Ford Falcon. Manual — part 237

307-01-51 Automatic

Transmission 307-01-51

GENERAL PROCEDURES (Continued)

Gear shift cable adjustment

Rear Band

For more information, refer to Section 307-05.

1. Measure distance ‘A’ from the Rear Servo Piston

to the inner face of the Transmission Case using

Band adjustment

vernier calipers.

1. Apply air at 650/700 kPa to the Rear Servo

Front band

apply area (B2 outer).

1. Measure projection of Front Servo Push Rod from

2. Measure travel of the Piston, subtract 3.75mm

Transmission Case.

and divide the remainder by 2.5 to find Shim

1. Apply air at 650/700 kPa to the Front Servo

size.

apply area (B1 outer)

3.

Release

Air.

2. Measure travel of Push Rod and subtract

4. Fit Shim as per 2 below and re-check Piston

3mm to find Shim size.

travel is 3.75mm

± 0.625mm.

3.

Release

Air.

NOTE: A minimum of one Shim is required at

4. Fit Shim as per 2 below and re-check Push

all times - minimum Shim size is 1mm.

Rod travel is 3 mm

± 0.25mm.

2. Fit the Shim(s) selected to the shank of the

NOTE: A minimum of one Shim is required at

Anchor Strut as follows:

all times - minimum Shim size is 1 mm.

1. Inspect Shims for damage, wear or corrosion

2. Fit the Shim(s) selected to the shank of the

and replace as necessary.

Anchor Strut as follows:

2. Shims are to be installed between the Case

1. Inspect Shims for damage, wear or corrosion

abutment face and the Anchor Strut flange.

and replace as necessary.

3. Shim(s) are to be fitted by hand and under no

2. Shims are to be installed between the Case

circumstances to be hammered or forced.

abutment face and the Anchor Strut flange.

4. Shim(s) are to be pressed on by hand until an

3. Shim(s) are to be fitted by hand and under no

audible click is heard. The click indicates that

circumstances to be hammered or forced.

the Shim is clipped home correctly.

4. Shim(s) are to be pressed on by hand until an 3. The Shim thickness available are:

audible click is heard. The click indicates that

1.

1

mm

± 0.05, 2.0mm ± 0.07

the Shim is clipped home correctly.

2.

1.2mm

± 0.05, 2.2mm ± 0.08

3. The Shim thickness available are listed below:

3.

1.5mm

± 0.06, 2.4mm ± 0.08

1.

1

mm

± 0.05, 2.0mm ± 0.07

4.

1.8mm

± 0.07, 2.7mm ± 0.09

2.

1.2mm

± 0.05, 2.2mm ± 0.08

NOTE: All hardware must be correctly

3.

1.5mm

± 0.06, 2.4mm ± 0.08

installed and torqued to specification.

4.

1.8mm

± 0.07, 2.7mm ± 0.09

Rear Band Adjustment

Front Band Adjustment

Oil cooler flushing

When a clutch or band failure or other internal trouble

has occurred in the transmission, any metal particles

or clutch plate or band material that may have been

carried into the cooler should be removed from the

system by flushing the cooler and lines before the

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307-01-52 Automatic

Transmission 307-01-52

GENERAL PROCEDURES (Continued)

transmission is put back into service. In no case

4. Connect the cooler lines to the transmission.

should an automatic transmission having a clutch or

I6 Auto transmission cooling lines

band failure or other internal trouble resulting in fluid

contamination, be put back into service without first

flushing the transmission oil cooler.
1. After installing a new or rebuilt automatic

transmission and converter assembly in the

vehicle, do not connect the cooler lines to the

transmission.

V8 Auto transmission cooling lines

2. Place a pan under the cooler lines.
3. Using an air pressure of 100 kPa and a cleaning

gun charged with clean transmission fluid, flush

the cooler and lines until the fluid from the return

line runs clean.

5. Fill the transmission with the specified Automatic

Transmission Fluid following the procedure

detailed under FILLING A DRY TRANSMISSION

AND CONVERTER in the ADJUSTMENTS

SECTION.

6. Check the system for leaks.

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307-01-53 Automatic

Transmission 307-01-53

REMOVAL AND INSTALLATION

2. Install a new external cross-shaft pin using tool

Inhibitor Switch

307-467.

Special Tool(s)

CAUTION: When using a pin punch to

remove/install the external cross shaft pin, be

Selector shift pin

sure to support the cross shaft to ensure that

Remover/Installer

it is not damaged.

3. Install the wiring connector. Check that the 2 pin

plug has the red silicon gasket in place.

4. Lower the vehicle.

Radiator Oil Cooler

Removal
1. Raise the vehicle.

When fluid leakage is found at the radiator oil cooler

the radiator must be replaced. The oil cooler cannot

2. Disconnect the wiring connector.

be separated from the radiator for servicing.

NOTE: Be careful not to lose the silicone seal

contained within the two-pin connector.

Oil Cooler Tube

3. Remove the external cross-shaft pin using pin

remover tool 307-467.

WARNING: Tubing and fittings must be free

of any kinks or restrictions i.e. flattened areas.

CAUTION: When using a pin punch to

When a fluid cooler steel tube must be replaced, the

remove/install the external cross shaft pin, be

replacement tube must be fabricated from the same

sure to support the cross shaft to ensure that

size steel tubing as the original line. Using the old

it is not damaged.

tube as a guide, bend the new tube as required. Add

4. Remove the two screws securing the switch and

the necessary fittings and install the tube. After the

remove the switch.

fittings have been tightened, add fluid as needed and

Installation

check for leaks. (Replacement tubing must be new

1. Engage the switch with the transmission cross

and clean, oxidised tubing is not acceptable).

shaft and install the two screws.

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307-01-54 Automatic

Transmission 307-01-54

REMOVAL AND INSTALLATION (Continued)

Gear Shift — Column Shift

1. For steering column components, refer to Section

211-04.

I6 Steering column components

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