Group 6 Manual Transmissions

6-1

PAGEPAGE. .6-1

PART 6-5FORD DESIGN FOUR-SPEED

TRANSMISSION. . . . . . . .

PART 6-6OVERDRIVE TRANSMISSION

PART 6-7SPECIFICATIONS 6-56

... .6-35

. .6-45., .6-10

.6-16

PART 6-1GENERAL TRANSMISSION SERVICE

PART 6-2MODEL 2.77 THREE-SPEED

TRANSMISSION PART 6-3

MODEL 3.03 THREE-SPEEDTRANSMISSION , PART 6-4

DAGENHAM FOUR-SPEEDTRANSMISSION ,. ... .6-25

TRANSMISSION SERVICEGENERAL

Page. . .6-8.. .6-8.. .6-8.. .6-9

Section Page1 Diagnosis and Testing 6-12 Common Adjustments and Repairs 6-8

Rear Seal Replacement 6-8Rear Bushing and Seal Replacement. . . . . . . . . . 6-8

SectionLubrication. . . . . . . . . .

3 Cleaning and InspectionCleaning. . . . . . . . . . . . .Inspection

causes and corrective measures arelisted in the order they should bechecked to eliminate all possibilityof maladjustment or faulty compo-nents outside of the transmissionprior to any transmission removaland disassembly. If the transmissionwas removed, repaired and rein-stalled, make certain the clutch andall the gear shift linkage is adjustedto specifications. Road test the ve-hicle to be sure that the problem hasbeen completely corrected.

D DIAGNOSIS AND TESTINGThe problems related to the trans- clutch, clutch linkage, steering col-

mission usually are: excessive umns and shift linkage. Before andamount of noise, hard shifting ef- during the road test make sure thatforts, transmission jumps out of gear, th I t h ' f t ,', I th, , , e c u c IS unc lomngproper y e

gears clash when transmission IS ", "shifted from one gear ratio to an- shift linkage IS properly adjusted, the

other, and lubricant leakage. steering column is properly aligned

The car should be road tested, if and, that the transmission is filledpossible, to determine or confirm to the proper level with lubricant,complaint. Under normal operating , , ,conditions, a large percentage of , The f?llowlOg dla~no~ls proced~retransmission complaints are due to IS compiled as a guide 10 correctingmaladjusted or faulty components problems related to manual transmis-outside of the transmission, such as, sions. Trouble symptoms, possible

ing, Group 5 (DriveshaftClutch), of the shop manual.

and

DIAGNOSIS GUIDE-TRANSMISSIONS

To eliminate all possibility of mal- in the clutch and/ or clutch linkage,adjustments or faulty components refer to Clutch Diagnosis and Test-

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6-2 GROUP 6 - MANUAL SHIFT TRANSMISSIONS

DIAGNOSIS GUIDE-TRANSMISSIONS (Continued)

TROUBLE SYMPTOMS POSSIBLE CAUSES CORRECTION

RATTLE OR BUZZ INFLOOR SHIFT LEVER(Continued)

1. Adjust levers and shift rods toproper crossover, torque nuts tospecification. Replace bell-mouthedrods or levers.

2. Replace bent rods or levers.

3. Clean and lubricate with Lithi-um base grease (no Polethylene).

4. Install correctly.

5. Replace defective parts. Installcorrectly.

No transmission overhaul should beattempted to correct this problem asit is often mistaken for a gratingnoise in the transmission.

1. Loose nuts at transmission le-vers and shift rods. If the nuts areloose, check for bell-mouthing ofslots.

2. Bent transmission shift rods orlinkage interference.

3. Lack of lubrication of shiftlinkage, trunnions and external shiftmechanism (floor shift).

4. Improperly located console andexcessive boot compression. (floorshift)

S. Grommets damaged allowinghold down bolts and/ or hold downwashers to ground out against lever(floor shift).

GEAR CLASH1. Adjust to specification.

CLUTCH LINKAGE1. Lack of clutch pedal reserve,

free play and total travel.2. Bottoming of clutch release

arm in window of clutch housing.

3. Bent or cracked equalizer bar.

2. Grind opening in clutch hous-ing or release arm to provide clear-ance.

3. Replace defective parts.

1-2. Adjust levers and shift rodsto proper crossover, torque nuts tospecification. Replace bell-mouthedrods or levers.

3. Replace bent rods.

SHIFT LINKAGE1. Improper crossover.2. Loose nuts at transmission le-

vers and shift rods. If the nuts areloose, check for bell-mouthing ofslots.



4. Clean and lubricate with Lith-ium base grease (no Polyethylene).

CLUTCH1. Excessive engine idle speed.2. Inadequate clutch pedal reserve

resulting in excessive spin time.

1. Adjust engine idle rpm.2. Adjust clutch linkage to speci-

fication. Check for damaged inputshaft pilot bearing or excessive clutchdisc runout-replace defective parts.

3. Adjust to specification.4. Check for burrs on splines, re-

place if necessary.5-7-8. Replace clutch disc.6. Align to specification.

3. Incorrect pedal free travel.4. Disc binding on transmission

input shaft.5. Excessive disc runout.6. Flywheel housing misalign-

ment.7. Oil or grease on clutch fac-

ings from:A. Release bearingB. engineC. release leverD. pilot bearingE. transmission

CONTINUED ON NEXT PAGE

PART 6-1 GENERAL TRANSMISSION SERVICE 6-3



GEAR CLASH (Continued) 8. Damagedclutch lining.

contaminatedor

1. A-B-C-D-F -G Replace worn ordefective parts.

TRANSMISSION1. Forward Gear Clash

A. Weak or broken insertsprings in the synchronizer assembly.

B. Worn blocking rings and/orcone surfaces.

C. Broken blocking rings.D. Excessive output shaft end

play.E. Shifter fork loose on shift E. Torque shifter

screws to specification.fork set

rails.

2. A. Adjust clutch to specifica-tion-See possible causes underClutch for gear clash trouble sym-toms.

B. Adjust engine idler rpm.CoD. Replace defective parts.

F. Binding input shaft pilotbearing (non-synchronized low geartransmission only).

G. Worn shifter forks or sleeves.2. Reverse Gear Clash (Allow ap-

proximately three-four seconds afterthe clutch pedal has been depressedbefore shifting into reverse gear).

A. If gear clash continues afterallowing proper time for the clutchplate to stop, check the clutch ad-justments to make sure that they arewithin specifications.

B. Excessive engine idle speed.C. Binding input shaft pilot

bearing.D. Worn or damaged clutch

disc

HARD SHIFTING1-2. Adjust levers and rods to

proper crossover, torque nuts to spec-ification. Replace bell-mouthed rodsor levers.

3. Replace bent rods or levers,


5. Install correctly





s. Improperly located console andexcessive boot compression (floorshift).

1. Align column properly, replacedefective column parts and fastentoe plate to firewall securely.

2-3-4. Replace defective parts.

STEERING COLUMNS1. Improper column alignment.

looseness, binding and worn surfaces.Make certain the toe plate at thebase of the column is fastened se-curely to the firewall.

2. Worn shift key or broken weldsecuring shift key to top or bottomof shift tube.

3. Loose shift lever pin in die castselector lever hub.

4. Keyway in die cast selector le-ver hub pounded out.

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CORRECTION---~

POSSIBLE CAUSESTROUBLE SYMPTOMS

HARD SHIFTING(Continued)

5. Align properly.

6. Replace defective parts. Tight-en screws securely.

5. Alignment of column to steer-ing gear pilot bushing.

6. Loose screws securing die cast-ing to bottom of tube. Excessive ra-dial movement in the column link-age. (If the vehicle has high mile-age or is subjected to hard use, eventhough the crossover has been prop-erly set, the column may have de-teriorated to a point where propercrossover engagement will not occurdue to excessive radial movement inthe column linkage (lost motion).

7. Lack of lubrication at columnlower plate.


1. Adjust to specification.CLUTCH LINKAGE

1. Loss of clutch pedal reserve,free play and total travel.

TRANSMISSION1. Excessive shift effort

A. Shift side cover loose ordamaged (Dagenham, Warner Gearfour speed overdrive transmissiononlv),

1. A. Torque screws to specifica-tion. Replace damaged cover.

B-C-E. Replace worn or de-fective parts.B. Shift levers, shafts or forks

worn or bent.C. Synchronizer worn or bro-

ken.D. Install correctly, replace de-

fective parts, if necessary.

2. A. Fill to bottom of filler plughole.

B-D. Free-up and clean parts,replace if necessary.

C-E. Re1Jlace defective parts.

D. Shift rail components notfunctioning properly.

E. VVorn shifter forks orsleeves.

2. Sticking in GearA. Low lubricant level.B. Corroded transmission le-

vers (shaft).C. Defective (tight) input shaft

pilot bearing.D. Stuck detent plug.E. Burred or battered teeth on

synchronizer sleeve and/ or inputshaft.

F. Shifter fork loose on shift F. Torque shifterscrew to specification.

fork ~et

rails.

GEAR JUMPOUT1-2 Adjust levers and rods to

proper crossover. Torque nuts tospecification. Replace bell-mouthedrods or levers.

3. ~eplace bent rods or levers.


SHIFT LINKAGE

1. Improper crossover.2. Loose nuts at transmission le-




5. Improperly located console andexcessive boot compression (floorshift).

5. Install correctly,

PART 6-1 - GENERAL TRANSMISSION SERVICE 6-5



GEAR JUMPOUT(Continued) 1. Align column properly, replace

defective column parts and fastentoe plate to firewall securely.

2. Align properly.

3-4. Replace defective parts.

5. Replace de f e c t i v e parts.Tighten screws securely.

STEERING COLUMNS1. Improper column alignment

looseness, binding and worn surfaces.Make certain the toe plate at thebase of the column is fastened se-curely to the firewall.




5. Loose screws securing die cast-ing to bottom of tube. Excessiveradial movement in the column link-age. (If the vehicle has high mile-age or is subjected to hard use, eventhough the crossover has been prop-erly set, the column may have de-teriorated to a point where propercrossover engagement will not occurdue to excessive radial movement inthe column linkage (lost motion).

TRANSMISSION1. Transmission

loo~e.misaligned or 1. Align to specification. Torque

transmission-to-flywheel housing boltsand flywheel housing-to-engine boltsto specifications.

2-3-5-6-7. Replace worn or de-fective parts.

4. Torque retainer bolts to speci-fication. Replace worn or defectiveparts.

8. Torque screws to specification.Replace damaged cover.

2. Bent or worn shift fork, leverand/ or shaft.

3. Worn input shaft pilot bearing.4. End play in input shaft (bear-

ing retainer loose or broken, looseor worn bearings on input and out-put shafts).

5. Detent springs broken.6. Detent notches worn.7. Worn clutch teeth on the re-

spective gear and/ or worn clutchteeth on synchronizer sleeve.

8. Shift side cover loose or dam-aged (Dagenham and Warner Gearfour speed and overdrive transmis-sion only).

9. Shifter forks loose on shiftrails.

9. Torque shifter fork set screwto specification.

LOCKED IN GEARWhen a complaint of momen-

tary locknut is encountered intransmissions with non-synchro-nized low - gear, determinewhether 0 r not a normal"blockout" condition exists. Ifa "blockout" condition does ex-ist, the customer should be in-formed that the transmission

1-2. Adjust levers and rods toproper crossover. Torque nuts tospecification. Replace bell-mouthedrods and levers.




3. Replace bent rods or levers.

6-6 GROUP 6 MANUAL SHIFT TRANSMISSIONS



CORRECTION1-2.. Adjust column properly, re-

place defective parts and fasten toeplate to firewall securely.

LOCKED IN GEAR(Continued)

gears cannot be pulled intomesh because of gear tooth totooth abutment which can beeliminated by releasing and de-pressing the clutch pedal again(thus spinning the clutch disc).This will re-index the drive anddriven gear teeth and allow thegears to mesh.

3. Align properly.


STEERING COLUMN1. Tricking of shift linkage. Make

certain that when slowly shiftingout of low gear, the low gear shiftlever at the transmission is com-pletely out of low gear detent priorto the column shift lever droppingthrough neutral crossover. If thetransmission shift lever is not com-pletely out of low gear detent, theshift interlock in the transmissionwill prevent engagement of secondgear and a lockup condition occurs.

2. Improper column alignment,looseness, binding and worn surfaces.Make certain the toe plate at thebase of the column is fastened se-curely to the firewall.



5. Loose shift lever pin in diecast selector lever hub.


7. Loose screws securing die cast-ing to bottom of tube. Excessive ra-dial movement in the column link-age. (If the vehicle has high mileageor is subjected to hard use eventhough the crossover has been prop-erly set, the column may have de-teriorated to a point where propercrossover engagement will not occurdue to excessive radial movement inthe column linkage (lost motion).Lack of lubrication at column lowerplate.

7. Replace defective parts. Tight-en screws securely. Clean and lubri-cate with Lithium base grease (noPolyethylene).

1-3. Install correctly, replac de.fective parts.

2. Replace defective parts.

TRANSMISSION1. Shift rail components not func-

tioning properly.2. Gear seizure.3. Synchronizer inse1'ts out of po-

sition.

NOISY IN FORWARDSPEEDS

1. Low lubricant level.

2. Transmission misaligned 0 rloose.

1. Fill to bottom of filler plughole.

2. Align to specification. Torquetransmission-to-flywheel housing boltsand flywheel housing-to-engine boltsto specifications.

3--,-5-6-7. Replace worn or de-fective parts.

3. Input shaft bearings worn ordamaged.

4. Output shaft bearing worn ordamaged.

CONTINUED ON NEXT PAGE

6-7PART 6-1 - GENERAL TRANSMISSION SERVICE


POSSIBLE CAUSES CORRECTIONTROUBLE SYMPTOMS

NOISY IN FORWARDSPEEDS (Continued)

~

5. Mainshaft gears worn or dam-aged. (In any case of scored orbroken gears, the mating gears shouldbe checked).

6. Countershaft gear or bearingsworn or damaged.

7. Failure of the operator to fullyengage the gears on every shift be-fore engaging the clutch and apply-ing engine power.

Gear roll-over noise, inherent inmanual transmissions, is caused bythe constant mesh gears turning atengine idle speed, while the clutch isengaged and the transmission in neu-tral; and throwout bearing rub aresometimes mistaken for mainshaftbearing noise.

Gear roll-over noise will disappearwhen the clutch is disengaged orwhen the transmission is engaged ingear. Throwout bearing rub will dis-appear when the clutch is engaged.In the event that a bearing is defec-tive, the noise is more pronouncedwhile engaged in gear under load orcoast than in neutral. When com-plaints of this nature are encountered,it will be necessary to road test thevehicle to determine if bearing noiseexists. Under no circumstancesshould any transmission rework beattempted to eliminate gear roll-over noise, or throwout bearing rub.

1-2. Replace worn or defectiveparts.

NOISY IN REVERSE 1. Reverse idler gear or shaft,worn or damaged.

Z. Reverse sliding gear worn orhTnke-

LUBRICANT LEAKS 1. Excessive lubricant. 1. Drain to bottom of filler plughole.

2. Free up.3. Add sealer and torque retainer

bolts to specifications. Replace de-fective parts.


5-6-7-8-10. Add sealer to bolts,and torque to specifications. Replacedefective parts.

2. Vent plugged.3. Input shaft bearing retainer

loose or cracked, seal or gasket dam-aged.

4. Worn or damaged extensionhousing seal.

S. Worn shifter shaft seals.6. Shift side c 0 v e r bolts not

sealed. (Dagenham and War n e rGear four speed and overdrive trans-mission only).

7. Shift side cover loose or gas-ket damaged. (Dagenham and War-ner Gear four speed and overdrivetransmission only).

8. Extension housing b 0 Its notsealed.

CONTINU~D ON N~XT PAG~



I COMMON ADJUSTMENTS AND REPAIRSREAR SEAL REPLACEMENT 3. Install the new seal in the exten-

1. Remove the driveshaft. sion housing with the tool shown in2. Remove the seal from the ex- Fig. 2.

tension housing with the tool shownin Fig. 1. 4. Install the driveshaft.

REAR BUSHING AND SEALREPLACEMENT

1. Remove the driveshaft fromthe car.

2. Insert the tool shown in Fig. 3into the extension housing until itgrips the front side of the bushing.

3. Turn the screw clockwise untilthe seal and the bushing are free ofthe housing.

4. Drive a new bushing into theextension housing with the tool shownin Fig. 4.

FIG. 1-Removing Extension Housing Seal

(

~

FIG. 4-lnstalling ExtensionHousing Bushing~ Tool-T60K.7697.8 OR

7657.A AND AdapterTool -T64P .7657.A

, T57L -7657 -A

.5. Install a new seal in the hous-

ing as shown in Fig. 2.6. Install the driveshaft.

~

C1175-C C1173-C LUBRICATIONLubrication level should be in line

with the bottom of filler hole rightside of transmission case.

FIG. 2-lnstalling ExtensionHousing Seal

FIG. 3-Removing ExtensionHousing Bushing and Seal

~ CLEANING AND INSPECTIONCLEANING to damage any parts with the scraper.

1. Wash all parts, except the ball Dry all par t s with compressedbearings, in a suitable cleaning sol- air.vent. Brush or scrape all foreign 2. Rotate the ball bearings in amatter from the parts. Be careful not cleanin~ solvent until all lubricant is

removed. Hold the bearing assemblyto prevent it from rotating and dryit with compressed air.

3. Lubricate the bearings with ap-Droved transmission lubricant and

PART 6-1 - GENERAL TRANSMISSION SERVICE 6-9

If any of these conditions exist, re-place the bearings.

6. Replace roller bearings that arebroken, worn or rough.

7. Replace the countershaft (clus-ter) gear if the teeth are chipped,broken or worn. Replace the counter-shaft if it is bent, scored or worn.

8. Replace the reverse idler gearor sliding gear if the teeth arechipped, worn or broken. Replacethe idler gear shaft if bent, worn orscored.

9. Replace the input shaft and gearif the splines are damaged or if theteeth are chipped, worn or broken.If the roller bearing surface in thebore of the gear is worn or rough,or if the cone surface is damaged,replace the gear and the gear rollers.

10. Replace all other gears thatare chipped, broken or worn.

11. Check the synchronizer sleevesfor free movement on their hubs.Make sure that the alignment marks(etched marks) are properly in-dexed.

wrap them in a clean, lint-free clothor paper until ready for use.

INSPECTION1. Inspect the transmission case

for being cracked, worn or damagedbearing bores, damaged threads orany other damage which could af-fect the operation of the transmis-sion.

2. Inspect the front face of thecase for small nicks or burrs thatcould cause misalignment of thetransmission with the flywheel hous-ing. Remove all small nicks or burrswith a fine stone.

3. Replace a cover that is bent ordistorted. Make sure that the venthole in the cover is open.

4. Check the condition of the shiftlevers, forks, shift rails and the leverand shafts.

5. Examine the ball bearing racesfor being cracked, worn or rough. In-spect the balls for looseness, wear,end play or other damage. Check thebearings for looseness in the bores.

12. Inspect the synchronizer block-ing rings for widened index slots,rounded clutch teeth and smooth in-ternal surfaces (must have machinedgrooves). With the blocker ring onthe cone, the distance between theface of the blocker ring and theclutch teeth on the gear must notbe less than 0.010 inches.

13. R e p I ace the speedometerdrive gear if the teeth are strippedor damaged. Make certain to installthe correct size replacement gear.

14. Replace the output shaft ifthere is any evidence of wear or ifany of the splines are damaged.

15. Inspect the bushing and theseal in the extension housing. Re-place them if they are worn or dam-aged. The bushing and/ or seal shouldbe replaced after the extension hous-ing has been installed on the trans-mission.

16. Replace the seal in the inputshaft bearing retainer.

17. Replace the seals on the camand shafts.

6-10

MODEL 2.77 THREE-SPEED TRANSMISSION

Page. .6-10. .6-10. .6-10. .6-11

Page. . . . . .6-12

. . .. . .6-12

. . . . ..6-12

. . . . . .6-12

. . . . ..6-13

.6-14. .6-14

,. . . . . . ..6-14

, . . . . . . . .6-15

. . . . . .6-15

. . . . . .6-15

Section1 Description and Operation. . . . . . . . .

Description. . . . . . . . . . . . . . . . . . . .Operation , ,.,.,...

2 In-Car Adjustments and Repairs. . . .Gear Shift Linkage Adjustment-

Comet, Falcon, and Fairlane (6 and8 cylinder) Gear Shift Linkage Adjustment-

Mustang. . . . . . . . . . . . . . . . . . . . .3 Removal and Installation. . . . . . . . . .

Removal. . . . . . . . . . . . . . . . . . . . . . .Installation. . . . . . . . . . . . . . . . . . . . .

6-11

6-116-126-12.6-12

Section4 Major Repair Operations Disassembly. . . . . . . . . . . . . . . . . . . . .

Parts Repair or Replacement. . . . . . .Gear Shift Lever """""""Cam and Shaft and Oil Seals. . . . . .Input Shaft Bearing. . . . . . . . . . . .Output Shaft Bearing. . . . . . . . . . .Synchronizer. . . . . . . . . . . . . . . . . .Countershaft Gear Bearings. . . . . ,Front Bearing Retainer Seal. . . . .

Assembly

DESCRIPTION AND OPERATIONward to force the blocking ring coni-cal surface against the matching coneon the constant mesh intermedi-ate gear located on the output shaft.When the vehicle is moving, as whenshifting from low to a higher gearratio, the internal teeth of the syn-chronizer sleeve and those on theblocking ring will not index until theintermediate gear is brought up ordown to the speed of the synchro-nizer sleeve which is rotating at out-put shaft speed.

The synchronizer sleeve with fur-ther movement will slide over theblocking ring and engage the clutchteeth on the constant mesh inter-mediate gear. Since the intermediategear is now locked to the outputshaft by means of the synchronizersleeve, power flow is from the inputshaft through the countershaft gearto the constant mesh intermediategear to the ouput shaft.

Engagement of third speed is thesame as second except for ratio. Inthird gear, the clutch teeth on theinput shaft are locked directly to theoutput shaft by the second and thirdspeed synchronizer to provide a ratioof 1:1.

Reverse gear is accomplished bymoving the first and reverse slidinggear rearward to engage the reverseidler gear. The drive is then fromthe input gear, through the counter-shaft gear, to and through the re-verse idler gear to the first and re-verse sliding gear which is splined tothe output shaft. The gears in this

C1345-B

-DESCRIPTION

The 2.77 C.D. three-speed trans-mission is used in all models with a170 or 200 C.W. engine. The des-ignation 2.77 C.D. is the actual dis-tance between the centerline of thecountershaft and the centerline ofthe input shaft.

An identification plate (Fig. 1) isattached to the upper right extensionhousing attaching bolt.

A synchronizer is provided forshifting to second and third speeds.Shifts to first and reverse speeds areaccomplished with a sliding gear.

Ball bearings support the inputshaft and gear and the center ofthe output shaft. Needle bearingsin the input shaft bore support thefront of the output shaft. The coun-tershaft gear (cluster gear) also runson 2 rows of needle bearings. A

bronze bushing is used in the reverseidler gear.

A bushing located at the rear ofthe extension housing supports therear of the output shaft. The syn-chronizer and the blocking rings arethe conventional tapered ring andstraight clutch gear type.

OPERATIONWhen first gear is selected, the

shift lever moves the first and reversesliding gear into mesh with the lowgear on the countershaft (cluster)gear. Power flow is now from the in-put gear, through the countershaftgear to the first and reverse slidinggear and out through the outputshaft.

When second gear is selected, theshift lever moves the second andthird speed synchronizer sleeve rear-

CHANGE WITHIN TRANSMISSION AFFECTINGINTERCHANGEABILITY OF COMPONENT PARTS

PART 6-2 MODEL 2.77 THREE-SPEED TRANSMISSION 6-11

position will rotate the output shaftin a reverse direction.

An interlock pin prevents selectionof more than one gear at a time. De-

tent balls are provided to hold theselected gear in the desired position.

IN-CAR ADJUSTMENTS AND REPAIRS

GEAR SHIFT LINKAGE

ADJUSTMENT-COMET,

FALCON, FAIRLANE

(6 AND 8 CYLINDER)

1. Place the gearshift lever in the

neutral position.

2.. L~oosen the two gearshift rod

ldiustment nuts.

3. Insert a dealer fabricated spe.

cial tool in the slot provided in the

lower steering column. (See Fig. 2

It may be necessary to align the

levers to insert the tool.

4. Tighten the two 2earshift rod

adjustment nuts.

5. Remove the tool from the slot

in the steering column.

6. Start the en~ine and shift the

selector lever to each position to

make sure it operates freely

GEAR SHIFT LINKAGE

ADJUSTMENT-MUSTANG FIG. 2-Comet, Falcon and Fairlane Gearshift linkage Adjustment

1. Loosen the three shift linkage

adjustment nuts. Install a 1/4 inch

diameter alignment pin through the

control bracket and levers a~ ~hnwn

in Fig. 3.

2. Tighten the three linkage ad-

justment nuts and then remove the

alignment pin.

3. Check the gear shift lever for a

smooth crossover. FIG. 3-Gearshift LinkaQe Adiustment-Mustana


REMOVAL AND INSTAllATION

the frame supports and allow it tohang by the brake cable.

9. Move the jack under the trans-mission. Remove the four trans-mission to flywheel housing mount-ing bolts.

10. Move the transmission backjust far enough to clear the inputshaft and remove it from under thecar.

INSTALLATION1. Install two guide pins in the

flywheel housing lower mountingholes. Start the input shaft throughthe release bearing. Align the outputshaft splines with the splines in theclutch disc. Move the transmissionforward on to the guide pins. If thetransmission front bearing retainerhangs-up on the release bearing hub,move the clutch release lever to freeit.

REMOVAL1. Raise the car on a hoist.2. Remove the driveshaft. Insert

the extension housing seal installa-tion tool, Fig. 2, Part 6-1, into theopening of the extension housing toprevent the lubricant from leakingout.

3. Disconnect the speedometer ca-ble from the extension housing, anddisconnect the gear shift rods fromthe transmission shift levers.

On a Mustang, remove the threebolts that attach the shift selectorassembly to the extension housingand allow the assembly to hang bythe shift lever.

4. Remove the two nuts retainingthe transmission rear support to thecrossmember.

5. Place a transmission jack underthe flywheel housing and raise therear of the engine slightly.

6. Remove the two cotter pins,nuts, and bolts that attach the cross-member to the frame supports.

7. Disconnect the brake cablefrom the equalizer lever. Separatethe lever from the crossmember.

8. Remove the crossmember from

4. Remove the two guide pins andinstall the two lower attaching bolts.Torque all attaching bolts to speci-fications.

5. Position the crossmember tothe frame supports. Install the equal-izer lever and brake cable.

6. Secure the transmission rearsupport to the crossmember. Securethe crossmember to the frame sup-ports and remove the transmissionjack.

7. Connect the gear shift rods andthe speedometer cable.

On a Mustang, position the shiftselector assembly to the extensionhousing and install the attachingbolts.

8. Remove the tool (Fig. 2, Part6-1) from the rear of the extensionhousing. Install the driveshaft, andtorque rear U-bolt nuts to specifica-tion.

9. Fill the transmission with ap-proved lubricant. Check the shiftingaction of the transmission.

10. Adjust the clutch pedal totaltravel, free travel and shift linkageas required.

2. Move the transmission forwarduntil the input shaft is through theclutch hub and enters the pilot bear-ing.

3. Install the two upper transmis-sion to flywheel housing attachingbolts and lockwashers.

MAJOR REPAIR OPERATIONS

DISASSEMBLY1. Mount the transmission in a

holding fixture and drain the lubri-cant.

2. Remove the transmission coverand gasket.

3. Remove the extension housingattaching bolts and remove the ex-tension housing and gasket. To pre-vent the output shaft from followingthe housing (with the resultant lossof needle bearings), tap the end ofthe output shaft with a soft-facedhammer while withdrawing the ex-tension housing. See disassembly(Fig. 4).

4. Remove the speedometer drivegear snap ring, the gear, and driveball from the output shaft.

S. Remove the retainer for thereverse idler shaft and countershaft(Fig. 4).

6. Hold the countershaft gear witha hook and using the tool (dummyshaft) shown in Fig. 5, drive thecountershaft rearward out of thecountershaft gear and the transmis-sion case. Then. carefully lower the

PARTS REPAIR ORREPLACEMENT

GEAR SHIFf LEVER1. Remove the snap ring from the

end of the selector shaft with pointedsnap ring pliers (Fig. 7).

2. Remove the flat washer andspring.

3. After removing two bolts, pullthe retainer, selector levers, andspacer from the shaft.

4. Drive the short selector leverpin from the shaft with a large pinpunch.

5. Drive the long trunnion pinfrom the shaft and remove thetrunnion and shaft.

6. If necessary to remove the studsfrom the selector levers, remove thecotter pins, flat washers, wave wash-ers and studs.

7. Lubricate all mating frictionsurfaces with Lubriplate before as-sembly.

8. Install the shaft in the bracket.Position the trunnion and drive thelon2 strai2ht pin through the trun-

countershaft gear and dummy shaftto the bottom of the case.

7. After removing the input shaftbearing retainer and gasket, removethe input shaft assembly and frontsynchronizer blocking ring from thetransmission case (Fig. 6).

8. Remove the synchronizer re-taining snap ring from the outputshaft. Then, while holding the syn-chronizer assembly together, pull theoutput shaft out of the transmissioncase. The intermediate gear and thelow and reverse gear will slide off theoutput shaft as it is withdrawn fromthe case. Lift the synchronizer assem-bly, intermediate, low and reversesliding gears out of the case and re-move the two shift forks. For ref-erence in assembly, notice whichsynchronizer hub end faces forward.

9. Using a soft drift, drive the re-verse idler shaft out of the transmis-sion case. Lift the reverse idler gearand the countershaft gear out of thecase.

10. Remove the shift levers.

pins that hold the cam and shaft as-semblies in the case (Fig. 8). Usehard, firm blows. Using a plastichammer, drive the intermediate andhigh cam and shaft toward the insideof the case and separate the detentballs and spring from the plunger.Push out the cam and shaft assem-blies, and remove the plunger.

2. If required, the cam and shaftoil seals in the case may be removedwith the tools shown in Fig. 9.

3. Install new seals in the case.4. Install the reverse and low shift

cam and shaft through the case open-ing. Assemble the spacer and springin the plunger. Apply grease to eachball and position them in each end ofthe plunger. Hold the plunger assem-bly in position and install the inter-mediate and high cam and shaft in

length of the pin is exposed on bothsides of the shaft.

9. Drive the short pin into theshaft until the pin is centered in theshaft.

10. Install the levers and spaceron the shaft as shown in Fig. 7.

11. Position the retainer and startthe bolts. Before tightening the boltsbe sure that the retainer is not inter-fering with free movement of theshaft. Tighten the boits.

12. Install the spring, flat washerand snap ring.

13. Install the lever studs if theywere removed.

FIG. 5-Removing or InstallingCountershaft

CAM AND SHAFTS AND OILSEALS

1. From the underside of the case,use a punch to drive out the taperedninn and into the shaft until an eQual

~.":)t ..i. 001-

,OIL SEAL 100/-

159L-100-8

~

~

Cl168-B

FIG. 9-Removing (am andShaft Oil Seals

Fiber Block

OIL SLINGER"

""c BEARING. ~~~

TooI-T53T.4621-8

J

INPUT SHAFf BEARING1. Remove the snap ring securing

the input shaft bearing, and press theinput shaft out of the bearing and oilslinger.6-Removing Input Shaft

~

j)

.""

C1170-A

FIG. 10-lnstalling Input ShaftBearing

'VER AS!7"'0

BOLT-379818- S

~+ !

GROMMET379~19. S

@

SPRING -/ 7208 0' PLUNGER -76125

':,..'~lc @ ~ TRUNNION - SNAP RING,~ / 7210 97527.5l.dJ r;;;. ~ STRAIGHT PIN (LONG) - F LA T WASHER -

~ SUPPORT - 379300.5 371681.57416 SPACER - STRAIGHT S

HAFT (SHORT)7C383 , -7Alll

SELECTOR SHAFT -7241 :"

J ?;:)

~~I:D:

SPRING-7C307

1\ RETA)NER-

7~48

~

SPACER -7C383 ~, ~-=

~FLAT WASHER -

44727-5COTTER PIN-

72016-5

Js;;JJ

1" SPRING -

7n7

}}-

--

,I

@ Aft) '- "'6~ BOL T -

376444-5-- 'SELEc-tOR LEV STUO-

u,.u ..'v 7285 7353 1...

7 -Gearshift Lever Disassembled-Typical

~SPRING WASHER

35141'7 "~

SELECTOR LEVER-;1?On ("'581-A

the case opening, allowing the ballsto register in the cam detents.

S. Align the cam and shaft grooveswith the openings in the shaft bossesin the case, and install the retainingpins. Check the cam action. Bentpins may restrict movement.

2. Press the input shaft bearingand oil slinger onto the input shaftwith the tool shown in Fig. 10, andinstall the snap ring on the shaft.

OUTPUT SHAFT BEARING1. Remove the snap ring securing

8-


FIG. 12-Removing InputShaft Seal

3. Align the etch mark on the hubwith the etch mark on the sleeve.Slip the hub and inserts into thesleeve making sure that the etchmarks are aligned.

4. Secure the hub and inserts inthe sleeve with the two insert springs.

COUNTERSHAFf GEARBEARINGS

1. Remove the flat washers, dum-my shaft, spacer, and roller bearingsfrom the countershaft gear.

2. Insert the spacer and dummyshaft into the countershaft gear.Position one flat washer at each endof the spacer (Fig. 4). Coat the borein each end of the countershaft withgrease and install twenty roller bear-ings in each end of the gear. Applya coating of grease to the othertwo flat washers and the thrust wash-ers and assemble at each end of thecountershaft gear. Note the positionof the tangs on the thrust washers.

3. Place the case in a vertical po-sition. Align the gear bore and thrustwashers with the bores in the caseand install the countershaft.

4. Place the case in a horizontalposition and check the countershaftgear end play with a feeler gauge.The end play should be 0.004-0.018inch. If not within these limits, re-place the thrust washers.

5. After establishing the correctend play, install the dummy shaft inthe countershaft gear and allow thegear to remain at the bottom of thecase until the output and input shaftshave been installed.

FRONT BEARING RETAINERSEAL

1. Remove the input shaft sealfrom the front bearing retainer asshown in Fig. 12.

2. Install a new input shaft sealas shown in Fig. 13.

assemble the needle bearings in theinput shaft. A thick film of greasecould plug the lubricant holes andprevent lubrication to the bearings.Install the front synchronizer block-ing ring on the input shaft.

4. Install the shift forks on thecam and shaft assemblies, with thelarge fork on the intermediate andhigh cam and shaft. The web of the

low and reverse fork must be to therear of the shaft center.

5. Start the output shaft throughthe rear opening of the transmissioncase. Place the low and reverse slid-ing gear on the shaft, followed by theintermediate gear. Tilt the outputshaft enough to allow the rear shiftfork to engage the sliding geargroove.

6. With the longer hub end for-ward slide the synchronizer assemblyon to the output shaft and engagethe synchronizer sleeve in the inter-mediate and high shift fork.

7. Install the synchronizer hubsnap ring.

8. Position the input shaft andsynchronizer front blocking ring inthe front of the case seating the out-put shaft pilot in the roller bearingsof the input gear.

9. Place a new gasket on the inputshaft bearing retainer. Install the in-put shaft bearing retainer, using seal-er on the bolts. Line up the draingroove in the retainer with the oilhole in the case.

10. Raise the countershaft gear toalign the dummy shaft with thecountershaft holes in the case. Startthe countershaft into the case fromthe rear, and carefully drive the shaftinto position.

11. Install the reverse idler gearshaft and the reverse idler shaft andcountershaft retainer.

12. Install the speedometer drivegear and drive ball. Then secure thegear with the snap ring.

13. Install a new gasket, and theextension housing, using sealer onthe bolts. Torque the bolts to speci-fication.

14. Install the shift levers.15. If the extension housing bush-

ing and/or seal is to be replaced,refer to Part 6-1, Section 2, for thedetailed instructions.

16. Pour lubricant over the en-tire gear train while rotating the in-put or output shaft. Install the trans-mission case cover and gasket. Usesealer on the bolts. The gasket ventholes must be toward the rear, andthe cover vent hole must be towardthe front.

17. Check transmission operationthrough. all shift positions.

ASSEMBLY1. If the countershaft gear is not

already positioned in the bottom ofthe case, do it at this time.

2. Position the reverse idler gear,and insert the shaft (from the rear)through the case just far enough tohold the gear.

3. Using a light coat of grease,

6.16

MODEL 3.03 THREE-SPEED TRANSMISSION

Page6-166-166-166-17

Page.6-19.6-19.6-19.6-21,6-21.6-216-22

.6-22

.6-22

.6-23

6-17

6-176-186-18

Section1 Description and Operation Description. . . . . . . . . . . . . . . . .

Operation 2 In-Car Adjustment and Repairs .

Gear Shift Linkage Adjustment-Comet. Falcon and Fairlane .

Gear Shift Linkage Adjustment-Mustang. . . . . . . . . . . . . . . . .

3 Removal and Installation. . . . . .Removal. . . . . . . . . . . . . . . -

SectionInstallation. . . . . . . . . . . . . .

4 Major Repair Operations. . .Disassembly Parts Repair or Replacement,

Gear Shift Lever Shift Levers and Seals. . .

Input Shaft Bearing Synchronizers. . . . . . . . . . ,

Countershaft Gear BearingsAssembly

DESCRIPTION AND OPERATION

DESCRIPTION

The 3.03 REF Model three-speed

transmission (Fig. 1) is used on all

cars having a 200 R.D. or 289 C.I.D.

engine. A 3.03 REG Model trans-

mission is used on all cars equipped

with a 390 C.I.D. engine. The desig-

This transmission is of the fully

synchronized type, with all gears ex-

cept the reverse gear and sleeve be-ing in constant mesh. All forward-

speed changes are accomplished

with synchronizer sleeves (Fig. 2)

instead of sliding gears. The synchro-

1-3-Speed Transmission

shaft and gear and the center of the

output shaft (Figs. 12 and 16). Roll-

er bearings in tb,e input shaft bore

and 19).

support the front of the output

shaft. The countershaft gear (cluster

gear) runs on two rows of roller

bearings. Two bronze bushings are

used in the reverse idler gear (Fig.

11). A bushing located at the rear

of the extension housing supports

the rear of the output shaft.

Synchronizers and blocking rings

are the conventional tapered ring and

straight clutch gear type (Figs. 17

The shift forks, shift rails, detent

mechanism, and related parts are

provided in the transmission case

(Fig. 9).

tween the centerline of the counter-

shaft and the centerline of the in-

put shaft.

A transmission service identifica-

tion tag is located on the right side

of the case at the front. The first

line on the tag will show the trans-

mission model and service identifica-

tion code when required. The second

nation 3.03 is the actual distance be-

line will show the transmission serial

number.

OPERATION

When the first-speed gear is se-

lected, the shift lever moves the

reverse gear and sleeve forward and

forces the synchronizer blocking ring

conical surface against the matching

cone on the constant mesh first gear

located on the output shaft. If the

nizers enable quicke,. shifts, greatly

reduce gear clash and permit down-

shifting, high to intermediate between

40-20 mph and from intermediate to

low below 20 mph.

The forward-speed gears are heli-

cal-cut and are in constant mesh

(Fig. 2). Gears used in the reverse

gear train are spur-cut and are not

synchronized.

Ball bearings support the input

PART 6-3 - MODEL 3.03 THREE-SPEED TRANSMISSION 6-17

LOW AND REVERSE SLIDING SLEEVE AND GEAR

FIRST-SPEED GEAR,

SECOND-SPEED GEAR""SECOND AND HIGH SYNCHRONIZER ""'" ffi;

OUTPUT SHAFT BEARING

OUTPUT SHAFT

INPUT SHAFT AND GEAR.

SPEEDOMETER GEAR=~,

INPUT SHAFT BEARING,IDLER SHAFT

COUNTERSHAFT~

REVERSE IDLER GEAR'"

COUNTERSHAFT CLUSTER GEAR

with the countershaft (cluster) gear,

the power flow is from the input

gear, through the countershaft gear,

to the constant mesh first gear,

through the reverse gear and sleeve

to the output shaft, and out the rear

of the transmission.

Engagement of second and third

gears is the same as first except for

ratio. In third gear, the input gear

and shaft is locked directly to the

output shaft by the second and third

speed synchronizer to provide a ratio

of 1:1.

Spur teeth are cut on the outside

of the reverse gear and sleeve. The

reverse gear and sleeve like the hub

are always locked to the output shaft.

Reverse gear is engaged by sliding

the reverse gear and sleeve into mesh

with the spur gear at the rear of the

idler gear. The drive is then from

the input gear, through the counter-

shaft gear, to and through the re-

verse idler gear to the output shaft

reverse gear and sleeve. The gears in

this position will rotate the output

shaft in a reverse direction.

A system of interlocks and detents

in the transmission case prevents the

selection of more than one gear at a

time and helps to hold any gear in

the selected position.

FIG. 2-Power Flow-3-Speed Transmission

The reverse gear and sleeve has

internal splines that, with further

movement, will slide over the block-

ing ring and engage external clutch

teeth on the constant mesh first gear.

Since first gear is now locked to the

output shaft and is always meshed

car is moving, the internal teeth of

the reverse gear and sleeve and

blocking ring will not index until

the constant mesh first gear is

brought up or down to the speed of

the reverse gear and sleeve which is

rotating at output shaft speed.


the lower steering column. (See Fig.3).

It may be necessary to align thelevers to insert the tool.

4. Tighten the two gearshift rodadjustment nuts.

S. Remove the tool from the slotin the steering column.

6. Start the engine and shift theselector lever to each position tomake sure it operates freely.

GEAR SHIFT LINKAGE

ADJUSTMENT-COMET,FALCON, FAIRLANE

1. Place the gear shift lever in the

neutral position.

2. Loosen the two gearshift rod

adjustment nuts.

3. Insert a dealer fabricated

special tool in the slot provided in

GEAR SHIFT LINKAGEADJUSTMENT-MUSTANG

1. Loosen the three shift linkageadjustment nuts. Install a 1/4 inchdiameter alignment pin through thecontrol bracket and levers as shownin Fig. 4.

2. Tighten the three linkage ad-justment nuts and then remove thealignment pin.

3. Check the gear shift lever for asmooth crossover.

GROUP 6 MANUAL SHIFT TRANSMISSIONS6-18

T1/2"

-L

FIG. 3-Comet, Falcon and Fairlane Gearshift Linkage Adjustment

AN ALIGNMENT TOOL CAN BE MADE FR~ 1/4"DIAMETER DRILL RDD BENT TO AN "L" SHAPE. THEEXTENSIONS SHOULD BE 1 . 1/2" AND 3.3/4" FROMTHE ELBOW. SHORT END OF ALIGNMENT TOOLSHOULD BE INSERTED INTO CONTROL BRACKET ANDLINKAGE HOLES UNTIL IT BOTTOMS.

~

SHIFT CGlTROLBRACKET

/

1/2'"Alignment Tool

/3.3/4'

/

C1539-B

FIG. 4-Three-Speed Shift linkage Adjustment

REMOVAL AND INSTAllATIONREMOV AL 3. Slide the front of the drive-

l. Raise the car on a hoist. shaft out of the extension housing2. Disconnect the driveshaft from and off the output shaft. Insert the

the rear V-joint fian!!e. tool shown in Fig. 2, Part 6-1, to

prevent the lubricant from leakingout.

4. Remove the cap screw and lockwasher that secures the speedometer

INSTALLATION1. Make certain that the machined

surfaces of the transmission case andthe flywheel housing are free of dirt,paint and burrs.

2. Install a guide pin in eachlower mounting bolt hole.

3. Start the input shaft throughthe release bearing. Align the splineson the input shaft with the splinesin the clutch disc. Move the trans-mission forward on the guide pinsuntil the input shaft pilot enters thebearing or bushing in the crankshaft.If the transmission front bearing re-tainer binds up on the clutch releasebearing hub, work the release bearinglever until the hub slides onto theretainer. Install the two transmis-sion-to-flywheel h 0 u sin g uppermounting bolts and lock washers.Remove the two guide pins and in-stall the lower mounting bolts andlock washers. Torque the fourmounting bolts to specifications.

4. Raise the rear of the enginehigh enough to provide clearance forinstalling the crossmember. Installthe two crossmember-to-frame sup-port attaching bolts, washers, andnuts. Do not tighten at this time.

S. Align the bolts in the trans-mission rear support with the bolt

cable retainer to the extension hous-ing. Pull the speedometer cable outof the extension housing.

5. Remove the cotter pin, flatwasher, and spring washer that se-cure the shift rods to the shift leverson the transmission.

6. On a car equipped with a floormounted gear shift selector lever,remove the three bolts that attachthe shift selector assembly to theextension housing and allow the as-sembly to hang by the shift lever.

7. Remove the two nuts securingthe transmission rear support to thecrossmember.

8. Raise the rear of the engineenough to remove the weight fromthe crossmember. Remove the twonuts, washers and bolts securing thecrossmember to the frame supports.Remove the crossmember.

9. Support the transmission witha transmission jack and remove thefour flywheel housing-to-transmissioncase attaching bolts and lock washers.

10. Move the transmission andjack rearward until the input shaft isclear of the flywheel housing.

11. Remove the transmission fromunder the car. Do not depress theclutch pedal while the transmissionis removed.

holes in the crossmember, then lowerthe engine and remove the jack. In-stall the two transmission rear sup-port-to-crossmember washers andnuts and torque to specifications.Tighten the crossmember-to-framesupport nuts.

6. On a car equipped with a floormounted gear shift selector lever, po-sition the shift selector assembly tothe extension housing and install theattaching bolts.

7. Connect each shift rod to itsrespective lever on the transmissionwith a spring washer, flat washer,and cotter pin.

8. Insert the speedometer cableand driven gear in the extensionhousing and secure with a cap screwand lock washer.

9. Remove the tool shown in Fig.2. Part 6-1, from the extension hous-ing. Slide the front universal jointyoke onto the output shaft and intothe extension housing. Connect therear universal joint to the axle pin-ion flange and torque the nuts tospecifications.

10. Fill the transmission to theproper level with the approved lubri-cant and lower the car.

11. Adjust the clutch pedal freetravel and the shift linkage as re-quired.

- MAJOR REPAIR OPERATIONSDISASSEMBLY 3. Remove the five cap screws

1. Mount the transmission in a and lock washers that attach theholding fixture and drain the lubri- extension housing to the case. Re-cant. move the extension and gasket from

2. Remove the nine cap screws the case.that attach the cover to the case. Re- 4. Remove the four cap screwsmove the cover and the gasket (Fig. and lock wahers that: attach the5) from the case. front bearing retainer to the case.

Remove the retainer and gasket fromthe case.

5. Remove the lubricant fillerplug from the right side of the case.Working through the plug opening,drive the roll pin out of the caseand countershaft with a 1/4 -inchpunch (Fig. 6).

6. Hold the countershaft gear with

CO

FXTFN~I()N HruJSING

FRONTBEARING RETAINER~

!7 CASE

!"

.cdr--.

£.--~=~ '!,f . , . '

"-' 1 ,'" "- "'-' -'-..1- ~ -

ra '~=:;~ ," SERIAL NUMBER PLATE

PLUGS~ =_--~:;"" f'/'

GASKET""

C 1561.A

FIG. 6-Removing CountershaftRoll Pin

C 1583 - A

5-Transmission Case and Related Parts-Typical


a hook and with the tool (dummyshaft) shown in Fig. 7, push thecountershaft out the rear of the case.

sible, then rotate the first and reverseshift fork upward, then lift it fromthe case.

13. Move the second and third-speed shift fork to the second speedposition to gain access to the setscrew. Remove the set screw fromthe fork. Rotate the shift rail 90°as shown in Fig. 10.

CJ584.A

FIG. 7 -Removing Countershaft

The countershaft (cluster) gearand thrust washers (Fig. 11) can belowered to the bottom of the case.Remove the countershaft from therear of the case.

7. Remove the snap ring that se-cures the speedometer drive gearon the shaft. Slide the speedometerdrive gear off the output shaft. Re-move the speedometer drive gearlock ball from the shaft.

8. Remove the snap ring that re-tains the output shaft bearing onthe shaft. Remove the bearing fromthe case and shaft as shown in Fig. 8

9. Place both shift levers in theneutral (center) position.

ring. It is necessary to move the gearforward to provide clearance whenremoving the output shaft assemblyin HEG models. On HEF models,the input shaft and gear is removedfrom the front of the case at thistime.

18. Rotate the second and third

~

~~--!

ClampBlock -Remover

FIG. 1 a-Rotating Second and Third-Speed Shift Rail

14. Lift the interlock plug (Fig. shift fork upward, and lift it from9) from the case with a magnet. the case.

15. Tap on the inner end of the 19. Carefully lift the output shaftsecond and third shift rail to remove assembly out through the top of thethe expansion plug (Fig. 9) from the case.front of the case. Remove the shift On HEG models, work the inputrail. shaft bearings and gear back through

16. Remove the second and third the bore in the case and out the top.detent plug and spring from the de- 20. Driving from the front of thetent bore. case, remove the reverse idler gear

17. Pull the input gear and shaft shaft from the case and then lift theforward until the gear contacts the reverse idler gear and two thrustcase, and then remove the large snap washers (Fig. 11) from the case.

- - C1427-A

FIG. 8-Removing Output ShaftBearing

10. Remove the set screw (Fig.9) that retains the detent springsand plugs in the case. Remove thedetent spring and plug from the case.

11. Remove the set screw that se-cures the first and reverse shift forkto the shift rail. Slide the first andreverse shift rail out through therear of the case.

12. Slide the first and reversesynchronizer forward as far as pos-

FIG. 11-Reverse Idler Shaftand Gear-Disassembled

21. Remove the snap ring fromthe front of the output shaft, thenslide the synchronizers and the sec-ond speed gear (Fig. 12) off theshaft.

equal length of the pin is exposedon both sides of the shaft.


10. Install the levers and spaceron the shaft as shown in Fig. 13.

11. Position the retainer and startthe bolts. Before tightening the boltsbe sure that the retainer is not inter-fering .w:ith free movement of theshaft'. Tighten the bolts.

12. Install the spring; flat washerand snap ring.


FIG. 14-Shift Lever andShaft-Disassembled

FIG. 1 2-0utput Shaft-Disassembled12. Remove the next snap ring

and tabbed thrust washer from theoutput shaft, and then slide the firstgear and blocking ring off the shaft.

23. Remove the next snap ringfrom the output shaft, and slidethe reverse gear and sleeve off theshaft.

SHIFT LEVERS AND SEALS1. Remove the nut, lock washer

and fiat washer that secures eachshift lever (Fig. 14) to the lever and~haft in the transmission case. Lift

the levers off the shafts. Slide eachlever and shaft out of the case. Dis-card the "0" ring from each shaft.

2. Lubricate the new seals withtransmission lubricant and installthem on the shafts.

3. Install the lever and shafts inthe case.

4. Position a shift lever on eachshaft and secure them with a flatwasher, lock washer and nut.

~PARTS REPAIR ORREPLACEMENTGEAR SHIFf LEVER

1. Remove the snap ring from theend of the selector shaft with pointedsnap ring pliers (Fig. 13).


3. After removing two bolts, pullthe retainer, selector levers, andspacer from the shaft.



6. If necessary to remove the studsfrom the selector levers, remove thecotter pins, flat washers, wave wash-ers and studs.


8. Install the shaft in the bracket.Position the trunnion and drive thelong straight pin through the trun-nion and into the shaft until an


INPUT SHAFf BEARING1. Remove the snap ring securing

the input shaft bearing (Fig. 15),and press the input shaft out of thebearing.

ing sure that all three insert slots arefully covered. With the alignmentmarks on the hub and sleeve aligned,start the hub into the sleeve. Placethe three inserts on top of the re-

taining spring and push the assemblytogether. Install the remaining insertspring, so that the spring ends coverthe same slots as does the otherspring. Do not stagger the springs.Place a synchronizer blocking ringon each end of the synchronizersleeve.

COUNTERSHAFT GEARBEARINGS

1. Remove the dummy shaft, 50roller bearings, and the two bearingretainer washers from the counter-shaft gear (Fig. 18).

2. Coat the bore in each end ofthe countershaft gear with grease.

2. Press the input shaft bearingonto the input shaft with the toolshown in Fig. 16 and install the snapring on the shaft.

C1025-8

FIG. 16-Replacing InputShaft Bearing

,NEEDLE BEARINGS (25 EACH

COUNTERSHAFT

1

qBEARINGRETAINER

C1414-A

BEA'RING -~ I

RETAINER ROLL PIN

FIG. 1 8-Countershaft Gear-Disassembled

SYNCHRONIZERS1. Push the synchronizer hub

from each synchronizer sleeve.2. Separate the inserts and insert

springs from the hubs. Do not mixthe parts from the second and thirdspeed synchronizer with the first andreverse synchronizer (Figs. 17 and19).

3. Install the rear insert spring(Fig. 20) in the groove of the firstand reverse synchronizer hub. Makesure that the spring covers all insertgrooves. Start the hub in the sleevemaking sure that the alignmentmarks are properly indexed. Positionthe three inserts in the hub makingsure that the small end is over thespring and that the shoulder is on theinside of the hub. Slide the sleeveand reverse gear onto the hub untilthe detent is engaged. Install thefront insert spring in the hub to holdthe inserts against the hub.

4. Install one insert spring (Fig.19) into a groove of the second andthird speed synchronizer hub, mak-


INCORRECT REARSPRING INSTAlLATIO7

CORRECT REARSPRING INSTALLATI7

FIG. 20-First and Reverse SpeedInstallation

3. Hold the dummy shaft in thegear and install the 25 roller bear-ings and a retainer washer in eachend of the gear.

4. Position the countershaft gear,dummy shaft. and roller bearings inthe case.

5. Place the case in a verticalposition. Align the gear bore and thethrust washers with the bores in thecase and install the countershaft.


7. After establishing the correctend play, install the dummy shaft inthe countershaft gear and allow thegear to remain at the bottom of thecase.

11. Position the output shaft as-sembly in the case. Position the sec-ond and third shift fork on the sec-ond and third speed synchronizer.

12. Place a detent plug spring anda plug in the case (Fig. 9). Placethe second and third speed synchro-nizer in the second speed position(toward rear of transmission). Alignthe fork and install the second andthird speed shift rail. It will be nec-essary to depress the detent plug toenter the rail in the bore. Move therail inward until the detent plug en-gages the forward notch (secondspeed position).

13. Secure the fork to the shaftwith the set screw. Move the syn-chronizer to the neutral position.

14. Install the interlock plug inthe case. If the second and thirdshift rail is in the neutral position,the top of the interlock will be slight-ly lower than the surface of the firstand reverse shift rail bore.

15. Move the first and reversesynchronizer forward to the firstspeed position. Place the first and re-verse shift fork in the groove of thefirst and reverse synchronizer. Ro-tate the fork into position and installthe first and reverse shift rail. Movethe rail inward until the center notch(neutral) is aligned with the detentbore. Secure the fork to the shaftwith the set screw. Install the re-maining detent plug and spring. Se-cure the detent spring with theslotted head set screw. Turn the setscrew in until the head is flush to0.020 inch below the top of thecase.

16. Install a new expansion plugin the case.

17. Hold the input shaft andblocking ring in position, and thenmove the output shaft forward toseat the pilot in the roller bearingsof the input gear.

18. Tap the input gear bearinginto place in the case while holdingthe output shaft to prevent the rollerbearings from dropping. Install thefront bearing retainer and new gas-ket, making sure that the oil returnslot is at the bottom of the case. In-stall and torque the four attachingscrews. to 30-36 ft-ibs.

19. Install the large snap ring onthe rear bearing. Place the bearingon the output shaft with the snapring end toward the rear of theshaft. Press the bearing into placewith the tool shown in Fig. 21. Se-cure the bearing to the shaft with asnap ring.

ASSEMBLY1. Place countershaft gear in

proper position at bottom of case.The countershaft gear will remain inthe bottom of the case until the out-put and the input shafts have beeninstalled.

2. Coat the reverse idler gearthrust surfaces in the case with a thinfilm of lubricant and position thetwo thrust washers (Fig. 11) inplace.

3. Position the reverse idler gearand dummy shaft in place. Align thegear bore and thrust washers withthe case bores and install the reverseidler shaft.

4. Measure the reverse idler gearend play with a feeler gauge. Endplay should be 0.004-0.018 inch. Ifthe end play is not within limits, re-place the thrust washers. If the end

Synchronizer Insert Spring

play is within limits, leave the re-verse idler gear installed.

5. Lubricate the output shaftsplines and machined surfaces withtransmission lubricant.

6. Slide the first and reverse gearand sleeve (Fig. 12) onto the out-put shaft with the teeth end of thegear facing toward the rear of theshaft. Secure it in place with thesnap ring.

7. Place the blocking ring on thetapered machined surface of the firstgear.

8. Rotate the gear as necessary toengage the three notches in theblocking ring with the synchronizerinserts. Secure the first gear with thethrust washer and snap ring.

9. Slide the blocking ring onto thetapered machined surface of thesecond gear. Slide the second gearwith blocking ring and the secondand third. gear synchronizer onto themainshaft. The tapered machinedsurface of the second gear must betoward the front of the shaft. Makesure that the notches in the blockingring engage the synchronizer inserts.Secure the synchronizer with a snapring.

10. Coat the bore of the inputshaft and gear with a thin film ofgrease. A thick film of grease willplug the lubricant holes and preventlubrication to the bearings. Installthe bearings (Fig. 15) in the bore.

If working on an HEG modeltransmission, install the input gearand bearing through the top of thecase and through the bore in thefront of the case. On HEF models,the input shaft is installed throughthe front of the case. Install the snapring in the bearing groove.


ing gasket with sealer and position iton the case.

24. Install lock washers on thefive attaching screws. Dip the threadsof the cap screws in sealer. Securethe housing to the case and torquethe cap screws to 42-50 ft-ibs.

25. Install the filler and drainplugs in the case. Make sure that themagnetic plug is installed in the bot-tom of the case.

26. Place the transmission in gear.Pour lubricant over the entire geartrain while rotating the input or out-put shaft.

27. Coat a new cover gasket (Fig.5) with sealer. Secure the cover withnine cap screws. Torque the screwsto 14-19 ft-ibs.

28. Check the operation of thetransmission in all of the gear posi-tions.

FIG. 21-lnstalling OutputShaft Rear Bearing

20. Hold the speedometer drivegear lock ball in the detent andslide the speedometer drive gear intoplace. Secure the gear with a snapring.

21. Place the transmission in thevertical position. Working throughthe drain hole in the bottom of thecase, align the bore of the counter-shaft gear and the thrust washerswith the bore of the case with ascrewdriver.

22. Working from the rear of thecase, push the dummy shaft outof the countershaft gear with thecountershaft. Before the counter-shaft is completely inserted in thebore, make sure that the hole thataccommodates the roll pin is inalignment with the hole in the case.Push the countershaft into place andinstall the roll pin.

23. Coat a new extension hous-

6-25

DAGEN HAM FOUR-SPEED TRANSMISSION

Page. .. . .6-25. " . .6-25..., .6-25

... . .6-26

.. .. .6-26

... . .6-26.6-26

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. ... .6-27

Page... .6-27.., .6-28

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. .. .6-28

... .6-29

... .6-29

. .. .6-29

. . . .6-30

Section

Disassembly Parts Repair or Replacement

Gear Shift Lever. . . . . . . . .Shift Cover .., Synchronizers. . . . . . . . . .

Input Shaft Bearing. . . . . .Countershaft Gear Bearings

Assembly

Section1 Description and Operation. . . . .

Description. . . . . . . . . . . . . . . . .Operation. . . . . . . . . . . . . . . . . . .

2 In-Car Adjustment and Repairs.Gear Shift Linkage Adjustments

3 Removal and Installation. . . . . .Removal. . . . . . . . . . . . . . . . . . .Installation 4 Major Repair Operations


DESCRIPTION1. The Dagenham four-speed

transmission (Fig. 1) is of the fullysynchronized type, with all gears ex-cept the reverse sliding gear being Inconstant mesh. All forward speedchanges are accomplished with syn-chronizer sleeves (Fig. 2) instead ofsliding gears. The synchronizers willenable quicker shifts, greatly reduce

gear clash and permit down-shiftingin all forward speeds.

The shift linkage is mounted di-rectly on the transmission extensionhousing (Fig. 1) and enters the driv-er's compartment through an open-ing in the floor pan. A flexible rub-ber boot is provided to seal thedriver's compartment from the ex-terior.

The shift pattern is shown on thetop of the gear shift lever knob. Afinger-operated release lever is pro-vided on the shift lever (Fig. 3) toprevent the transmission from beingaccidentally shifted into reverse gear.

The forward speed gears are heli-cal-cut and are in constant mesh(Fig. 2). <fears used in the reversegear train are spur-cut and are notsynchronized.

Ball bearing assemblies supportthe input gear and the center of theoutput shaft (Figs. 8 and 9). Rollerbearings in the input gear bore sup-port the front of the output shaft.The countershaft gear (cluster) alsoruns on two rows of roller bearings.A bronze bushing is used in the re-verse idler gear (Fig. 17). The rearof the output shaft is supported bythe driveshaft front yoke which inturn runs on a steel-backed bushingthat is pressed into the extensionhousing.

Synchronizers and blocking ringsare the conventional tapered ringand straight clutch gear-type (Fig.16).

A removable shift cover containsthe shift cams, forks, shafts, detentsand interlocks (Figs. 13 and 14).

A service identification tag is lo-cated under the upper right hand ex-tension to case attaching bolt. Thetag will show the transmission modeland service identification code whenrequired.OPERATION

When first gear is selected, theshift lever and linkage move the firstand second shift fork and synchro-

C 1586. A

1 -4.Sol!l!d Floor Shift Transmission


FIG. 2-Power Flow-4-Speed Transmission

nizer sleeve toward the rear andforce the synchronizer blocking ringconical surface against the matchingcone on the output shaft first gear.If the car is moving, the synchro-nizer sleeve, blocking ring and firstgear clutch teeth will not index untilfirst gear is brought up or down tothe speed of the synchronizer andthe output shaft. The synchronizersleeve has internal splines that, with

further movement, will slide overthe blocking ring and engage exter-nal clutch teeth on the first gear.Since first gear is now locked to theoutput shaft and is always meshedwith the countershaft (cluster) gear,the power flow is from the inputgear, through the countershaft gear,to the first gear on the output shaft,through the synchronizer sleeve andhub to the output shaft and out the

rear of the transmission.Engagement of second and third

gears is the same as first except forratio.

Fourth gear operation is accom-plished in the same manner as first,second, and third, but the input gearis locked directly to the output shaftand the ratio is 1:1.

Spur teeth are cut on the outsideof the first and second gear synchro-nizer sleeve. The sleeve and hub arealways locked to the output shaft.Reverse gear is engaged by slidingan idler gear into mesh with theteeth on the first and second syn-chronizer sleeve and the spur teethon the countershaft gear. The driveis then from the input gear, throughthe countershaft gear, through theidler gear, to the output shaft reversegear (synchronizer sleeve) and theoutput shaft, which is rotated in areverse direction.

A system of interlocks and detentsin the shift cover prevents the selec-tion of more than one gear speed ata time and helps to hold any gear inthe selected position.

IN-CAR ADJUSTMENT AND REPAIRS

AN ALIGNMENT TOOL CAN BE MADE FR~ 1/4"DIAMETER DRILL RDD BENT TO AN "L" SHAPE. THEEXTENSIONS SHOULD BE 1 - 1/2" AND 3 . 3/4" FROMTHE ELBOW. SHORT END OF ALIGNMENT TOOLSHOULD BE INSERTED INTO CONTROL BRACKET ANDLINKAGE HOLES UNTIL IT BOTTOMS.

..., ~- 1-

GEAR SHIFT LINKAGEADJUSTMENT

To adjust the linkage, place theshift lever in the neutral position andraise the car on a hoist. Insert a 1/4-inch fabricated alignment tool intothe alignment hole as shown in Fig.3. If the rod will not enter, check forbellied or bent shift rods. If the shiftrods are the correct shape, check forloose lever lock nuts at the rod ends.Reset the linkage by loosening thethree rod-retaining lock nuts andmoving the levers until the alignmenttool will enter the alignment holes.Make sure the transmission shift le-vers are in neutral and the reverseshift lever is in the neutral detent(Fig. 1). Install the shift rods andtorque the lock nuts to 15-20 ft-lbs.Remove the alignment tool. Operatethe shift levers to make sure that thedetents are engaging. Lower the carand check for smooth cross-over op-eration.

3.3i4',

--SHIFT LINKAGE

ADJUSTMENT NUTS

C 1587 - A

FIG. 3-Gear Floor Shift linkage Adjustment-Typical


1. Remove the starter cable fromthe starter and remove the starter.

3. Disconnect the driveshaft atthe pinion flange and tape the

REMOV AL1. Raise the car on a hoist.

PART 6-4 DAGEN HAM FOUR-SPEED TRANSMISSION 6.27

12. Support the transmission andremove the flywheel housing-to-en-gine and engine rear plate-to-hous-ing attaching bolts.

13. Move the transmission andflywheel housing assembly towardthe rear until the transmission inputshaft splines are clear of the clutchassembly. Lower the transmission.

Do not depress the clutch pedalwhile the transmission is removed.

INSTALLATION1. Raise the transmission and

align the input shaft splines withthose in the clutch hub. Move thetransmission forward until the fly-wheel housing is against the engine.

2. Install the flywheel housing-to-engine and engine rear plate-to-hous-ing attaching bolts. Torque the boltsto specifications.

3. Position the transmission sup-port crossmember to the underbodyand install the attaching bolts.

4. Lower the engine and trans-mission and install the extensionhousing-to-engine rear support at-taching nuts. Torque the nuts tospecifications.

5. Position the shift linkage con-trol bracket to the extension housingand install the attaching bolts.

6. Secure each shift rod to its re-spective lever with the spring wash-er, flat washer and retaining pin.

7. Connect the parking brakefront cable to the equalizer bar andthe speedometer cable to the exten-sion housing.

8. Connect the clutch release rodto the clutch equalizer shaft and tothe clutch release lever. Attach theretaining clip and lever return spring.

9. Remove the tool from the ex-tension housing and slide the drive-shaft yoke onto the transmission out-put shaft, being careful not to dam-age the seal.

10. Be sure the pinion flange lo-cating slots are clean, and then po-sition the U-joint. Install the boltsand torque them to specifications.

11. Install the back-up lampswitch (if so equipped) on the shiftlinkage control bracket.

12. Install the starter and cable.13. Place both forward gear shift

levers and the reverse shift lever inthe neutral position and insert a 1/4inch diameter alignment tool in theshift linkage alignment hole (Fig. 3).Adjust the linkage and tighten theadjusting nuts. Remove the align-ment tool. Adjust the clutch pedalfree travel as required.

14. Fill the transmission to theproper level with specified lubricant.

15. Lower the car. Check theshift crossover motion for full shiftengagement and smooth crossoveroperation.

V-joint bearing races in place if thejoint does not have a strap spotwelded to it. Pull the driveshaft offthe transmission and insert the toolshown in Fig. 2, Part 6-1 into theseal and extension housing to pre-vent lubricant leakage.

4. Remove the back-up lampswitch (if so equipped) from theshift linkage control bracket.

5. Remove the clip from theequalizer bar at the clutch releaserod and remove the rod. Removethe linkage return spring from therelease lever.

6. Disconnect the parking brakefront cable from the equalizer bar.Disconnect the speedometer cablefrom the extension housing.

7. Loosen the shift linkage ad-justing nuts shown in Fig. 3.

8. Remove the retaining clip, flatwasher and spring washer that se-cures the shift rods to the shift le-vers.

9. Remove the bolts that attachthe shift linkage control bracket tothe extension housing and allow theassembly to hang by the shift lever.

10. Support the engine with atransmission jack and remove the ex-tension housing-to-engine rear sup-port attaching nuts.

11. Raise the rear of the engineand remove the transmission supportcrossmember from the underbody.

MAJOR REPAIR OPERATIONS

diameter thrust washer is positionedbetween the rear of the countershaftgear and the case and that the larg-er diameter steel and bronze wash-ers are at the front (Fig. 17).

11. Thread a 5/16-24 bolt into therear of the reverse idler gear shaftand pull the shaft using tools T50T-7140-B (adapter) and T59L-I000-A(puller). Remove the idler gear.

12. Remove the lock washer andnut which retains the speedometerdrive gear and spacer from the rearof the output shaft.

13. "Remove the speedometer gearand drive ball. Remove the speed-ometer gear spacer (Fig. 8).

14. Place the output shaft assem.bly in an arbor press as shown inFig. 9 and press the bearing, adapt-er, first gear, first and second specdsynchronizer assembly, and secondgear off the shaft. Do not lose the



2. Insert a reworked screwdriver(Fig. 4) through the clutch releaselever and unhook the retainer thatsecures the clutch release lever to theretainer bracket.

3. Remove the four attachingbolts and the flywheel housing fromthe transmission.

4. Remove the eight attachingbolts and the shift cover from thetransmission.

S. Remove the three bolts and theinput gear bearing retainer from thefront of the transmission.

6. Remove the four bolts that se-cure the extension housing and out-put shaft bearing adapter to thetransmission case. In the event thattwo long and two shorter bolts are

used, the two longer bolts must beinstalled in the upper right and low-er left holes (viewed from the rear).Remove the extension housing.

7. Working from the front of thecase, drive the countershaft, with adrift, until it is just clear of the frontwall of the case. Hold the counter-shaft gear with a hook and using thetool shown in Fig. 5, push the coun-tershaft out of the countershaft(cluster) gear and transmission case.Carefully lower the countershaftgear to the bottom of the case.

8. Remove the output shaft as-sembly from the rear of the case(Fig. 6).

9. Remove the input gear andbearing (Fig. 7) from the front ofthe case.

10. Lift the countershaft gear as-sembly out through the cover open-ing of the case. Note the smallest


~

"

J!~;

RELEASE LEVERRETAINER

-.s:

RELEASE LEVERBRACKET

GRIND ScrewdriverBLADE AS SHOWN

""'"./

RELEASE LEVER RETAINER HOOK

~-~,'

J,c

icY~ ~~",#"-. .'"

.CLUTCHRELEASE

LEVER

/

"<~C1390 -B

end of the selector shaft with point-ed snap ring pliers (Fig. 11).


3. After removing two bolts, pullthe retainer, selector levers, andbracket from the shaft.



6. If necessary to remove thestuds from the selector levers, re-move the cotter pins, flat washers,wave washers and studs.


8. Install the shaft in the bracket.Position the trunnion and drive thelong straight pin through the trun-nion and into the shaft until an equallength of the pin is exposed on bothsides of the shaft.


10. Install the levers and the neu-tral index bracket on the shaft asshown in Fig. 11.

11. Position the retainer and startthe bolts. Before tightening the boltsbe sure that the retainer is not inter-fering with free movement of theshaft. Tighten the bolts.

12. Install the spring, flat washerand snap ring.


4-Removing or Installing Clutch Release Lever Retainer

C1397-A

SHIFf COVER

1. Remove the levers from thecam and shafts (Fig. 12).

2. Remove the roll pin from theupper fork and shaft and remove theshaft and forks.

3. Remove the reverse cam andshaft.

4. Rotate the reverse fork andshaft to disengage the detent balland remove the fork and shaft (Fig.13). Hold a cloth over the shaft cov-er boss nearest to the fork to catchthe detent ball and spring when theshaft clears the boss hole.

5. Remove the 1-2 and 3-4 shiftcam assemblies. Hold a cloth overthe interlock and cam assemblies tocatch the detent balls.

6. Push the interlock sleeve,spring and remaining ball out of thecover.

7. Remove the 1-2 and 3-4-to-re-verse interlock pins from the reverse

FIG. 5-Removing or Installing Countershaft

first speed gear sleeve retainer ball. shaft as shown in Fig. 10.15. Wit~ snap rin~ pliers, remove PARTS REPAIR OR

th~ snap rmg from m front of .the REPLACEMENTthIrd and fourth-speed synchroDlzeron the output shaft. Press the third GEAR SHIFf LEVERgear and the synchronizer off the 1. Remove the snap ring from the

PART 6-4 DAGEN HAM FOUR-SPEED TRANSMISSION 6-29

the one in the cover and install thelock pin.

18. Check all shift positions forfreedom of movement, detent andinterlock action.

,COUNTERSHAFT GEAR IS RESTING ON BOTTOM OF CASE

(Dummy Shaft INSTAllED) (1392-8

FIG. 6-Removing or Installing Output Shaft

SYNCHRONIZERS1. Before disassembling the syn-

chronizers, scribe an alignment markacross the hub and sleeve if they donot have alignment marks. The align-ment marks will permit the sleevesand hubs to be assembled in theiroriginal positions.

2. Remove the front and rear in-sert springs from both synchronizerassemblies (Fig. 15).

3. Slide the sleeves off the hubs.Remove the hub inserts (detents).

4. Place the long inserts (detents)into the slots in the 1-2 synchronizerhub and slide the combination sleeveand reverse gear over it making surethat the etch or scribe marks on thehub and sleeve are aligned (Fig.15). Snap the insert springs intoplace. The tab on each spring mustset into the underside of an insert.

S. Position the short inserts (de-tents) into the slots in the 3-4 syn-chronizer hub and slide the clutchsleeve over it making sure that theetch or scribe marks are aligned. In-stall the insert springs in the samemanner as with the 1-2 synchronizer.

FIG. 7 -Input Gear and Bearing-Disassembled

INPUT SHAFT BEARING1. If the input shaft anc;i gear

bearing needs replacing, remove itas shown in Fig. 16.

2. Press the bearing onto the in-put shaft with the outer race snapring groove toward the front (Fig.16).

3. Install the snap rings on thebearing outer race and on the gearshaft with snap ring pliers.

COUNTERSHAFfGEARBEARINGS

1. Remove the thrust washersfrom each end of the countershaftgear (Fig. 17).

2. Remove the dummy shaft fromthe gear.

3. Remove the two washers and22 roller bearings from each end ofthe gear. Coat the bore in each endof the countershaft with grease.

4. Place the tool (dummy shaft)shown in Fig. 5 in the countershaft(cluster) gear. Starting on eitherend, drop a steel washer (Fig. 17)over the tool and into the gear. In-stall 22 roller bearings into the gear.Lay another steel washer on the ends

1-2 and 3-4 shift cams in, and be-tween, all shift positions. The sleeveto cam clearance must be a mini-mum of 0.0005 inch and a maxi-mum of 0.010 inch. Service sleevesare available in the following lengths:c0.010 inch: 1.2875, 1.2905,1.2935, 1.2965, 1.2995, and 1.3025.

15. With the 1-2 and 3-4 shiftcams in neutral and the 1-2 and 3-4-to-reverse interlock pin resting onthe cams, install the reverse shaft de-tent spring and ball and the reversefork and shaft.

16. Install the reverse shift camthrough the cover and into thealigned fork and shaft. Install the re-verse cam operating lever (washerand nut loose).

17. Position the 1-2 and 3-4 forksonto the shift cams and install thefork shaft. Ali2n the shaft hole with

fork and shaft bosses in the cover.8. If the seals need replacing, re-

move them with a screwdriver andinstall them as shown in Fig. 14.

9. Place the 1-2 and 3-4-to-re-verse interlock pins in the holes inthe reverse fork and shaft bosses(Figs. 12 and 13).

10. Install the 3-4 shift cam in thecover.

11. Install the parts of the 1-2and 3-4 cam interlock, sleeve, ball,spring and another ball, in that or-der.

12. Hold the 3-4 cam in neutralposition and the 1-2 ball depressedwhile the 1-2 cam is installed in thecover.

13. Install the 1-2 and the 3-4levers, washers and nuts.

14. Check the clearance betweenthe interlock. detent sleeve and the

of the bearings and the thrust wash-ers that were previously selected.

S. Repeat the above operation forthe other end of the gear. Do notlose the bearings and washers in theinitially assembled end when invert-ing the gear to assemble the oppositeend.

ASSEMBLY1. Place the second gear on the

rear of the output shaft with theclutch teeth and tapered synchro-nizer end toward the rear. Install ablocking ring with the clutch teethtoward the front (Fig. 8).

-INSTALLATION REMOVAL

emoving and Installing Output Shaft Bearing

C1400-8

PART 6-4 DAGEN HAM FOUR-SPEED TRANSMISSION 6-31

2 AND 3 SHIFTER FORK\3 AND 4 SHIFTER FORK

"FORK GUIDE/ REVERSE SHIFTER SHAFT AND FORK

REVERSE SHIFTER SHAFT~ DETENT BALL AND SPRING

~.:y: ANO 2 CAM AND SHAFT

,..~,.s, CAM AND SHAFT

./'RETAINING

D""PLUNGERS

3 AND 4 CAM/"AND SHAFT

REVERSE LEVER

) J,

INTERLOCK AND DETENTBALLS AND SPRING

~~

~\9>r;;:., .&

1 AND'2 LEVER.

~

'-"'/3 AND 4 LEVER

@(9 C 1588- A

FIG. 1 2-Gear Shift (over Disassembled

2. Install the first and second syn-chronizer and reverse gear assemblyon the rear of the output shaft withthe shift fork groove toward therear. Be sure the second-speed block-ing ring is not cocked on the gearand that the three index slots alignwith the synchronizer inserts (de-tents).

3. Install the first-speed blockingring with the clutch teeth to the rearand the slots engaging the synchro-nizer inserts (detents). Pack greaseinto the ball pocket on output shaftthen insert the first-speed gear sleeveretainer ball. See (Fig. 8).

4. With taper and clutch teeth tofront, and the sleeve (bushing)shoulder to the rear, slide the firstgear and sleeve onto the output shaftand align the slot on the I.D. of thefirst-speed gear sleeve over the ball.

S. Assemble the output shaft ballbearing into the recess in the bearingadapter. Position the adapter andbearing on the rear of the output

with the wide thrust surface of thehub toward the rear. Align theblocking ring slots with the synchro-nizer inserts (detents). The hub toshaft spline fit may require a slightpress to assemble.

9. Using snap ring pliers, installthe snap ring in its groove on thefront of the output shaft.

10. Position the countershaftgear, dummy shaft, and roller bear-ings in the case.



13. After establishing the correctend play, install the dummy shaft inthe countershaft gear and allow thegear to remain at the bottom of thecase until the output and input shaftshave been installed.

14. Using a light film of grease,install roller bearings in the bore ofthe input shaft and gear. A thick filmof grease could plug the lubricantholes and restrict lubrication to thebearings.

15. Install the input shaft andgear in the case front bore. Place thefourth gear blocking ring on the rearof the input gear with the clutchteeth forward.

16. Enter the output shaft assem-bly through the rear of the case andguide the output shaft front pilotinto the input gear bore and bearings(Fig. 7). Be sure the fourth gearsynchronizer blocking ring slots in-dex with the inserts (detents) on the3-4 synchronizer.

17. Raise the countershaft (clus-ter) gear and thrust washers untilthe countershaft can be insertedfrom the rear of the case into thegear and bearings. The shaft shouldpush through, easily displacing thetool. Push on the shaft until it con-tacts the front of the case (Fig. 5).Position the flat on the rear of thecountershaft in a horizontal plane soit will align with the slot in the ex-tension housing. Tap the shaft intoplace.

18. Install the reverse idler gearwith the fork groove toward the rearand the idler shaft flat horizontal andparallel with the countershaft flat.

19. Position a new extensionhousing gasket on the rear of thecase, using a non-drying sealer.

shaft with the adapter forward. Holdthe first gear and sleeve (bushing)forward and place the assembly in apress with the tool resting againstthe rear of the bearing inner race.Press the bearing until .it is seatedfirmly against the first gear sleeve(bushing).

6. Place the spacer, speedometergear drive ball, speedometer gear(shoulder to rear), lock washer (tabinto speedometer gear), and nut onthe output shaft (Fig. 8). Torque thenut to 80 ft-ibs to insure axial loca-tion of the synchronizer hub, firstspeed gear sleeve, rear mainshaftbearing, spacer and speedometerdrive gear on the output shaft.Loosen the locknut and retorque to25 ft.-lbs. Bend the washer over aflat on the nut.

7. Set the third-speed gear on thefront of the output shaft with theclutch teeth toward the front. Placethe blocking ring on the gear.

8. Install the 3-4 synchronizer


case, bearing and adapter beforetorquing the bolts. If two long andtwo short bolts are used, install thetwo long bolts in the upper right andlower left holes.

21. If the input gear bearing re-tainer seal needs replacing, refer toFig. 19. Install the new bearing re-tainer gasket, using sealer. Install thebearing retainer with the drain slotfacing downward. Apply sealer tothe bolts and torque to specifications.

22. Place the 1-2 and 3-4 syn-chronizer in neutral and the reverseidler gear in reverse (forward) po-sition. Set the reverse shift lever inthe reverse position. Install a newshift cover gasket on the case, usingsealer. Install the shift cover. Usesealer on the bolts and torque themto specifications.

23. Install the flywheel housing.Use sealer on the retaining bolts andtorque them to specifications.

24. Install the clutch release bear-ing on the clutch release lever. Posi-tion the release lever through thehousing from inside the housing andclip the lever retainer onto its hookas shown in Fig. 4.

FIG. 13-Transmission Shift Mechanism Details

SEALS C1423-A

FIG. 14--lnstalling (am and Shaft Seals

20. Install the extension housing. (Fig. 18). Using sealer, install theAlign the dowel in the housing with extension housing bolts. Be sure thethe hole in the rear bearing adapter housing is seated squarely on the

PART 6-4 - DAGEN HAM FOUR-SPEED TRANSMISSION 6-33

FIG. 1 5-Synchronizers Disassembled

~ _c_-REMOVAL INSTALLATION

FIG. 1 6-Removing and Installing Input Gear Bearing

-""""""'--C1403-B

GROUP 6 - MANUAL SHIFT TRANSMISSIONS6-34

FIG. 19-Removing InputShaft Bearing Retainer Seal-

Typical

1 7 -Countershaft and Idler Gear Disassembled

1 8-Extension Housing Installation

6-35

FORD DESIGN FOUR-SPEED TRANSMISSION

Page.6-35.6-35.6-35.6-36.6-36.6-37.6-37.6-37.6-38.6-38

Page.. .6-39.. .6-39.. .6-40.. .6-40., .6-41. . .6-41. . .6-41.. .6-41.. .6-41

SectionParts Repair or Replacement.

Gear Shift Lever. . . . . . . . . ,Cam and Shaft Seals. . . . . . ,Input Shaft Bearing. . . . . .Synchronizers. . . . . . . . . . . .Countershaft Gear BearingsReverse Idler Gear BearingsInput Shaft Seal. . . . . . . . . .

Assembly

Section1 Description and Operation. . . .

Description. . . . . . . . . . . . . . . .Operation. . . . . . . . . . . . . . . . . .

2 In-Car Adjustment and RepairsShift Linkage Adjustment 3 Removal and Installation. . . . .

Removal. . . . . . . . . . . . . . . . . .Installation ..., 4 Major Repair Operations. . . . .

Disassembly


housing (Fig. 1) and enters the driv-er's compartment through an open-ing in the floor pan. A flexible rub-ber dust boot (Fig. 3) is provided toseal the driver's compartment fromthe exterior.

The shift pattern is shown on thetop of the gear shift lever knob. Afinger-operated release lever is pro-vided on the shift lever to preventthe transmission from being acciden-tally shifted into reverse gear. Allforward-speed gears in the transmis-sion are helical-type, however, the

reverse sliding gear and the exteriorof the first- and second-speed syn-chronizer sleeve are spur-type gears.The specifications of this sectionPart 6-6 lists the transmission modelnumbers and vehicles in which theyare used.

A transmission service identifica-tion tag is located on the right sideof the case at the front. The first lineon the tag will show the transmissionmodel and service identification codewhen required. The second line willshow the transmission serial number.

The four-speed transmission willbe designated by the numeral 5 onthe vehicle warranty plate.

DESCRIPTIONThe Ford designed 4-speed trans-

mission (Fig. 1) is of the fully syn-chronized type with all gears exceptthe reverse sliding gear being inconstant mesh. All forward-speedchanges are accomplished with syn-chronizer sleeves. The synchronizerswill enable quicker shifts, greatly re-duce gear clash, and permit down-shifting into any forward-speed gearwhile the car is moving.

The shift linkage is mounted di-rectlv on the transmission extension

OPERATIONIn first-speed (Figure 2), the first-

and second-speed synchronizer sleeveis moved rearward by the shift fork.The sleeve engages the first-speedblocking ring, which acts as a coneclutch applied to the free-wheelingfirst-speed gear. This action speedsup or slows down the first-speed gearto match the speed of the outputshaft. Further movement of thesleeve locks the first-and-second-speed synchronizer hub to the first-speed gear by means of internalsplines. On engagement of the clutch,power flows through the input shaftand gear to the meshed countershaftgear and thence to the first-speedgear. This gear transmits the powerthrough the locked synchronizer hubto the transmission output shaft. Allthe other forward-speed gears are inidler motion, as they are all <;triven-Four-Speed Transmission


by the countershaft (cluster) gear,but they do not transmit power be-cause they are not locked to the out-put shaft. All the forward-speedshifts are made in the same manneras the first-speed shift, due to theconstant-mesh features.

SECOND SPEEDG~AR

Reverse gear is engaged by mov-

ing the reverse sliding gear forward

on the reverse idler gear until it

meshes with the external teeth (spur-

type) of the first- and second-speedsynchronizer sleeve. Movement ofthe sliding gear is accomplished bythe center shaft lever. With all for-

ward-speed synchronizer sleeves in

neutral, power flow in reverse is

through the input shaft to the con-

stant-mesh countershaft (cluster)gear, thence to the constant mesh re-verse idler. Splines then carry the

power through the reverse slidinggear to the first-and-second speedsynchronizer sleeve which is locked

to the output shaft. As the reverse

sliding gear is meshed with the syn-

chronizer sleeve, power is transmit-ted to the output shaft, rotating it in

a reverse direction.FIG. 2-Power Flow

An alignment tool can be madefrom 1/4" diameter drill rod bent toan "L" shape. The extensions shouldbe lV2" and 33/4'; from the elbow.Short end of alignment pin shouldbe inserted into control bracket and

linkage holes until it bottoms.2. Tighten the three linkage ad-

justment nuts and then remove the

alignment pin.3. Check the gear shift lever for

a smooth crossover.

SHIFT LINKAGEADJUSTMENT

1. Loosen the three shift linkageadjustment nuts. Install a Y4 inchdiameter alignment tool through thecontrol bracket and levers as shownin Fig. 3.

PART 6-5 FORD DESIGN FOUR-SPEED TRANSMISSION 6-37

C1590-A

FIG. 3-Adjusling Shift Linkage


curing the crossmember to the framesupports. Remove the crossmember.

8. Support the transmission on ajack and remove the bolts that at-tach the transmission to the flywheelhousing.

9. Move the transmission andjack rearward until the transmissioninput shaft clears the flywheel hous-ing. If necessary, lower the engineenough to obtain clearance fortransmission removal.


INSTALLATION

1. Make sure that the mountingsurfaces of the transmission and theflywheel housing are free of dirt,paint, and burrs. Install two guidepins in the flywheel housing lowermounting bolt holes. Move the trans-mission forward on the guide pinsuntil the input shaft splines enter theclutch hub splines and the case is po-sitioned against the flywheel housing.

REMOV AL1. Raise the car on a hoist.2. Disconnect the drive shaft

from the rear U-joint flange. Slidethe drive shaft off the transmissionoutput shaft and install the exten-sion housing seal installation toolinto the extension housing to preventlubricant leakage.

3. Disconnect the speedometercable from the extension housing.

4. Remove the retaining clip, flatwasher and spring washer that se-cures the shift rods to the shift le-vers.

5. Remove the bolts that attachthe shift linkage control bracket tothe extension housing and allow theassembly to hang by the shift lever.

6. Support the engine with atransmission jack and remove thetwo nuts securing the transmissionrear support to the crossmember.

7. Raise the rear of the enginewith the transmission jack. Removethe two nuts, washers and bolts se-

2. Install the two upper transmis-sion to flywheel housing mountingbolts snug and then remove the twoguide pins. Install the two lowermounting bolts. Torque all mountingbolts to specifications.

3. Raise the rear of the enginehigh enough to provide clearance forinstalling the crossmember. Installthe two crossmember-to-frame sup-port attaching bolts, washers, andnuts. Do not tighten at this time.

4. Align the bolts in the transmis-sion rear support with the bolt holesin the crossmember, then lower theengine and remove the jack. Installthe two transmission rear support-to-crossmember washers and nutsand torque to specifications. Tightenthe crossmember-to-frame supportnuts.

s. Position the shift linkage con-trol bracket to the extension housingand install the attaching bolts.

6. Secure each shift rod to its re-spective lever with the spring wash-

GROUP 6 MANUAL SHIFT TRANSMISSIONS6-38

9. Place both forward gear shiftlevers and the reverse shift lever inthe neutral position and insert a 1/4inch diameter alignment tool in theshift linkage alignment hole (Fig. 3).Adjust the linkage and tighten theadjusting nuts. Remove the align-ment tool. Adjust the clutch pedalfree travel as required.

10. Fill the transmission to theproper level with the specified lubri-cant.

er, flat washer, and retaining pin.7. Connect the speedometer cable

to the extension housing.8. Remove the extension housing

installation tool and slide the for-ward end of the drive shaft over thetransmission output shaft. Connectthe drive shaft to the rear V-jointflange.

11. Lower the car. Check theshift crossover motion for full shiftengagement and smooth crossoveroperation.

;'-SET SCREW. 377885. S

I MAJOR REPAIR OPERATIONS~



2. Remove the cover attachingscrews from the case. Lift the coverand gasket from the case.

3. Remove the extension housingattaching screws and lock washers.Remove the housing and the gasket.

4. Remove the input shaft bearing ,retainer attaching screws. Slide theretainer off the input shaft.

S. Support the countershaft gearwith a wire hook. Working from thefront of the case, push the counter-shaft out the rear of the case asshown in Fig. 4. Lower the counter-shaft to the bottom of the case withthe wire hook. Remove the hook.

FIRST AND SECOND, SPEED SHIFT FORK

SCREW ~'7886 . 5 \3

..~-

tJ]

THIRD AND FOURTHSPEED SHIFT RAIL

7241 \~

i

REVERSE SHIFT FORK7?1'~

~.-"~T--REVERSE SHIFT RAil

~

~

~::::;;:;;~ ~I

t~~

~

Too/--T64P-7111-A

EXPANSION'LUG-74112-S

\-

~,~ij DETENT PLUG -7C316

---

~,

~

!1

QU7.D.ISPRING

7234 /BOLT

78206.5

,,1\,.""\I'

(!fj-MAGNETIC DRAIN PLUG -373719

C 1568- A

FIG. 5-Shift Rails and Forks Disassembled

from the third- and fourth-speed shiftfork. Tap on the inner end of theshift rail to unseal the expansion plugfrom the front of the case. Thenwithdraw the third- and fourth-speedshift rail from the front of the case.

Do not lose the interlock pin fromthe shift rail.

10. Remove the set screw fromthe first- and second-speed shift fork.Slide the first- and second-speed shiftrail out the reaT nf th~ ca~e

FIG. 4-Removing Countershaftfrom Case

6. Place the first-and-second-speedgear shift lever and the reverse shiftlever in the neutral position. Placethe third- and fourth-speed gear shiftlever in the third-speed position.

7. Remove the bolt that retainsthe third- and fourth-speed shift raildetent spring and the plug in the leftside of the case as shown in Fig. 5.Remove the spring and the plug witha magnet.

8. Remove the detent mechanismset screw from the top of the case.Remove the detent spring and plugwith a small magnet.

9. Remove the attaching; screw

!l-SPRING .7234

(4-DETENT PLUG. 7C316FIRST AND SECOND SPEED SHIFT RAIL

7240

THIRD AND FOURTH ffi_SCREW. 377886 . S. SPEED SHIFT FORK. 7230 . \)!

-SCREW. 377886. S

DETENT PLUG-@7C316

INTERLOCK PIN R) 7235 Y

PART 6-5 - FORD DESIGN FOUR-SPEED TRANSMISSION 6-39

21. Lift the reverse idler gear andthe thrust washers from the case. Becareful not to drop the bearings andthe dummy shaft from the gear.

22. Lift the countershaft gear andthe thrust washers from the case. Becareful not to drop the bearings orthe dummy shaft from the counter-shaft gear.

23. Remove the snap ring fromthe front of the output shaft. Slidethe third- and fourth-speed synchro-nizer (Fig. 11) blocking ring and the

11. Remove the interlock plug andthe detent plug from the top of thecase (Fig. 5) with a magnet.

12. Remove the snap ring that se-cures the speedometer drive gear tothe output shaft. Slide the gear offthe shaft, then remove the speedom-eter gear drive ball.

13. Remove the snap ring that se-cures the output shaft bearing to theshaft.

14. Remove the output shaft bear-ing as shown in Fig. 6.

FIG. 8-Removing OutputShaft Assembly

Toof-T63P-7025-

Tool-T64P-7025-B- DETAil 1

DETAil 4FORD, FAIRlANE

. AND MERCURYDETAIL 5

COMET AND FALCON-" --~ ~

Tool-T52T-6500-DJD C1513.A

FIG. 9-Rotating ReverseShift Rail

DETAIL 2

C1533-A

FIG. 6-Removing Output Shaft Bearing

15. Remove the input shaft and HIRDbearing and the blocking ring from Tthe front of the case.

16. Move the output shaft to theright side of the case to provideclearance for the shift forks. Rotatethe forks as shown in Fig. 7, then liftthem from the case.

17. Support the thrust washer andfirst-speed gear to prevent them fromsliding off the shaft, then lift the out-put shaft assembly from the case asshown in Fig. 8. .

18. Remove the reverse gear shiftfork set screw. Rotate the reverseshift rail 90° as shown in Fig. 9.Slide the shift rail out the rear of thecase. Lift the reverse shift fork fromthe case.

19. Remove the reverse detentplug and spring from the case witha magnet.

20. Remove the reverse idler gearshaft from the case as shown in Fig.10.

~vn'

SPEEDSHIFT.ORK

""

FIRST ANDREVERSE. SPEED

SHIFTFORK FIG. 10-Removing Reverse

Idler Gear Shaft

25. Remove the next snap ring,then slide the first- and second-speedsynchronizer, blocking ring and thefirst-speed gear off the shaft.

26. Remove the thrust washerfrom the rear of the shaft.

~v.. v. ~..~.. ..,~."~ --_c c-TO RIGHT SIDE OF CASE C 1527-A

FIG. 7 -Removing Shift Forksfrom Case

third-speed gear off the shaft.24. Remove the next snap ring

and the second-speed gear thrustwasher from the shaft. Slide the sec-ond-speed gear and the blocking ringoff the shaft.


GEAR SffiFf LEVER1. Remove the snap riD


CAM AND SHAFT SEALS1. Remove the attaching nut, lock

washer and the flat washer fromeach shift lever and remove the threelevers.

2. Remove the three cam andshafts from inside the case.

3. Remove the O-ring from eachcam and shaft (Fig. 13) and discardthe O-rings.

4. Dip the new O-rings in gear lu-bricant and install them on the camand shafts.

5. Slide each cam and shaft intoits respective bore in the transmis-sion case.

6. Position a shift lever on eachcam and shaft and secure with a flatwasher, lock washer and nut.INPUT SHAFT BEARING

1. Remove the snap ring that se-

Position the trunnion and drive thelong straight pin through the trun-nion and into the shaft until an equallength of the pin is exposed on bothsides of the shaft.


10. Install the levers and the neu-tral index bracket on the shaft asshown in Fig. 12.

11. Position the retainer and startthe bolts. Before tightening the boltsbe sure that the retainer is not inter-fering with free movement of theshaft. Tighten the bolts.

U. Install the spring, flat washerand snap ring.


FIG. 11-0utput Shaft Disassembled

end of the selector shaft with pointedsnap ring pliers (Fig. 12).


3. After removing two bolts, pullthe retainer, selector levers, andbracket from the shaft.


5. Drive the long trunnion pinfrom the shaft and remove the trun-nion and shaft.

6. If necessary to remove the studsfrom the selector levers, remove thecotter pins, flat washers, wavewashers and studs.


8. Install the shaft in the bracket.

PART 6-5 - FORD DESIGN FOUR-SPEED TRANSMISSION 6-41

.. ROLLER BEARINGS

:' \i,i..I

.-r

DO"""

INPUT SHAfTAND GEAR

.. a,R~TAINERW, ,

I:' '~~~wIf

ASSEMBLY-- -SPRING

I PLUNGERIi

-' I'"

R,nr.""""

, PIN (LONG)SC:IECTOR SHAFT

RFvERSE SELECTORLEVER

NEUTRAL INDEX, } BRACKET I ~'f;,j' ~'" 1-2 SELECTOR

SPACER, '-,~ LEVER TRUNNION ~ ,~If> ,. SNAP RINC'

STRAIGHT PIN r ~ SPRINr(SHORT) "' ,

COmR PIN-, 'd;!Ii,~..",1FLAT WASHER--~W~ fr;r~ WAVE WASHER/' ~U~ e v':r

3-4 SELECTOR LEVER RETAINER /FLAT WASHER

C1406-8

v..I '..- -- FRONT BEARING

SNAP RINGS

FIG. 14-lnput Shaft Gear Disass4

2. Press the input shaft gear outof the bearing as shown in Fig. 15.

3. Press a new bearing onto theinput shaft with the tool shown inFig. 15.

4. Secure the bearing with a snapring.

SYNCHRONIZERS1. Push the synchronizer hub from

each synchronizer sleeve (Fig. 16).2. Separate the inserts and insert

springs from the hubs. Do not mixthe parts of the first- and second-

FIG. 12-Gear Shift LeverDisassembled- T vDical

FIRST AND SECOND SPEED CAM AND SHAFT - 7C124

COUNTER..~n A. VI' I:WA.lIR~ARINGS

1. Remove the dummy shaft, twobearing retainer washers, and the 21roller bearings (Fig. 17) from eachend of the coun\ershaft gear.

2. Coat the bore in each end ofthe countershaft gear with grease.

3. Hold the dummy shaft in thegear and install the 21 roller bear-ings and the retainer washer in eachend of the gear.

REVERSE GEAR CAMAND SHAFT

7C124~_o~ RING - 7288

~ ~-O.RING

7288 ;

THIRDIAND FOURTH "~SPEED CAM AND SHAFT """

7C124 1

7005,-FIRST AND SECO/"I"I SPEED SHIFT LEVER - 7290

~ 5

( ,

r,J'-- REVERSE SHIFT LEVER - 7290

I--'

"--

~

REVERSE IDLER GEARBEARINGS

1. Slip the reverse idler slidinggear off of the reverse idler gear(Fig. 18).

2. Remove the dummy shaft, twobearing retainer washers and the 44roller bearings from the reverse idlergear.

3. Coat the bore in each end ofthe reverse idler gear with grease.

4. Hold the dummy shaft in thegear and install the 22 roller bear-ings and the retainer washer in eachend of the gear.

5. Install the reverse idler slidinggear on the reverse idler gear mak-ing sure that the shift fork groove istoward the front (Fig. 18).

~ (co: Q!

44727- .

34807-5.33800-5

~'--

~,THIRD AND FOURTH

SPEED SHIFT L. EVFR - 7285 ,44727-5

34807 - 53380'0- S

C1591-A

INPUT SHAFf SEAL1. Remove the seal from the input

shaft bearing retainer as shown inFig. 19.

2. Coat the sealing surface withlubricant.

3. Install the seal as shown inFig. 20.FIG. 13-Cam and Shafts and Shift Levers Disassembled

speed synchronizer with the third-and fourth-speed synchronizer.

cures the bearing to the shaft(Fig. 14).

ASSEMBLY1. Coat the countershaft gears

~.~_.,..,~ n..'~C1415-8

mbled

3. Position the hub in the sleeve,making sure that the alignmentmarks are properly indexed.

4. Place the three inserts intoplace on the hub. Install the insertsprings making sure that the irregu-lar surface (hump) is seated in oneof the inserts. Do not stagger thesprings.

~~~.~~ ~ ~~._-


---INST ALLA nON C1403-B

-~ ~~~'.l""""=-REMOVAL

FIG. 1 5-Replacing Input Shaft Bearing

ETCH MARKSSLEEVE

INSERT~ INSERT SPRING

,INSERT SPRINGINSERT

INSERT ((

~

GROOVE TO FACETOWARD FRONT

OF TRANSMISSION

C1523-A

end play, install the dummy shaft inthe countershaft gear and allow thegear to remain at the bottom of thecase.

6. Coat the reverse idler gearthrust surfaces in the case with a thinfilm of lubricant and position the twothrust washers (Fig. 18) in place.

7. Position the reverse idler gear,sliding gear, dummy shaft and theroller bearings in place making surethat the shift fork groove in the slid-ing gear is toward the front of thecase.

8. Align the gear bore and thrustwashers with the case bores and in-stall the reverse idler shaft.

9. Measure the reverse idler gearend play with a feeler gauge. Endplay should be 0.004-0.018 inch. Ifthe end play is not within limits, re-place the thrust washers. If the endplay is within limits, leave the reverseidler gear installed.

10. Position the reverse gear shiftrail detent spring and detent plug inthe case. Hold the reverse shift forkin place on the reverse idler slidinggear and install the shift rail fromthe rear of the case. Secure the forkto the rail with the Allen head setscrew.

11. Install the first- and secondspeed synchronizer onto the front ofthe output shaft (Fig. 11) makingsure that the shift fork groove is to-ward the rear of the shaft.

12. Position the blocking ring onthe second-speed gear.

13. Slide the second-speed gearonto the front of the shaft, make surethat the inserts in the synchronizerengage the notches in the blockerring.

14. Install the second-speed gearthrust washer and snap ring.

15. Slide the third-speed gear ontothe shaft with the synchronizer conedsurface toward the front.

16. Place a blocking ring on thethird-speed gear.

17. Slide the third- and fourth-speed gear synchronizer onto theshaft making sure that the inserts inthe synchronizer engage the notchesin the blocking ring.

18. Install the snap ring on thefront of the output shaft.

19. Position the blocking ring onthe first-speed gear.

20. Slide the first-speed gear ontothe rear of the output shaft makingsure that the notches in the blockingring engage the synchronizer inserts.

21. Install the heavy thrust washeron the rear of the output shaft.

-THIRD AND FOURTH SPEED SYNCHRONIZER

FIG. 16-Synchronizers Disassembled

thrust surfaces in the case with a thin thrust washers with the bores in thefilm of lubricant and position a thrust case and install the countershaft.washer (Fig. 17) at each end of the 4. Place the case in a horizontalcase. position and check the countershaft

2. Position the countershaft gear, gear end play with a feeler gauge.dummy shaft, and roller bearings in The end play should be 0.004-0.018the case. inch. If not within these limits, re-

3. Place the case in a vertical po- place the thrust washers.sition. Align the gear bore and the 5. After establishing the correct

PART 6-5 FORD DESIGN FOUR-SPEED TRANSMISSION 6-43

THRUSTWASHER

7119

j ";/

.,i'

;-ROLLER BEARINGS- 7C 1512- B

FIG. 17 -Countershaft Gear Disassembled

REVERSE IDLERGEAR SHAFT

7"0

ROLLER BEARINGS ~~,n'

7D271(22) ".,.

""""""""~~""""'~ .

~~ C) '\J

,j ~

"THRUST WASHER7149

.REVERSE IDLER GEAR. 7142

~"'~"""'""I~

RETAINERWASHER /.,>'

351529.5 ~ I

"\.~\""' ("\, ~ ---\\ ~~~

. REVERSE SLIDING GEAR. 7D223\ ' c~",~# - - -\ "!iii/~~

.--':THRUST WASHER. 7149C 1528 - B

FIG. 1 8-Reverse Idler Gear Disas

21.. Support the thrust washer andfirst-speed gear to prevent themfrom sliding off the shaft. Carefullylower the output shaft assembly intothe case as shown in Fig. 8.

23. Position the first- and second-speed shift fork and the third- andfourth-speed shift fork in place ontheir respective gears and rotatethem into place.

24. Place a detent plug (Fig. 5) inthe detent bore. Place the reverseshift rail into neutral position.

25. Coat the third- and fourthspeed shift rail interlock pin withgrease and position it in the shift rail.

27. Align the first- and second-speed shift fork with the case boresand slide the shift rail into place. Se-cure the fork with the set screw. In-stall a detent plug and spring in thedetent bore. Thread the set screw intothe case until the head is flush to0.020 inch below the surface of thecase.

28. Coat the input gear bore witha thin film of grease, then install the15 roller bearings in the bore. Athick film of grease could plug thelubricant holes and restrict lubrica-tion to the bearings.

29. Position the front blockingring in the third- and fourth-speedsynchronizer. Place the input shaftgear in the transmission case makingsure that the output shaft pilot entersthe roller bearings in the input gear.

30. Place a new gasket on the in-put shaft bearing retainer. Dip theattaching bolts in sealer and installand tighten them to specifications.

31. Install the output shaft bear-ing as shown in Fig. 21. Install thesnap ring to retain the bearing.

32. Position the speedometer geardrive ball in the output shaft andslide the gear into place. Secure thegear with the snap ring.

33. Place the transmission in avertical position as shown in Fig. 22.Align the countershaft gear bore andthrust washers with the bore in thecase. Install the countershaft.

34. Use a new gasket and securethe extension housing to the casewith the attaching screws. Use a seal-er on the extension housing attach-ing screws. Torque the screws tospecifications.

35. Install the filler and drainplugs in the case if they were re-moved. Make sure that the magneticplug is installed in the bottom of thecase.

36. Pour the specified lubricantover the entire gear train while rotat-ing the input shaft.

37. Place each shift fork in all po-sitions to make sure that they oper-ate properly.

38. Use a new cover gasket andinstall the cover. Coat the cover at-taching screws with sealer and installand tighten them to specifications.

39. Coat the third- and fourth-speed shift rail plug bore with a seal-er and install a new expansion plug.

40. If the extension housing bush-ing and seal are to be replaced, re-fer to Section 4.

sembled

26. Align the third- and fourth-speed shift fork with the shift railbores and slide the shift rail intoplace making sure that the three de-tents are facing toward the outsideof the case. Place the front synchro-nizer into third-speed position and in-stall the set-screw in the third- andfourth-speed shift fork. Move thesynchronizer to the neutral position.Install the third- and fourth-speedshift rail detent plug, spring and boltin the left side of the transmissioncase (Fig. 5). Place the interlockplug (tapered ends) in the detentbore.


FIG. 22-lnstallingCountershaft-- -.

C1526-AFIG. 19-Removing Input Shaft Seal

Tool-T63P-7025-A.

Toof-T64P,7025.B- DETAIL 1

DETAIL 4FORD, FAIRLANEAND MERCURY- DETAilS

COMET AND FALCON

,DETAil 3

'DETAil 2

C1518-A

FIG. 21-lnstalling Output Shaft Bearing

6-45

OVERDRIVE TRANSMISSION

SectionPage.6-45.6-45

Page.6-47.6-48.6-49.6-49.6-50

.6-50.6-50

.6-50.6-50.6-52.6-52

.6-52

.6-52

.6-52

.6-53

.6-53

6-45

.6-456-45

.6-45

.6-45

.6-46

.6-46

.6-47

.6-47

.6-476-47

.6-47

.6-47

Mechanical Operation. . . . . . . . . . . .Electrical System Operation. . . . . . .

4 In-Car Adjustments and Repairs. . . . .Overdrive Control Cable Adjustment.

5 Transmission Removal and InstallationRemoval. . . . . . . . . . . . . . . . . . . . . . . . .Installation. . . . . . . . . . . . . . . . . . . . . . .

6 Major Repair Operations. . . . . . . . . . .Disassembly Parts Repair or Replacement. . . . . . . .

InputShaft Synchronizer. . . . . . . . . . . . . . . . . . .

Output Shaft Bearing. . . . . . . . . . . .Cam and Shaft Seals ,Countershaft Rollers. . . . . . . . . . . . .

Assembly. . . . . . . . . . . . . . . . . . . . . . . .

Section1 Diagnosis and Testing. . . . . . . . . . . . .

Mechanical Checks Overdrive Control Handle Clearance

Check. . . . . . . . . . . . . . . . . . . . . .Overdrive Control Lever Position

Check. . . . . . . . . . . . . . . . . . . . .Pawl Engagement Check Electrical Checks Governor Circuit Check. . . . . . . . .

Solenoid Circuit Check Interrupter Circuit Check. . . . . . .

2 Cleaning and Inspection Cleaning. . . . . . . . . . . . . . . . . . . . . . .

Inspection. . . . . . . . . . . . . . . . . . . . . . .3 Description and Operation Description. . . . . . . . . . . . . . . . . . . . .

Operation. . . . . . . . . . . . . . . . . . . . . . .

DIAGNOSIS AND TESTING

When trouble occurs in the over-drive unit, check the mechanical op-eration of the unit before checkingthe operation of the overdrive elec-trical control system.

MECHANICAL CHECKS

OVERDRIVE CONTROLHANDLE CLEARANCE CHECK

Check the specified clearance be-tween the overdrive control handleshank and the bezel on the instru-ment panel.

OVERDRIVE CONTROL LEVERPOSITION CHECK

Raise the car and check the posi-tion of the overdrive control lever atthe overdrive unit housing. The levershould rest firmly against its stop atthe rear. If the lever is not all theway back the overdrive shift railmay be locking the pawl and pre-venting it from engaging the balkring gear.

With the engine stopped and theclutch engaged, shift the transmissionto third or second gear and shift theoverdrive control lever to the auto-matic (rearward) position. The driveshaft should then turn freely in aclockwise direction (when viewedfrom the front), but should lock upwhen turned counterclockwise.

With the transmission remaining

in third or second gear, shift theoverdrive control lever to the locked-out (forward) position. The driveshaft should lock up when turnedeither clockwise or counterclockwise.

PAWL ENGAGEMENT CHECKCheck the mechanical engagement

of the pawl with the balk ring gear,using the following procedure:

1. Turn the ignition switch to theON position and raise the car.

2. Shift the overdrive control leverto the locked-out (forward) position,and shift the transmission to neutral.

3. Turn the drive shaft clockwiseand, at the same time ground thegovernor white wire with a jumper.The solenoid will click, indicatingthat it is energized.

4. Keep the solenoid energized,and shift the transmission to third orsecond gear to lock the transmissionoutput shaft against rotation. Shiftthe overdrive control lever to the au-tomatic (rearward) position.

5. Turn the drive shaft clock-wise. At less than 1/4 turn of thedriveshaft, the pawl will engage thebalk ring gear and lock the driveshaft against rotation in both direc-tions.

If the pawl does not engage thebalk ring gear, replace the solenoidand repeat the test. If the pawl still

does not engage, remove the over-drive unit from the car for inspec-tion and repair.

ELECTRICAL CHECKS

GOVERNOR CIRCUn CHECK1. Turn the ignition switch ON

and OFF, and listen for the relay orsolenoid to click. If either clicks assoon as the ignition switch is turnedON, the governor circuit (Fig. 1) isgrounded or the relay is defective.

2. To determine which conditionis present, remove the wire from theTH-SW terminal on the relay andturn the ignition switch ON. If therelay clicks, the relay is defective. Ifit does not click, the governor circuitis grounded.

3. To check the governor opera-tion when the relay does not click asthe ignition switch is turned On, dis-connect the wire at the TH-SW ter-minal.

4. Raise the rear wheels off thefloor.

5. Connect a test lamp betweenthe battery and the wire removedfrom the TH -SW terminal.

6. Start the engine and, with thetransmission in third-speed, bring thespeedometer reading up through 28mph. The lamp should light at orabout this speed.

7. Throttle the en gin e down


connected to the BAT terminal dur-ing ignition work. .

Z. Disconnect the blue wire withan orange band (Fig. 1) from itsconnector near the solenoid, andground it to the transmission casewith a jumper.

3. With the engine running at fastidle, push the kickdown switch stemin until it bottoms (Fig. 2). Whenthe stem bottoms, the engine shouldstop.

ground. If the lamp lit at the IGNend and not at the other, replacethe fuse. Sometimes the fuse will"open" under the fuse end caps wherethe "open" cannot be seen.

4. With current at both ends of thefuse, connect the test lamp betweenthe solenoid terminal and at aground. Ground the TH-SW termi-nal. The lamp should light. If it doesnot, replace the relay.

5. With the relay working proper-ly, the solenoid should click when theTH-SW terminal is grounded. If itdoes not, connect a jumper from theSOLENOID relay terminal to theshort blue wire separated from itsconnector near the solenoid. If thesolenoid does not click when the re-lay closes with the jumper wire con-nected, replace the solenoid. If itdoes click, replace the wire from theSOLENOID relay terminal to theconnector.

INTERRUPTER CIRCUITCHECK

If the interrupter circuit does notground the engine ignition momen-tarily when the driver depresses theaccelerator pedal to the floor, theoverdrive unit cannot shift from over-drive to direct.

1. The first check of the ignitioninterrupter circuit is at the ignitioncoil. The black wire which runsfrom the ignition coil to the kick-down switch must be connected tothe DIST terminal on the coil.Sometimes this wire is improperly

STEM BEUCRANK ..~;-; s;-~

FIG. 2-Kickdown SwitchInstallation

If it does not stop, the circuit isopen between the ruST terminaland the connector.

4. To check the ignition ground-ing contacts inside the solenoid, dis-connect the jumper and remove thesolenoid from the overdrive unit.

FIG. 1-0verdrive Electrical System

through 22 mph and at or about thisspeed the lamp should go out. If thelamp lights, and goes out at or aboutthese speeds, the governor and gov-ernor circuit are working properly.

8. Turn the ignition switch ONand raise the car. Disconnect the yel-low wire from the white wire at thegovernor connector.

9. Ground the white wire on thetransmission case. If the relay andsolenoid click, the governor circuit isworking properly from the TH-SWterminal to the connector (Fig. 1),and the trouble is in the yellow wireor the governor. If the relay and so-lenoid do not click when the whitewire is grounded, the trouble is be-tween the TH -SW terminal and theconnector (Fig. 1).

SOLENOID CIRCUIT CHECK1. With the engine stopped and

the ignition switch ON, ground theTH -SW terminal on the relay. Ifthe relay and solenoid click as theground is made and broken, the sole-noid circuit is working properly. Ifthe relay does not click as the TH-SW terminal is grounded, check therelay IGN terminal with a test lamp.

2. With the ignition switch ON,the test lamp should light when it isconnected between the IGN terminalon the relay and at a ground. If itdoes not, the trouble is between theignition switch and the IGN termi-nal.

3. Connect the test lamp at theother end of the fuse and at a

PART 6-6- OVERDRIVE TRANSMISSION 6-47

S. Attach the solenoid to anadapter so that the stem can extendfully when the solenoid is energized.Make sure the solenoid is grounded.

idle, press in on the kickdown switch

stem until it bottoms. The engine

should stop. If it does not, replace

the solenoid.

6. Connect both solenoid wires attheir connectors.

7. Ground the governor wire witha jumper.

8. With the engine running at fast

Clean and inspect the transmis-sion unit parts in the same manneras for the conventional transmis-sion. Clean all overdrive parts thor-oughly.

INSPECTION

Check the balk ring tension, asshown in Fig. 3 for a pull of 31/2-51/2pounds. Read the spring scale whilethe balk ring is turning, because theinitial effort required to start thering turning may be considerablyhigher than the specified pull. Re-place the assembly if the tension isnot within specifications.

Check the inner surface of thefree-wheel clutch outer race. If thesurface is worn or "chattered," theoverdrive output shaft must be re-placed.

FIG. 3-Checking Balk Ring Tension

Check the clutch rollers for cracksand wear. Replace the complete set

of 12 rollers if any are cracked orworn.

front). At a lower ratio than 0.70:1,it will turn counterclockwise.

OverdriveTo shift the overdrive unit from

the direct (1.00:1) to overdrive(0.70:1) the sun gear is held againstrotation (Fig. 5).

This is accomplished by engaginga pawl in the balk ring gear whichis splined to the sun gear.

In overdrive, the power flow isfrom the transmission output shaftto the planet carrier splined to it,through the planet gears and thento the sun gear. With the sun gearheld against rotation, the planetgears are forced to "walk around"the sun gear and drive the internalring gear. The transmission outputshaft will then drive the overdrivemain shaft at a ratio of 0.70:1.

In overdrive, the overrunningclutch is uncoupled because the outerrace (overdrive main shaft) is turn-ing faster than the clutch cam (trans-mission output shaft). Overdrive is atwo-way drive; the engine can drivethe rear wheels and the rear wheels

CLEANING

DESCRIPTIONThe overdrive transmission is used

on Fairlane cars having 289 C.I.D.engines. A transmission service iden-tification tag is located under the up-per right extension to case attachingbolt. The tag will show the transmis-sion model and service identificationcode when required.

The overdrive unit is basically anautomatic planetary transmission at-tached to the rear of a conventionalthree-speed transmission (Fig. 4) toprovide four forward speeds insteadof three. The overdrive can be me-chanically locked out by a control ca-ble located on the instrument panel.

The electrical system which con-trols the operation of the overdrivewhen the control cable is pushed in,consists of a relay, a manual kick-down switch, solenoid, governor, andthe circuit wiring.

OPERATION

MECHANICAL OPERATION

Direct, Free-Wheeling DriveWhen the control handle is pushed

in, the drive through the overdriveunit from start to approximately 28mph is direct (1.00:1) and free-wheeling.

The power flow is from the trans-mission output shaft, through theoverrunning clutch (free-wheel unit),to the overdrive main shaft (Fig. 5).

This drive is said to be free-wheel-ing because the overrunning clutchpermits the transmission output shaftto drive the overdrive main shaft,but it does not permit the drive toreverse. In a free-wheeling drive, theengine can drive the rear wheels, butthe rear wheels cannot drive the en-gine.

In direct, free-wheeling drive, theplanetary gearing is in neutral, be-cause the sun gear can run free. Itcan rotate clockwise (from thefront), counterclockwise, or standstill, depending on the relativespeeds of the planet carrier (trans-mission output shaft), and the inter-nal ring gear (overdrive main shaft).At a 0.70: 1 ratio, the sun gear willstand still. At a higher ratio, the sungear will turn clockwise (from the


4-0verdrive Transmission

OVERDRIVEMAIN SHA"T

TRANSMISSIONOUTPUT SHAFT

BALK RINGGFAI?

B~LK RING INTERNAlLOCK-UP TEETH

,, PLANET

CARRIER. GEAR

-SHIFTRAilPAWL--

OVERRUNNINGCLUTCH SUN GEAR

-,SUN

GFARSOLENOID

'.3'8

OVERDRIVE C1107-4

the lock-up teeth on the planet car-rier (Fig. 5).

When the sun gear is locked to theplanet carrier, the planetary gearingis locked as one mechanical unit andthe transmission output shaft islocked to the overdrive main shaft.This lock-up is necessary in reverse,because the transmission output shaftreverses its rotation and thereforecannot drive the overdrive mainshaft through the overrunning (one-way) clutch. The lock-up in reverseis accomplished by the low and re-verse position. This locked-up driveis also necessary when the car ispushed to start the engine, since theoverrunning clutch will not transmit

power from the overdrive main shaftto the transmission output shaft.

ELECTRICAL SYSTEMThe overdrive electrical system,

which engages and disengages thepawl, consists of a relay, a manualkick-down switch, a solenoid, a cen-trifugal governor and the circuitwiring.

There are three separate circuits(Section 1, Fig. 1) in the electricalsystem: a governor circuit whichopens and closes the relay, a sole-noid circuit which supplies currentthrough the relay to energize the so-lenoid, and an ignition interruptercircuit, which momentarily grounds

can drive the engine.To shift from overdrive back to di-

rect, the pawl is disengaged from thebalk ring gear, permitting the sungear to run free. The overdrive gear-ing is now in neutral. As soon as thespeed of the transmission outputshaft comes up to the speed of theoverdrive main shaft, the overrunningclutch automatically locks up and di-rect drive is restored.

Locked-Out DriveWhen the control handle is pulled

out, the overdrive unit cannot func-tion at any car speed. This lockout isaccomplished by the shift rail movingthe sun gear into engagement with

. 5-0verdrive Power Flow

PART 6-6 - OVERDRIVE TRANSMISSION 6-49

the engine ignition for full-throttledownshift (kickdown).

is driving the overdrive main shaftthrough the overrunning clutch, allelements of the planetary gearingare revolving as a unit, and in acounterclockwise (from the rear) di-rection. This rotates the balk ringagainst the pawl.

When the driver releases thethrottle, the overdrive main shaftoverruns the transmission outputshaft. When this overrun exceeds theratio of 0.70: 1, the sun gear andbalk ring reverse, releasing the pawlto engage the balk ring gear.

The position of the balk ring,should the solenoid be energizedwhen the car is coasting (engineidling) up through 28 mph, is shownin the right view of Fig. 6. Underthis condition the sun gear will berotating clockwise (from the rear)and the pawl will be blocked.

The pawl engages when the enginespeeds up, and brings the transmis-sion output shaft up through the0.70:1 ratio with the overdrive mainshaft. This action will cause the sungear to reverse its clockwise (fromthe rear) rotation and release thepawl to engage the bulk ring gear.

Pawl Disengagement

The pawl disengages under twoconditions. First, when the car speeddrops below approximately 22 mph,the governor opens the circuitthrough the relay and de-energizesthe solenoid, permitting the returnspring to pullout the pawl. Second,the driver may shift the overdriveback to direct drive at any roadspeed, by pressing the acceleratorpedal to the floor so that it depressesthe kickdown switch stem.

When this happens, the kickdownswitch opens the governor circuitthrough the relay, and de-energizesthe solenoid, permitting the returnspring to try to pullout the pawl.

Also, it closes the interrupter cir-cuit and grounds the ignition longenough for the return spring to pullout the pawl.

Normal ignition is restored assoon as the pawl comes out, and thesolenoid stem opens the ignitiongrounding contacts. The actual timeof ignition interruption is equal tothat required for one revolution ofthe crankshaft.

Pawl Engagement

The electrical system does not op-erate until car speed reaches approx-imately 28 mph. At this speed, thegovernor contacts close, permittingcurrent to flow from the batterythrough the relay to the solenoid.

There are two coils in the sole-noid, usually referred to as the "pull-in" and "hold-in" coils. The pull-incoil is energized only while the sole-noid plunger is being pulled in. Assoon as the plunger is in, a set ofpoints inside the solenoid opens thepull-in circuit.

As the plunger is pulled in, an en-gaging spring and a return spring are

engaged.Under pressure from the pawl en-

gaging spring, the pawl is pushed inuntil it strikes the balk ring.

The usual position of the balkring when the solenoid engagingspring pushes the pawl against it isshown in the left view of Fig. 6.When the transmission output shaft

BALK RING GEAR SUN GEAR

~

~

./~{

,// ~BALK RING POSITION

(COASTING) PAWL ENGAGED C 1574- ASOLENOID BALK RING POSITION

STEM (ENGINE DRIVING)

FIG. 6-Pawl and Balk Ring Positions


2. Position the overdrive cable un-til there is 1/4 inch clearance betweenthe cable control handle and bezel.

3. Move the overdrive control le-ver to the rear against the stop. When

moving the lever, be careful not to

move the cable out of position.

4. Tighten the control cable lock

nut on the overdrive.

OVERDRIVE CONTROLCABLE ADJUSTMENT

1. Loosen the overdrive cablelock nut at the overdrive control le-ver.

GROUP 6 - MANUAL SHIFT TRANSMISSIONS6-50

4. Remove the overdrive transmis-sion from the car, following the pro-cedure given in Part 6-2 for remov-ing the 3-speed Conventional Drivetransmission.


the 3-speed Conventional Drive trans-mission.

2. Connect the overdrive controlcable to the lever on the side of theoverdrive unit. With the cable con-nected, there must be 1/4 inch clear-ance between the control handleshank and the bezel when the leverat the overdrive housing is againstits rear stops.

3. Connect the solenoid and gov-ernor to the connectors near the so-lenoid.

4. Install the overdrive wiringharness in its clip on the transmis-sion.

INSTALLATIONThe overdrive unit must be assem-

bled and installed on the transmissionbefore the transmission is installed inthe car.

1. Install the overdrive transmis-sion in the car, following the proce-dure given in Part 6-2 for installing

ClUTCH-TO-CARRIER RETAINERof the free-wheel unit rollers thatdrop out. Remove the rest of therollers.

9. Remove the speedometer gearretaining snap ring. Remove thegear and drive ball.

10. If the overdrive output shaftbearing is to be replaced use the toolsshown in Fig. 8.

100/-1531-

Toof-4621.K

j

OVERDRIVE HOUSING

SNAP RING HOLE

INSTALLATION

C 1113-B

REMOVAL/' C 1575~

fiG. 7-Removing OverdriveHousing

6. Remove the four overdrivehousing to transmission case bolts,and the overdrive control shaft pin.

7. Pull the overdrive control leverand shaft out as far as possible.Spread the snap ring that retains theoverdrive output shaft bearing andthen remove the overdrive housing(Fig. 7).

It may be necessary to tap theoverdrive output shaft with a soft-faced hammer to free the outputshaft bearing from the housing.

8. Remove the overdrive outputshaft from the assembly. Catch any

FIG. 8-Replacing OutputShaft Bearing

11. Remove the free-wheel unitretainers (Fig. 9). Then remove theclutch, planet carrier, sun gear, andshift rail.

12. Remove the snap ring fromthe adapter, and then remove theplate and trough, balk ring gear andpawl.

13. Remove the input shaft bear-ing retainer and gasket (Fig. 10).

Replace the input shaft seal withthe same tools that are used on theconventional 3-speed transmission.

14. Rotate the overdrive adapter

~ 'CLUTCH- TO-TRANSMISSION OUTPUT

SHAFT RETAINER C1011-A

FIG. 9-Removing Free WheelUnit Retainer

to expose the countershaft lock, andremove the lock.

15. With a drift, drive the coun-tershaft toward the rear until it justclears the hole at the front of thecase, support the countershaft gearwith a hook then push the counter-shaft out of the rear with the toolshown in Fig. 11.

16. Lower the countershaft gearto the bottom of the case to provideclearance for removal of the inputshaft and bearing. Tap the inputshaft and bearing out of the front ofthe case.

17. Remove the shift lever shaftretaining pins (Fig. 12).

18. Pull the low and reverse shiftlever out as far as it will go; thenremove the low and reverse fork.

19. Remove the overdrive adapterand transmission output shaft as anassembly (Fig. 13).

20. Remove the snap ring at thefront of the transmission output

REMOVALThe overdrive unit cannot be re-

moved from the car as a separateassembly. Remove the transmissionand overdrive unit together, follow-ing the steps detailed below:

1. Disconnect the solenoid andgovernor wires from the connectorsnear the solenoid.

2. Remove the overdrive wiringharness from its clip on the trans-mission.

3. Disconnect the overdrive con-trol cable from the lever on the sideof the overdrive unit and from theclamp at the solenoid.


holding fixture. Then, drain the trans-mission and the overdrive unit.

2. Remove the solenoid retainingscrew, and then rotate the solenoidabout 1/4 turn to remove it.

3. Remove the governor.4. Remove the transmission cover

and gasket.5. With a sharp punch, pierce the

snap ring hole cover in the overdrivehousing (Fig. 7), and remove thecover.

PART 6-6 OVERDRIVE TRANSMISSION 6-51

FIG. 10-0verdrive Transmission Disassembled

shaft, and then slide the synchronizerintermediate gear, and the slidinglow a~d reverse gear off the shaft.

21. Lift the countershaft gear,thrust washers and dummy shaftfrom the case.

11. Drive the reverse idler gearshaft out of the rear of the case witha brass drift and a hammer, and re-


C1012-A. --

Tool-T56P-7111-B

FIG. 11-RemovingCountershaft

LOW AND REVERSE CAM DETENT BALLS INTERMEDIATE AND HIGH CAM

FIG. 14-Cams and Detent Balls Installed

C1119-8

FIG. 12-Removing ShiftLever Shaft Retaining Pin

-REMOVAL INSTALLATION

C1114-8

FIG. 16-Synchronizer

3. Position the baffle in the adapt-er (Fig. 17). Tap the bearing andshaft into place in the adapter.

4. Install the snap ring to retainthe bearing.

CAM AND SHAFf SEA~1. Remove the nuts and lock

SNAP RING BEARING

FIG. 13-Removing OutputShaft and Adapter

move the idler gear from the case.1.3. Remove the lock plunger,

spring, pin, and detent balls from thecase (Fig. 14).

FIG. 1 S-Replacing InputShaft Bearing

unit (Fig. 10) by sliding the inter-mediate and high sleeve off the hub.Remove the three inserts and twosprings from the hub.

2. Assemble the synchronizer unitby installing the two springs on thehub and placing the three inserts inthe hub. Hook one spring end in aninsert as shown in Fig. 16.

3. After lining up the etchedmarks on the sleeve and hub splines,slide the sleeve into place on the hub.

OUTPUT SHAFT BEARING1. Remove the snap ring which

retains the output shaft in the adapt-er (Fig. 17), and tap the bearing outof the adapter. Remove the bafflefrom the adapter.

2. Remove the snap ring and pressthe old bearing off and the new bear-ing _on with the tools shown in Fig.18.

-~--- --TRANSMISSION OUTPUT SHAFT (1117.8

FIG. 17-Removing OutputShaft Bearing Snap Ring

Install the snap ring to retain thebearing.


INPUT SHAFT BEARING1. If the input shaft bearing is to

be replaced, remove the snap ringthat retains the bearing, and pressthe bearing and baffle off the shaft(Fig. 15).

2. Press a new bearing into placeon the gear and shaft.

SYNCHRONIZER1. Disassemble the synchronizer

PART 6-6 - OVERDRIVE TRANSMISSION 6-53

REMOVAL INSTALLATIONC 1118.8

and transmission outMtshaft assem-bly in the transmission.

14. Engage the shift forks withthe high and intermediate sleeve, andwith the low and reverse slidinggear.

15. Seat the overdrive adaptersquarely against the transmissioncase, and secure with a cap screw.

16. Coat the bore of the inputshaft with a thin film of grease andinstall the pilot roller bearings.

17. Place the blocking ring on theinput shaft gear and hold them in po-sition. Move the input shaft forwardto seat the output shaft pilot in theroller bearings of the input shaft.

18. Tap the input shaft and bear-ing into the case with a soft ham-mer, and at the same time line upthe slots in the blocking ring with thesynchronizer inserts.

19. Place a new gasket on the in-put shaft bearing retainer, and holdit in place with gasket sealer.

20. Install the input shaft bearingretainer to the transmission case.

21. Swing the transmission to aninverted position in the fixture.

22. Remove the cap screw hold-ing the adapter in place. Pull theadapter outward approximately 1/4inch, and rotate it to expose thecountershaft hole.

23. Work the countershaft gearin., normal position by rotating theinput and output shafts.

24. Push the countershaft into thecase from the rear.

25. Align the slots in the counter-shaft with the slot in the reverse idlershaft and install the lock plate.

26. Rotate the adapter to its nor-mal position and set it squarelyagainst the transmission case. Checkthe blocking rings to make sure theslots are aligned with the synchroniz-er inserts.

27. Swing the transmission so thatthe input shaft is pointing down.

28. Place the balk ring gear as-sembly and pawl in the adapter (Fig.19).

29. Place the plate and trough as-sembly in the adapter and install its

snap ring.30. Install the sun gear and shift

rail (Fig. 20).31. Install the planet carrier and

the clutch cam. Install the retainers.32. Install the 12 clutch rollers

and hold them in position with astrong rubber band.

33. Rotate the roller cage coun-terclockwise (from the rear) untilthe rollers are off the cam surfaces.

FIG. l8-Replacing OutputShaft Bearing

washers that secure the levers on thecam and shaft units, and remove thelevers from the shafts and cams.

2. Remove the cams and shafts,detent balls, pin, spring, and sleeve(Fig. 10) from the case.

3. Remove the seals with a suit-able puller and discard.

4. Install the new seals with a suit-able driver.

5. Install the intermediate andhigh cam and shaft assembly in thecase.

6. Insert a detent ball, sleeve,spring and pin in the bore of the case.Move the cam and shaft so that thedetent ball seats in the neutral (cen-ter) notch.

7. Install the low and reverse camand shaft assembly, and then installthe levers on the shafts with nuts andlock washers.

8. Install a detent ball in thesleeve at the low and reverse end.Then push the low and reverse camtoward the detent ball far enough tohold the ball in place in the neutralnotch. The ball must seat in thenotch of the cam.

9. Install the shift lever shaft re-taining pins (Fig. 12).

10. In order to assure positiveshifting, and eliminate the possibilityof engaging more than one set ofgears at the same time, the clearancebetween the ramp of one cam andthe sleeve must be checked.

COUNTERSHAFf ROLLERS1. Remove the thrust washers

from each end of the countershaft.2. Remove the dummy shaft, re-

tainer washers, rollers, and spacerfrom the countershaft gear.

3. Position the spacer and thedummy shaft in the countershaft.

4. Place a retainer washer in eachend of the countershaft gear.

5. Apply grease to all of the roll-ers and place them in each end ofthe countershaft gear.

6. Apply grease to the two re-maining retainer washers and to thecontact surface of the thrust wash-ers. Install the retainer washers andthe thrust washers on each end of thegear.

ASSEMBLYAlways use new gaskets and gas-

ket sealer during assembly. To pro-vide initial lubrication, apply a thincoating of lubricant on all parts be-fore installation.

1. Position the countershaft gear,dummy shaft, and roller bearings inthe case.



4. After establishing the correctend play, install the dummy shaft inthe countershaft gear and allow thegear to remain at the bottom of thecase.

5. Install the reverse idler gear inthe case, with the chamfered gearteeth ends toward the front.

6. Drive the reverse idler shaftinto the case, with the locking notchaligned with the countershaft hole.

7. Install the low and reverse slid-ing gear on the output shaft, withthe shifter fork groove toward thefront.

8. Install the intermediate gear onthe output shaft, with the clutchteeth toward the front.

9. Place a b10cki~g ring on the in-termediate gear, and install the syn-chronizer assembly on the transmis-sion output shaft, with the hubthrust surface toward the rear (Fig.16). Install the snap ring that retainsthe synchronizer.

10. Install the shift forks in thecams inside the transmission case.

The offset in the low and reversefork goes toward the front.

11. Install a new solenoid seal inthe overdrive adapter.

12. Place a new gasket on theoverdrive adapter and hold it inplace with gasket sealer.

13. Install the overdrive adaDter

MANUAL SHIFT TRANSMISSIONSGROUP 66-54

KEEP SHIFTFORK INGROOVE

BALK RING GEARPAWL

...

~

...

-- "Co'.' -SHIFT RAIL SUN GEAR C1014-A

FIG. 20-Sun Gear and ShiftRail Installation

37. Install the overdrive housingover the overdrive output shaft andshift rail.

38. If the overdrive output shaftbearing snap ring does not drop intoits groove when the housing is seatedsquarely on the adapter, pry theoverdrive output shaft bearing to-ward the rear, working through thesnap ring hole. Install the overdrivehousing attaching bolts.

39. Engage the overdrive shaft le-ver by pushin~ it inward. The lever

is correctly engaged when a springload is apparent as the leveris pushed forward.

40. Install the retaining pin in theoverdrive housing to hold the controlshaft in place.

41. If the overdrive housing bush-ing and seal are to be replaced, usethe same tools which are used onconventional transmissions.

42. Thread the governor into theoverdrive housing.

43. Position the solenoid in theadapter. Rotate the solenoid 1/4 turnfrom normal position so that thehalf ball on the solenoid stem canengage the pawl.

If the solenoid stem is properly en-gaged, the solenoid cannot be re-moved from the overdrive in its nor-mal position. Any attempt to pull itout will merely compress the engag-ing spring in the solenoid. Install thetwo solenoid attaching screws.

44. Install the drain plugs in thetransmission case and in the over-drive housing. Make sure the mag-netic plugs are installed in the bot-tnm of the case.

~-~~~- "ii[;i~;,\"" '

INSTALL WITH MACHINEDRECESS IN THIS POSITION CIOI3-A

FIG. 19-Plate and TroughInstalled

The rubber band will hold themthere.

34. Slide the overdrive outputshaft carefully over the clutch roll-ers. The rubber band will not affectoperation of the overdrive.

35. Align the shift rail spring withthe holes in the overdrive housing.

36. Place a new gasket on theoverdrive adapter, and hold it innlace with 2asket sealer (Pi2. 21).

SEA.L

...OVERDRIVE MAINSHAFT

AND GEARC1580-A

FIG. 21-0verdrive UnitDisassembled

6-56

SPECIFICA liONS

THREE-SPEED TRANSMISSION-2.77

GEAR RATIOS -Gear

ThiSpe

1~

EngineC.I.O.

I70-IV

I7D-IV

20D-IV

-First

Speed

3.293.292.76

-SecondSpeed

1.831.831.69

Reverse

4.46

4.46

3.74

TransmissionModel

HED-BH

HED-BJ

HED.BG

Car Usage

Falcon

Falcon Ranchero

Mustang

Falcon, Comet,Fairlane

ird

led

-.-J:1

1.00:1

1.00:1

HED-BF 200-1V 2.76 1.69 1.00:1 3.74

CLEARANCES LUBRICANT REFILL CAPACITIES

Application Pints (Approximate)

2All Models

TORQUE LIMITS

LUBRICANTS & SEALERS

THREE-SPEED TRANSMISSION-3.03

GEAR RATIOS

Ratio

EngineC.I.D.

200-IV H.D.289-2V-4V

390-2V-4V

FirstSpeed

2.99

-SecondSpeed

1.75

ThirdSpeed

1.00:1

Car Usage Reverse

3.17

TransmissionModel

HEF.GXF airlane-HEG-WHEG-X

HEF-CX

HEF-CW

-2.42

-1.61

-1.00:1

-2.33Fairlane and

Comet

Falcon and Comet

Mustanl!289.2V-4V

289.2V-4V

-2.99

2.99

-1.751.75

-1.00:1

1.00:1

-3.17

3.17

THREE-SPEED TRANSMISSION-3.03 (Continued)CLEARANCES LUBRICANT REFILL CAPACITIES

Inches

0.004-0.018

0.004-0.018

Description

Countershaft Gear End Play

Reverse Idler Gear End Play TORQUE LIMITS

Description Ft-lbs.

30-36

,

! 42-50

; 14-19

; 18.23 10.18 10-15

20-30

37.42

LUBRICANTS & SEALERSInput Shaft Bearing Retainer to Transmission Case

Material

Mild EP Gear OilC3RZ 19547-B

Lube GreaseM-4659

Application Extension Housing to Transmission Case

Access Cover to Transmission CaseTransmission

I Gear Shift Control Levers to Cam and Shaft

[ Shift Fork to Shift RailMain Shaft Roller Bearing

Countershaft Gear Roller Bearing I Filler Plug to CaseSealer

M-4G91-B

Lithium Base Grease(No Polyethylene)

C3VY-19586-A

Bolts and Gaskets Drain Plug to Case

Transmission to Flywheel HousingSteering ColumnLower Plate Detent Set Screw (Special)

*Flush to 0.020 inches below top of case.

DAGEN HAM FOUR-SPEED TRANSMISSION

GEAR RATIOS -Ratios

EngineC.I.D.

200-IV

VehicleUsage

Mustang

TransmissionModel

-2nd

2.21

-3rd

1.41

-4th

1.1

-Rev.

3.34

1 st

3.16HEJ-E

TORQUESCLEARANCES

Description Ft.-Lbs.

40-45

40-45

23-28

12-15

20-25

12-15

15-20

15-20

Description Inches

0.008-0.022Countershaft Gear End Play Extension Housing to Case Bolts

Flywheel Housing to Case Bolts

Flywheel Housing to Engine Bolts, Input Shaft Bearing Retainer Bolts

Output Shaft Bearing Nut

Shift Housing Retaining Bolts

Shift Lever to Linkage Cap Screws

Shift Rod Lock Nuts

FORD FOUR-SPEED TRANSMISSION

GEAR RATIOS -Ratios

3rd

1.36

-Rev.

2.78

Trans. Model

HEH-BV

Vehicle Usage

Falcon,Comet, Fairlane

FairlaneComet

Mustang ;:Mustang

-1st

2.78

2nd

1.93

4th

Direct

-2.32

-HEHoAR

EngineDisplacement

289.2V289.2V & 4V

390-2V & 4V-2.32

-

1.69

-1.29

-Direct

-2.78

2.32HEH-BW

HEH-BX

-2.78

2.32

-1.931.69

-1.36

1.29

-Direct

Direct289-4V

289-4V H.P.

FORD FOUR-SPEED TRANSMISSION (Continued)TORQUES LUBRICANT REFILL CAPACITIES

Description

Input Shaft BearingRetainer to Trans-mission Case

Extension Housing toTransmission Case

Access Cover toTransmission Case

Gear Shift Leverto Cam and Shaft

Shift Fork to ShiftRail

Filler Plug to Case

Drain Plug to Case

Detent Set Screw(Special)

Part Name Ft.Lbs.

19-25

Application Pints (Approximate)

Bolt- 5/16-18 x 3f4 Hex Head All Models 4

-Bolt-7/16-14 X IV4 Hex Head I 42-50

-14-19Screw-15/16-18 x 0/8 Hex Head

Screw-5/16-18 x 1 Hex Head

Nut-3fs-24 Hex-18-23

-10-18Screw-5 / 16-24 x .92 Set

locking

Plug-¥2-14

Plug-¥2-14 (Magnetic)

Screw-3fa-16 x .88 Set

--10-20

20-30

flush to0.020"belowsurface

10-18

CLEARANCES

Third and Fourth ShiftRail Detent Bolt

Bolt-%-16 x .38 Hex Head

Transmission to I Bolt-7/ 16,14Flywheel Housing Bolts I --., '00 -.-37-42

OVERDRIVE

GEAR RATIOS-Ratios

3rd

Direct

Trans.Model

HEK-X

VehicleUsage

Fairlane

1st

2.80

2nd

1.69

Rev.

3.80

-0.0.

.70

Trans. Assy.Part Number

C50R-7003-N

EngineDisplacement

289-2V

TORQUE SPECIFICATIONS LUBRICANTS & SEALERS

Description Ft.Lbs.

: 12-15

~rl2:i5I

42-50

12-15

Input Shaft Bearing Retainer to Transmission Case Bolt- -Transmission to Flywheel Housing Bolts

I Gearshift Housing to Transmission Case Bolts

Transmission Extension Housing to Case Bolts or Nuts

Gearshift Control Levers to Cam and ShaftAssembly Nuts

Overdrive Assembly to Transmission Case Nuts-37-42

35-40

10-20

20-30

Engine Rear Support to Extension Housing Bolts

Filler Plug to Case

Drain Plug to Case (Magnetic)

TRANSMISSION COMPONENT END PLAY

Component End Play

0.004-0.018

0.001-0.007

LUBRICANT REFILL CAPACITIESCountershaft Gear to Case

Cam Ramp to Interlock Shift Sleeve-Clearance

6-59PART 6-7-SPECIFICATIONS

SERVICE TOOLS (Continued)SERVICE TOOLS

Group 6 Manual Transmissions

Documents

Transcript of Group 6 Manual Transmissions