Ford Falcon. Manual — part 259

308-02-9 Clutch

Controls 308-02-9

REMOVAL AND INSTALLATION

3. Remove the push on decoupler from the clutch

Clutch Pedal

pedal pin.

Removal
1. Remove two M6 nuts and bolts, Clutch assembly

can now be removed.
NOTE: Ensure that inserts in pedal box remain in

place.

4. Pull the clutch master cylinder forward until the

line clip is accessible. Remove the clip and

disconnect the line.

2. Clutch Master Cylinder is now free of bracket but

still retained on pedal by push-on fix.

Installation
1. To install, reverse the removal procedure.

Clutch Master Cylinder

Removal and Installation

WARNING: Clutch fluid contains polyglycol

ethers and polyglycols. Avoid contact with eyes.

Wash hands thoroughly after handling. If brake

fluid contacts eyes, flush eyes with running water 5. Disconnect the clutch master cylinder rod from the

for 15 minutes. Get medical attention if irritation

clutch pedal arm. Remove the clutch master

persists. If taken internally, drink water and

cylinder from the vehicle.

induce vomiting. Get medical attention

immediately.

CAUTION: Clutch fluid is harmful to painted

or plastic surfaces. If the clutch fluid is spilled

onto a painted or plastic surface, wash it

immediately with water.
1. Partially drain the clutch reservoir.

Drain to just below the clutch reservoir nipple.

2. Remove the hose at the clutch reservoir.

6. Remove the reservoir line from the clutch master

cylinder.

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308-02-10 Clutch

Controls 308-02-10

REMOVAL AND INSTALLATION (Continued)

7. To install, reverse the removal procedure.

5. To install, reverse the removal procedure.

Install new hose clamps on the reservoir line.

1. Position the clutch slave cylinder to the

transmission and install the bolts.

Refill the brake master cylinder with the

specified fluid.

2. Bleed the clutch hydraulic system. For

additional information, refer to procedure in

Bleed the clutch hydraulic system. For

this chapter.

additional information, refer to procedure in

this chapter.

Clutch Hydraulic Fluid Tubes

Slave Cylinder

Removal and Installation

Removal and Installation

WARNING: Clutch fluid contains polyglycol

1. Remove the transmission. For additional

ethers and polyglycols. Avoid contact with eyes.

information, refer to Section 308-03.

Wash hands thoroughly after handling. If brake

NOTE: Inspect the clutch housing for traces of

fluid contacts eyes, flush eyes with running water

fluid. If brake fluid is visible, install a new clutch

for 15 minutes. Get medical attention if irritation

slave cylinder.

persists. If taken internally, drink water and

induce vomiting. Get medical attention

2. Remove the clutch slave cylinder.

immediately.

1. Remove the bolts.

2. Remove the clutch slave cylinder.

CAUTION: Clutch fluid is harmful to painted

or plastic surfaces. If the brake fluid is spilled

onto a painted or plastic surface, wash it

immediately with water.
1. Partially drain the clutch reservoir.

Drain to just below the clutch reservoir nipple.

2. Remove the hose at the clutch reservoir.
3. Disconnect the hydraulic line from the clip on the

instrument panel.

1. Using a 3/32-inch punch and hammer, drive

out the roll pin and discard it.

2. Disconnect the hydraulic line.

4. Disconnect the hydraulic line from the clutch

master cylinder.

3. Inspect the clutch slave cylinder for the following:

5. Disconnect the lower end of the hydraulic line

1. Worn or damaged boot.

from the clutch slave cylinder.

2.

Leaking

fluid.

6. Disconnect the hydraulic line from the clip on the

transmission.

3. Contract and return smoothly.

NOTE: Make sure the O-ring is in the outlet port

or on the tube connector.

CAUTION: The clutch release hub and

bearing is prelubricated and should not be

7. To install, reverse the removal procedure.

cleaned with solvent. The clutch release hub and

8. Bleed the clutch hydraulic system. For additional

bearing are replaced as an assembly. Do not

information, refer to procedure in this chapter.

disassemble for inspection or replacement.
4. Inspect the clutch release bearing as follows:

1. Rotate the outer race while applying pressure.

If the bearing rotation is rough, install a new

clutch slave cylinder.

2. Inspect for wear or damage.

If wear pattern is continuous (not

segmented) and the wear appears to be

deep in bearing face, install a new clutch

slave cylinder.

G56334 en

308-02-11 Clutch

Controls 308-02-11

REMOVAL AND INSTALLATION (Continued)

Clutch Reservoir

Removal and Installation
1. Remove the two M6 nuts securing the reservoir to

the reservoir bracket.

2. Remove the cap, drain the reservoir of all fluid

and replace cap.

3. Undo clamp on reservoir line and remove

reservoir.

4. To install, reverse removal procedure.

G56336 en

308-03a-1

Manual Transmission — I6

308-03a-1

SECTION : 308-03a Manual Transmission — I6

VEHICLE APPLICATION : 2003.0 BA Falcon
CONTENTS

PAGE

SPECIFICATIONS

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..308-03a-3

DESCRIPTION AND OPERATION

Manual Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . ..308-03a-4

Manual

Transmission

. . . . . . . . . . . . . . . . . . . . . . . . . . .308-03a-4

DIAGNOSIS AND TESTING

Manual Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . ..308-03a-8

Inspection and Verification . . . . . . . . . . . . . . . . . . . . . . . . .308-03a-8

Symptom

Chart

. . . . . . . . . . . . . . . . . . . . . . . . . . . . ..308-03a-8

GENERAL PROCEDURES

Transmission Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . .308-03a-10

Transmission Inspection . . . . . . . . . . . . . . . . . . . . . . . . ...308-03a-10

Aluminium Transmission Case Service . . . . . . . . . . . . . . . . . . . 308-03a-10

Taper Roller Bearings Inspection . . . . . . . . . . . . . . . . . . . . . .308-03a-11

Fluid Level Check . . . . . . . . . . . . . . . . . . . . . . . . . . . .308-03a-11

Drain and Refill Transmission . . . . . . . . . . . . . . . . . . . . . . ...308-03a-11

REMOVAL AND INSTALLATION

Rear Extension Housing Oil Seal . . . . . . . . . . . . . . . . . . . . . ..308-03a-12

Shift Lever and Boot Assembly . . . . . . . . . . . . . . . . . . . . . . .308-03a-13

Speedometer Transducer and Drive Gear . . . . . . . . . . . . . . . . . . 308-03a-14

Concentric Slave Cylinder (CSC) . . . . . . . . . . . . . . . . . . . . . .308-03a-14

Transmission Damper . . . . . . . . . . . . . . . . . . . . . . . . . ...308-03a-14

Reversing Light Switch . . . . . . . . . . . . . . . . . . . . . . . . . .308-03a-15

Transmission Cross - Member . . . . . . . . . . . . . . . . . . . . . . ..308-03a-15

REMOVAL

Special Service Tools . . . . . . . . . . . . . . . . . . . . . . . . . ...308-03a-17

Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .308-03a-17

INSTALLATION

Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .308-03a-18

DISASSEMBLY

Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .308-03a-19

DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .308-03a-26

Input Shaft Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . ...308-03a-26

Input shaft — to — output shaft bearing cup . . . . . . . . . . . . . . . . . 308-03a-27

Output Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..308-03a-28

Countershaft Bearing — Front . . . . . . . . . . . . . . . . . . . . . . ..308-03a-35