the converter, making sure that the pressure plate and snap ring Fig. 43. the drive gear engages the converter hub. Rotate 9. The pressure plate should be held downward as the the pump to make s

17-10-21 Co Automatic Transmission 17-10-21 PUMP ASSEMBLY - 7A103 FRONT PUMP SEAL - ?A24E DRIVEN GEAR SELECTIVE THRUST FlASHER 70014 -i U SEAL RINGS 70429

17-10-22 CO Automatic Transmission 17-10-22 b 6 7 l JJL7r. 9 2U I i 21 t / / 22 23 24 I I I 26 27

17-10-23 Co Automatic Transmission 17-10-23 INPUT SHELL AND SUN GEAR 2. Remove the thrust washer from the input shell and sun gear Fig. 5.Disassembly 3. Working from inside the input shell remove the sun 1. Remove the external snap ring from the sun gear gear. Remove the internal snap ring from the gear. as shown in Fig. 50. Assembly 1. Install the forward snap ring on the forward end short end of the sun gear Fig.

17-10-24 Co Automatic Transmission 17-10-24 SPRINGS MUST BE INSTALLED IN POCKETS MARKEr N ONI Y FIG. 39. Removing Reverse-High Clutch Piston 10 SPRING DESIGN 02354-iC FtG. 42 Reverse-High Clutch Piston Return Spring Locations REMOVAL FIG. 43 Checking Reverse-High Clutch Snap FIG. 40 Replacing Reverse-High Clutch Rear

17-10-25 Co Automatic Transmission 17-10-25 DISC SPRING PLATE FORWARD DRIVEN PLATE REAR PRESSURE CLUTCH OUTER SEAL 76070 CvLI N DR-7A360

_ 17-10-26 C6 Automatic Transmission 17-10-26 CHECK BETWEEN SNAP RING AND PRESSURE PLATE FIG. 52 Output Shaft Hub and Ring Gear flOLLER.p SNAP FIG. 49 Checking Forward Clutch Clearance SPRING ASSEMBLY-7E392 SPRING ASSEMBLY TOOL-T73P77O60-A RING-377135/ REAR

17-10-27 Co Automatic Transmission 17-10-27 4. Install a roller into each of the spring assembly Assembly compartments Fig. 53h 1. Dip the two new seals in clean transmission fluid. 5. Install the bushing on top of the spring assembly. 2. Install the seals on the piston. 6. Install the remaining snap ring at the reor of the low-reverse clutch hub to secure the assembly Fig. 53. LOW-REVERSE CLUTCH PISTON Disassembly 1. Remove the inner and the outer seal from the reverse clutch piston. "This publication contains material that is reproduced and distributed under a license to Detroit Iron from Ford Motor Company. No further reproduction

17-10-28 CO Automatic Transmission 17-10-28 SPECIFICATIONS APPROXIMATE REFILL CAPACITIES Ct TRANSMISSION SELECTIVE THRuST WASHERS CS TRANSMISSION U.S. Meease Imp. aWrt Identification Color Thnjet WSiar Thickness-Inch J All Mcdels 12-1/4 pot j±qtsliJ Blue 0,056.0,960 Natural White

17-15-1 FMX Automatic Transmission 17-15-1 PART FMX Automatic Transmission 17-15 Applies To Ford/Mercury/LTD Il/Thunderbird/Cougar SUBJECT PAGE SUBJECT- PAGE ADJUSTMENTS DISASSEMBLY AND ASSEMBLY Cont’d. Front Band Adjustment 15-4 Rear Support Bushing Removal Rear Band Adjustment 15-5 and Installation 15-22 Transmission 15-11 DESCRIPTION 15-1 RE

17-15-2 FMX Automatic Transmission 17-15-2 STATOR TURBINE OUTPUT SHAFT EXTENSION ROUSING SECONDARYSUN GEAR SECON0ARY PINION CONVERTER CLUTCH __- CONTROL VALVE BODY ENGINE CRANKSHAFTV REAR CLUTCH PIS

17-154 FMX Automatic Transmission 17-15-3 REVERSE - HIGH INTERMEDIATE SERVO LOW REVERSE SERVO FORWARD CLUTCH LOW SERVO UPPER MODULATOR VALVE CONVERTER -COMPENSATOR

17-15-4 FMX Automatic Transmission 17-15-4 ADJUSTMENTS The only adjustments on the transmission are the Alternate Front Band Adjustrnent-Using Tool front and rear bands. 1581.7195-A To prevent damage to the transmission and to assure 1. Drain the fluid from the transmission. If the same proper band adjustment, it is essential that the tools and fluid is to be used again in the transmission procedures described below are used whenever the after the band adjustment, filter the fluid bands are adjusted. through a 100-mesh screen as it drains from the transmission. Reuse the fluid only If it Is FRONT BAND ADJUSTMENT

7-15-5 FMX Automatic Transmission 17-15-5 TOOL -TJIP-7 1310-S ndTlIP77310M D2018-IA FIG. 7 Adjusting Rear Band-LTD Ill Thunderbird/Cougar FIG. 6 Adjusting Rear Band-Except LTD Il/ tighten the adjusting screw until the tool handle Thunderbird/Cougar clicks. The tool is a preset torque wrench which 10. Place a new gasket on the pan, and install the clicks and breaks when the torque on the adjusting screen and p

17-15-6 FMX Automatic Transmission 17-15-6 16. Support the transmission on a transmission jack. 18. Lower the transmission and install the upper two Secure the transmission to the jack with safety converter housing-to-engine baits. Torque bolts to chain. Remove the two engine rear support to specification as listed at the end of this Part. transmission bolts. Remove the two crossmember to 19. Lower the vehicle and fill the transmission with frame side rail attaching bolts and nuts. Raise the transmission fluid, following the recommended transmission slightly to take the weight off the procedure. Refer to Part 17-01. crossmember. Remove the rear support to 20. Check the transmission, converter ass

17-15-7 FMX Automatic Transmission 17- 15-7 pressure regulator first. Then, install the other end of the tube into the main control valve assembly by tapping it gently with a soft hammer. COMPENSAOR MAIN PRESSURE PRESSURE TUBE OILTUBE 7. Install the compensator pressure tube to the pressure regulator and the control valve body. 8. Turn the manual valve one full turn

17-15-8 FMX Automatic Transmission 17-15-8 TOOL - 1175-AC TOOL - TSOT-l 00-A D1927-ZB FIG 0 Removing Extension Housing Seal 3. Install the attaching bolts and torque to specification as listed at the end of this Part. EXTENSflN FIOUSING 4. Torque the control valve body attaching bolts to specification as listed at the end of this Part. TOO L-T52L.7O-GAE 5. Check the clearance between the manual valve and manual lever actuating pin as given in Control Valve Body Installation. 6. Adjust the front band as outlined in this Part. 7. Install the vacuu

17-15-9 FMX Automatic Transmission 17-15-9 7. Remove the two engine rear support-to-extension BUSHING housing attaching bolts and remove the support. T52L7O-HAE 8. Remove the extension housing attaching bolts. Slide the housing off the output shaft and remove the gasket. When removing the extenson / housing, hold the output shaft and rear support from moving rearward to prevent the

17-15-10 FMX Automatic transmission 17-15-10 Fig. 14. When removing the governor, hold the output shaft and rear support from moving rearward to prevent the needle bearing and race from dropping out of location. Installation 1. Lubricate the governor valve parts with clean GOVERNOR-_..... transmission fluid. Make certain that the valve moves freely in the valve body bore. 2. Position the governor valve body on the counterweight with the cover facing toward the front of the vehicle. install the two attaching screws, and torque to specification. 3. Reinstall the extension housing as outlined in this ATrACHING SCREWS Part of the manual. PRESSURE REGULATOR Removal

17-15-11 FMX Automatic Transmission 17-15-11 15. Remove the extension housing attaching bolts and 6. Install the rear servo and strut as outlined under housing. Rear Servo Installation. 16. Remove the output shaft and rear support 7. Install the main control valve assembly as outlined assembly. under Control Valve Body Installation. 17. Remove the parking pawl pin from the case with a magnet. 8. Torque the front servo attaching bolts to specification as listed at t

17-15-12 FMX Automatic Transmission 17-15-12 Transmission End Play Check 1. Remove one of the front pump attaching bolts. Mount the dial indicator support Tool 77067 in the front pump bolt hole. Mount a dial indicator on the support so that the contact rests on the end of the turbine shaft. 2. Install

17-15-13 PMX Automatic Transmission 17-15-13 SEAL RINGS- 70019 NEEDLE ASSEMBLY OUTPUT SHAFT- 1 REAR SUPPORT / aDVESNOR DRIVE ALL 7A3a3 GOVERNOR ASSEMBLY- N 7C03 01020-2C FIG- 17

17-15-14 FMX Automatic Transmission 17-15-14 HANDLE PRESS RAM 4TOOL TG4L ?003 AS -..---- PRESS RAM HANDLE - TOOL-TS4L-1J03-A4 IDOL -‘54L-IOOJ-55 TOOL 15417003 Ab 01745-10 TDOL- 164L-’003-94 FIG. 20 Replacing Transmission Case Bushing

17-15-15 FMX Automatic Transmission 17-15-15 SUPPORT CENTER CAGE 8. Install the governor assembly, aligning the groove SPRING with the ball in the output shaft. 1ANETARY CLUTCH HOLLER 9. Install the governor with the governor body plate toward the front of the vehicle Fig. 16. Install the governor snap ring. 10. Insert the extension housing oil seal replacer and

17-15-16 FMX Automatic Transmission 17-15-16 toward the centerline of the transmission case, If the converter and converter housing were against the servo attaching bolts. While holding the removed from the transmission, install these servo in this position, torque the attaching bolts to components. Position the transmission assembly on specification. the transmission jack, and refer to transmission 25. Install the front servo apply tube. installation procedures outlined in this Part. 26. Install the pressure regulator body and attaching CONTROL VALVE BODY bolts. Torque the bolts to specification. 27. Install the control and converter valve guides and

17-15-17 FMX Automatic Transmission 17-15.17 COVER S. CHECK BALL AND SPRING PLATE 1 SIDE PLATE - 7739 SEPARATOR PLATE - 7734 ACCUMULATOR I SPRING RETAINER I-? SHIFT VALVE

17-15-18 FMX Automatic Transmission 17-15-18 16. Remove the check ball spring and check ball. 8. Install the transition valve and spring in the lower Remove the 3-2 kickdown control valve spring and body. valve. 9. Install the 2-3 shift valve spring retainer and spring. 17. Remove the 1-2 shift accumulator valve spring Install the 2-3 shift delay valve, spring, and throttle retainer from the cover. Remove the spring, 1 -2 shift reducing valve in the sleeve. Slide the assembly into accumulator valve and 1-2 shift accumulator position in the lower body. Do not restake the lockout valve. sleeve. 18. Remove the thro

17-15-19 FMX Automatic Transmission 17-15-19 SEAL 7C050 -74294 SNAP RING BODY- 74094 PISION SEAL RETAINEO ISMALLP 7A761 74294 SPR NO -7A003 ADJUSTI.4 SCREW LEVER-1330 mnt STE

_ 17-15-20 FMX Automatic Transmission 17-15-20 Install the servo spring with the small coiled end 5. Check the actuating lever for free movement. against the servo piston. 3. Install the spring retainer. Compress the spring with GOVERNOR a C-clamp. Then install the snap ring. The snap Disassembly ring must be fully seated in the groove. 1. Remove the governor valve body cover.4. Install the actuating lever, with the socket in the lever bearing on the piston stem. Install the 2. Remove the valve body from the counterweight. actuating lever shaft, aligning the retaining pin 3. Remove the plug, sleeve, and the valve and spring

17-15-21 FMX Automatic Transmission 17- 15-2 1 7. Inspect the control pressure and converter pressure 8. Remove the manual shaft seal and case vent tube. valves and bares far burrs and scares. Remove oil Remove the oil cooler return check valve from the burrs carefully with crocus cloth. back of the case. 8. Check the free movement of the valve in their bares. Assembly Each valve should fall freely into its bore when both the valve and bare are dry. Coat the outer diameter af a new manual shaft seal with sealer, then install the seal in the case with a 9. Inspect the valve springs for distortion.

17-15-22 FMX Automatic Transmission 17-15-22 PUMPASSEMBLV_1A;03 DIO47-1C FIG. 33 Front Pump Disassembled IAN DL E _.TOOL-T6AL-7003-A2 - TOOL..TG4L-7003-C7 FIG. 36 Installing Front Pump Seal D1748.IA FIG. 34 Replacing Front Pump Housing Bushing 5. Press a new bushing into the pump housing with the handle and tool shown in Fig. 34. 6. If any parts other than the stator support, bushings or oil seal are found defective, replace the pump as a unit. Minor burrs and scores may be removed with crocus cloth. The stator support is service

________________ 17-15-23 FMX Automatic Transmission 17-15-23 S. Use the cape chisel Fig. 40 and cut along the bushing seam until the chisel breaks through the - HANDLE bushing wall. Pry the loose ends of the bushing up with an awl and remove the bushing. TOOL T64L.7OO FIG. 38 Installing Rear Support Housing Bushing 4. Install the pressure tubes in the support housing.

17-15-24 FMX Automatic Transmission 17-15-24 TOOL 168P-/0158-A CLUTCH DSTU REAH CLUTCH 1,fl,pl - 02038 1A FIG. 42 Installing Rear Clutch Piston FRONT fixture, with the seal toward the thin.walled end. CLUTCH Hold the piston and large fixture, and insert as a CYL INDEP unit into the cylinder. Push down over the small fixture until the large tool stops against the shoulder in the cylin

17-15-25 FMX Automatic Transmission 17-15-25 -HANDLE FIG. 44 Removing Front Clutch Piston 01752-IA bushing wall. Pry the loose ends of the bushing up with an awl and remave the bushing. FIG. 45 Installing Input Shaft Bushing Assembly 1. If the input shaft bushing was removed, slip a new bushing over the end of the installation tool and position the tool and bushing to the bushing hole. Then, press the bushing into the input shaft as shown in Fig. 45. 2. Lubricate all parts with tra

17-15-26 FMX Automatic Transmission 17-15-26 FIG. 48 Installing Clutch Plates clearance of 0.002 to 0.009 inch should exist between the ends of the rings. If equipped with plastic seals that are worn or damaged, cut the seals from the shaft with a sharp knife. Be careful not to score the ring grooves. Assembly

17-15-27 FMX Automatic Transmission 17-15-27 SPECIFICATIONS APPROXIMATE REFILL CAPACITIES CLUTCH PLATES FMX TRANSMISSION FMX TRANSMISSION U.S. Imp.1 Forward Clutch Rear Clutch Measure Measure Trans. Steel Friction Selective Plate Selective Plate Steel Friction Free Pack All Car Lines 11 9-1/4 Model Plates Plates Thickness Identification Plates Plates Clearance 0.0565-0.0605 No Stripe SELECTIVE THRUST WASHERS PHB

18-00-1 Noise, Vibration and Harshness Diagnosis 18-00-1 NOISE, VIBRATION AND GROUP 18 HARSHNESS DIAGNOSIS PART TITLE PART NO. PART TITLE PART NO. Noise, Vibration and Harshness Diagnosis - General Instructions 18-01 CF2535-2A Noise, Vibration and Harshness - Diagnosis General Instructions Applies Ta All Cars SUBJECT PAGE SUBJECT PAGE TESTS TESTS Cont’d. C

18-01-2 s!LYraton and Harshness Diagnosis-General Instructions 18-01-2 set tire pressures to recommended specifications. Notice are intended for trailer towing. Tires of this nature if the tire pressures are above recommended settings. produce a harsh ride when the vehicle is in an If so, it would be a cause of a harsh ride condition. unloaded condition. Advise the customer of this When performing a road test, the following factors must situation. be taken info consideration to properly isolate the d.Check for tires that are not recommended by the condition. Remember that a thorough road test manufacturer. Different brands of tires often give will quickly isolate the problem area. a different ride quality to

18-01-3 Noise, Vibration and Harshness Diagnosis-General Instructions 18-01-3 The engine run up test is applicable to manual transmissions, with the exception of the stall test. NOTE: Because the vehicle is stationary during TOOL - T6gp 4602-A engine run up checks, other noises and/or vibrations will became noticeable which were not evident under normal driving conditions. For instance, all engines have a natural vibration point which con be felt in neutral but not under normal driving conditions. Far this reason, the use of a tachometer is mandatory to verify the presence of the real cause. ENGINE ACCESSORY CHECK a.With the engine stopped, visually inspect, adjust, torque or replace: sail drive belts for cracking or fraying. * the condition of all pulleys. See if they

18-01-4 Noise, Vibration and Harshness Diagnosis-General Instructions 18-01-4 CHECKS FOR VIBRATION WITHOUT TIP IN properly. Perform an ‘on-the-car" balance check of all four 4 tire-wheel assemblies. Vibrations that occur at steady road speeds of 40 NOTE: Balance check of tire-wheel assembliesmph or above, are usually attributed to tire and wheel must be made by spinning the assemblies, one atimbalance. These vibrations can be felt in the steering a time, with the car supported by the framewheel, floor pan, and in the seat. Excessive tire and

18-01-5 Noise, Vibration and Harshness Diagnosis-General Instructions 18-01-5 If the total radial runout still exceeds the limits will remain virtually constant under the same conditions. shown, match the highest radial point on the tire In the event this whine condition is experienced an a with the lowest radial point an the wheel and again customer’s car, he should be advised that this is a measure the radial runout of the assembly on the characteristic of this radial ply tire tread design. car. The use of the new Radial Tire design with increased If the wheel-tire assembly is still over the limit for tire life, improved handling ability and improved either radial or latera

"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."

r IMPORTANT SAFETY NOTICE Appropriate service methods and proper repair procedures are essential for the safe, reliable operation of all motor vehicles as well as the personal safety of the individual doing the work. This Shop Manual provides general directions for accomplishing service and repair work with tested, effective techniques. Following theni will help assure reliability. There are numerous variations in procedures, techniques, tools, and parts for servicing vehicles, as well as in the skill of the individual doing the work. This Manual cannot possibly anticipate all such variations and provide advice or cautions as to each. Accordingly, anyone who departs from the instructions provided in this Manual must first establish that he compromises neither his personal safet

GROUP AND PART INDEX VOLUME 2 ENGINE I VEHICLE IDENTIFICATION 20-01 GENERAL GASOLINE ENGINE SERVICE 21-01 2.3L 1-4 ENGINE 21-05 aaL/4.1L 200/250 CID 1-6 ENGINES

foreword... This 1978 Car Shop Manual has been prepared to provide information covering normal service repairs and maintenance for 1978 Ford Passenger Cars manufactured in the United States and Canada. It is divided into five volumes, each covering a specific major area: Volume 1 - Chassis Volume 2- Engine Volume 3 - Electrical Vorume 4- Body Volume 5 - Maintenance and Lubrication. Information in each volume is divided into Groups covering a general system. The table of contents on the cover of each volume indicates the Group title, number, and volume in which each Group is located. For 1978, the basic p

On the first page of each Group there is an index listing the Part title and Part number for each component covered within the Group. The first page of each Part contains an index to locate service operations covered in that Part. This Group-Part breakdown is also indicated in the page number located at the top of each page. - Page 21Example: 11-02-21 Group 11 - Part 02 Metric conversion tables have been included at the back of each volume to aid in converting specifications in this manual to the metric equivalent. The descriptions and specifications in this manual were in effect at the time this manual was approved for printing. Ford Motor Company reserves the right to disc

20-00-1 Identification Codes 20.00-1 GROUP VEHICLE IDENTIFICATION 20 PART Vehicle Identification 20-01 MFD. BY FORD MOTOR CO. IN U.S.A. 8S63H1OOOO1 j VEHICLE IDENTIFICATION MUMBERI I’TL 08/77 GVS%l-t 5892 MFD.BY FORDMOTORCO. IN U.S.A. G.A%R: FRONT 2964 REAR 2928 DATE. 08/77 GVWR 6538 GAWR: FRONT 2964. REAR 3375 TI-Its

20-0-2 Car Identification Codes 20-01-2 GENERAL DESCRIPTION The remaining information on the V.C. Label consists of the following vehicle identification OFFICIAL VEHICLE IDENTIFICATION NUMBER codes: The official Vehicle Identification Number The BODY code is two numerals and a letter VI N Fig. 1 for title and registration purposes is identifying the body style. stamped on a metal tab that is fastened to the The CDL color code is a number and letter instrument panel close to the windshield on the indicating the exterior paint color code and vinyl driver’s side of the car and is Visible from outside. roof type and color if e

20-01-3 Car Identification Codes 20-01-3 IDENTIFICATION CODES DISTRICT CODES DISTRIcT CODES ASSEMBLY PLANT CODES LINCOLN-MERCURY FORD Code LeTter District Code DiIt rlct Cede District A Atlanta 00 Special

20-01-4 Car Identification Codes 20-01-4 BODY SERIAL AND STYLE CODES Body Body Body Body Sen.] Style Serial Style Vehicle Code Code Body Type Model Vehicle Code Code Body Type Model PINTO 10 62B 2-Or. Sedan Base COUGAR 92 53D 4-Dr. Pillar Hardtop cougar Ii 849 3-Dr. Sedan Base 91 650 2-Or. Hardtop

21-00-1 Gasoline Engines 21-00-1 - - - -- - GROUP GASOLINE ENGINES 21 - - - 6000 PART TITLE PART NO. PART TITLE PART NO. General Gasoline Engine Service 21-01

21-01-2 General Gasoline Engine Service 21-01-2 GENERAL INFORMATION All engines incorporate a closed-type crankcase CAUTION: Do not operate the engine with the ventilation system and exhaust emission control system. hood open until the fan has been first examined All engine emission control systems are covered in detail for possible cracks and separation. in Group 29 Diagnosis and Volume 5 Maintenance. To maintain the required exhaust emission levels, the ENGINE IDENTIFICATION fuel system, ignitian system and engine must be kept in good operating condition and meet recommended For quick engine identification, refer to the Safety adjustment specifications. Certification Decal s

21-01-3 General Gasoline Engine Service 21-01-3 r8S63Hl0000lor I VEHIcLE IDENTIFICATION NUMBER SAFETY CERTIFICATION DECAL TYPICAL MFD.BYFCJRDMOTORCO INUSA I ‘a IF IL’ ‘a U, N * ‘a’ N F R0 I ‘004 RI ‘a N 2> I III’, ‘a 111k LI 9l OR’l ‘a It ‘at I CONSECUTIVE UNIT NC. VINYL ROOF TYPE:COI.OH ‘alIt If ‘alIt I I-I DIR ‘al InIIR SI I lilt I

__ 21-01-4 General Gasoline Engine Service 21-01-4 ENGINE IDENTIF ‘CATION LABS ENGINE CODE LABEL IDENTIFICATION CHART TYPICAL V-B YEAR 95 40 CANADA CALIF A AIR CONDITIONING II A I S

21-01-5 General Gasoline Engine Service 21-01-5 DIAGNOSIS AND TESTING POSITIVE CLOSED-TYPE CRANKCASE VENTILATION SYSTEM All emission system related components testing and 1. If compression improves considerably, the piston diagnosis is covered in Part 29-02, Light Duty Engine rings are at fault. Diagnosis and Testing. 2. If compression does not improve, valves are sticking COMPRESSION TEST or seating poorly. 3. If two adjacent cylinders indicate low compressionCompression Gauge Check

21-01-6 General Gasoline Engine Service 21-01-6 TOOL. -6 566 On the stud mounted rocker arms, remove the rocker arm stud nut, fulcrum seat, oil deflector and rocker arm. Use the adapter for ball.end push rods. 3. Make sure the push rod is in the valve lifter socket. Install a dial indicator in such a manner as to have the ball socket adapter of the indicator on the end of the push rod and in the same plane as the push rod movement Fig. 4 or 5. 4. Connect an auxiliary starter switch in the starting circuit. Crank the engine with the ignition switch OFF. "Bump the crankshaft over until the tappet is on the base circle of the c

21-01-7 General Gasoline Engine Service 21-01-7 collapsed Part 2 1-01 check gap between valve tip Assembled tappets can be tested with Tool 6500-E and rocker arm to determine if any other valve train to check the leak down rate. The leak dawn rate parts are damaged, worn, or out of adjustment. specification is the time in seconds far the plunger to move a specified distance of its travel while under a 50 lb load. Test the tappets as follows: ACCEPTABLE U MACC FPT ARL F 1. Disassemble and clear the tappe

21-01-8 Generol Gasoline Engine Service 21-01-8 All Except 2.3L 1-4 Engine On all V-8 engines, prying against the aluminum- nylon camshaft sprocket, with the valve train load on the camshaft, can break or damage the sprocket. Therefore, the rocker arm adjusting nuts must be backed off, or the rocker arm and shaft assembly must be loosened sufficiently to free the camshaft. After

21-01-9 General Gasoline Engine Service 21-01-9 Install a dial indicator on the cylinder block as shown in Fig. 15. Hold the camshaft gear against the cortsncrr thrust plate and zero the indicator. TOOL-420;c FIG. 12 Checking Camshaft End Play-2.8L V-6 Engine FIG. 15 Checking Timing Gear Runout-2.BL V-6 Engine Rotate the crankshaft to turn the camshaft,

21-01-10 General Gasoline Engine Service 21-01-10 FLYWHEEL RUNOUT-AUTOMATIC TRANSMISSIONS Remove the spark plugs. Install a dial indicator so that the indicator point rests on the face of the ring gear adjacent to the gear teeth. Hold the flywheel and crankshaft forward or backward as far as possible to prevent crankshaft end play from being indicated as flywhe

21-01-11 General Gasoline Engine Service 21-01-11 ADJUSTMENTS TOO L-TIOP-6513-AHYDRAULIC VALVE CLEARANCE-EXCEPT 2.3L 1-4 AND 2.8L V-6 ENGINES The 2.3L 1-4 engine is an overhead cam engine with hydraulic lash adjusters. Refer to Part 21-05 for adjustment procedures. The 2.8L V-6 engine has mechanical tappets. Refer to Part 21-12 for adjustment procedures. On V-B engines, the valve arrangement on the left bank is E-l-E-I-E-l-E-l and on the right bank is I-E4-E-l-E- I-F. For the 1-6 engine, the valve arrangement is E-l-l-E-I E-E-l-E-l-l-E. A shorter or longer push rod is available far service to provide a means of compensating far dimensional changes in the valve mechanism. Refer to

21-01-12 General Gasoline Engine Service 21-01-12 5.OL 302 CID and 7.5L 460 CID V-8 Engines No. 2 Intake No. 7 Exhaust No. 3 Intake No. 3 Exhaust No. 6 Intake No. 8 Exhaust 5.7L 351 CID "M" and "W" V-8 Engines SMALLFRACTURES No. 2 Intake No- 4 Exhaust No. 5 Intake No. 5 Exhaust No. 6 Intake No. 8 Exhaust Engines With Positive Stop Rocker Arm Studs POOR Each stud nut should be removed and inspected A3I93IC for conditions shown in Fig. 21 when adjusting valve clearance. FIG. 21 Inspection of Rocker Arm Stud Nut

21-01-13 General Gasoline Engine Service 21-01-13 impact slide hammer TS9L-100-B and TSOT-100-A or INSTALLATION pry it out with a large drift punch. Clean and inspect Cup-Typethe plug bore. Prior to installing a core plug the plug bore should Cup-type core plugs Fig. 25 are installed with the be inspected for any damage that would interfere with flanged edge outward. The maximum diameter of this the proper sealing of the plug. If the bore is damaged plug is located at the outer edge of the flange. The it will be necessary to true the surface by boring for the flange on cup-type plugs flares outward with the largest diameter at the outer sealing edge.nex

21-01-14 General Gasoline Engine Service 21-01-14 SEA LINO SEA LING EDGE EGGS BEFORE BE F OR E INSTALLATION IN ETA L LATLO N CUP TYPE EXPANSION TYPE PLUG EXPANSIUN IYPE CORE PLUG

21-01-15 General Gasoline Engine Service 21-01-15 FR Lj F OR V. A PG F aCE OFS_I,3E ALY I 76 014 BEAD OF CSaZ ‘9526A OR B TO PFAR rac’ SEALER AS INU!CATEO ON BEAR NC BLOCK CAP BOTH SIDES LEAVE’ 8 GAP FUR SEALER P B P SI U N U’ / C-

2141-16 General Gasoline Engine Service 21-01-16 Installtion 1. Coat the oil seal to cylinder block surface of the oil seal with oil. Coat the seal contact surface of the oil seal and crankshaft with l.ubriplate or equivalent. Start the seal in the recess and install It wIth the tool as shown in Fig. 30. Drive the seal TOOL T?2C 6165-A into position until it is firmly seated. 2. Install the rear plate and the flywheel. Tighten flywheel bolts to specification. 3. Install the clutch disc and clutch pressure plate, if so equipped. Align clutch disc before tightening pressure plate attaching screws. 4. Install the flywheel housing. 5. Install the transmission.

21-01-17 General Gasoline Engine Service 21-01-17 the finished seat and valve face will be concentric and If the blue is transferred to the bottom edge of the valve the specified interference angle will be maintained. This face, raise the valve seat. is important so that the valve and seat will have a compression-tight fit. Be sure that the refacer grinding VALVES wheels are properly dressed. Minor pits, grooves, etc, may be removed. Discard Grind the valve seats of all engines to a true 45 valves that are severely damaged, if the face runout degree angle Fig. 32. Remove only enough stock to cannot be corrected by refinishing or stem clearance clean up pits and grooves or to correct the valve seat