Ford Falcon. Manual — part 263
308-03a-14
Manual Transmission — I6
308-03a-14
REMOVAL AND INSTALLATION (Continued)
4. Apply loctite to thr
eads. Screw the knob onto the 2. Detach the fluid hose from the mounting clips and
shift lever until it starts to tighten, continue
extricate it from the flywheel housing.
tightening until the graphics on the knob are
correctly aligned.
Speedometer Transducer and Drive
Gear
Removal
NOTE: Only vehicles not fitted with ABS utilise a
transmission driven speedometer transducer, hence
the following removal/installation procedures are
pertinent only to such vehicles.
1. Raise
the
vehicle.
2. Disconnect the wiring plug.
3. Remove the transducer.
3. Using a T30 Torx® driver remove the two CSC
4. Pry off the retaining clip and remove the gear.
mounting bolts that attach the CSC to the flywheel
5. Remove the ’O’ ring seal.
housing.
Installation
Installation
1. Install the ’O’ ring.
1. Place the CSC in the position shown and install
the two CSC mounting bolts. Torque to
2. Install the gear and the retaining clip.
specification.
3. Lubricate the seal and gear with transmission oil.
2. Route the CSC hydraulic hose in the orientation
4. Install the transducer into the housing and
shown and tighten the CSC-to-hydraulic hose
connect the wiring.
fitting. Torque to specification.
5. Lower the vehicle.
NOTE: Ensure the hydraulic hose is mounted in
the clips located on and in the flywheel housing.
Concentric Slave Cylinder (CSC)
Transmission Damper
Removal
NOTE: Before the CSC can be removed the
Removal
transmission must be removed from the vehicle and
1. Undo the nuts on the three transmission damper
the clutch bled according to the procedure setout in
mounting bolts.
Section 308-01.
2. Remove the transmission damper mounting bolts.
1. Undo and disconnect the CSC fluid hose from the
3. Detach the damper and mounting bracket from
CSC using a suitable 10-mm spanner.
the transmission extension housing.
Installation
1. Position the transmission damper and bracket
such that the holes in the bracket line up with the
holes in the extension housing.
2. Insert the three transmission damper mounting
bolts through the aligned holes in the damper
bracket and extension housing.
3. Thread the damper mounting nuts onto the bolts.
Torque to specification.
NOTE: The damper mounting nuts are of the
Nyloc® variety and should be replaced each time
the transmission damper is removed.
Item
Description
1
Hose Clip
2
CSC-to-Hose fitting
3
Bleed Screw
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308-03a-15
Manual Transmission — I6
308-03a-15
REMOVAL AND INSTALLATION (Continued)
5. Detach the transmission-to-isolator mounting plate
Reversing Light Switch
from the transmission, remove the nuts from the
two mounting bolts numbered (3).
Removal
1. Disconnect the wiring plug and remove the switch
from the left hand side of the case with a 22 mm
socket.
Installation
1. Clean the threads of the switch and apply pipe
sealant with Teflon to the threads.
2. Install the switch and torque to specification.
Transmission Cross - Member
Removal
1. Raise the vehicle on a hoist and support the
transmission on a trolley jack.
2. Remove the four cross-member to chassis
mounting bolts.
3. Unscrew the isolator-to-cross member mounting
Item
Description
nut (numbered (6)) from the bolt numbered (2) in
1
Isolator-to-Cross Member Bracket
the figure below, together with the two bolts
2
Bolt - (M10x89) Wafer HD
numbered (5).
3
Bolt - (M8x46)x2 Wafer HD
4. Remove and disassemble the cross
4
Insulator Element
member-to-isolator assembly.
5
Nut - (M10x1.25)
6
Bolt - (M10x1.5x25)x2
7
Screw - (M10x50)x4 (Trilobial)
8
Transmission Cross Member
9
Transmission-to-Isolator Mounting Plate
10
Nut - (M8x1.25)
Installation
1. Position the transmission-to-isolator mounting
plate in the orientation shown and attach it to the
transmission by installing the two mounting bolts
numbered (3) and mating nuts (numbered (10)).
Torque nuts to specification.
NOTE: Ensure that the isolator to cross-member
bolt (numbered (2)) is installed in the mounting
plate before affixing it to the transmission.
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308-03a-16
Manual Transmission — I6
308-03a-16
REMOVAL AND INSTALLATION (Continued)
2. Assemble the cross member isolator assembly
and attach it to the transmission isolator mounting
plate.
3. Install the two screws numbered (5) and attach
the nut numbered (6). Torque all screws and nuts
to specification.
4. Using a transmission jack, ensure that the
transmission cross member is aligned with the
mounting points on the underside of the chassis.
5. Install the two cross-member-to-chassis mounting
screws (numbered (7)). Torque screws to
specification.
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308-03a-17
Manual Transmission — I6
308-03a-17
REMOVAL
Special Service Tools
WARNING: Failure to match marks when
re assembling the driveshaft may induce
Tool Number
Description
driveline vibration.
T40
Torx Bit (Countershaft)
NOTE: Before disassembly, mark the matching
E1673U15A
Puller Adaptor (Use with
points on the slip yoke and transmission output
E1673P or E1673MT)
shaft. Mark the mating points on the CV flange,
companion flange, nut and balance nut (if fitted).
T50
Torx Bit (Pivot Pin)
Re-assemble with matching points matched
± 1
E9319
Snap Ring
spline, and all mating hardware in original hole.
Expander/Installer
8. Bleed the concentric slave cylinder (CSC)
E9320
Input Shaft Seal Installer
according to the procedure set out in section
Kit
308-01. Disconnect the CSC hydraulic clutch line
E9318
Countershaft Bearing
from the firewall.
Cup
Remover/Installer
WARNING: Failure to support CSC
connector during tightening or loosening of
E7518B
Bearing Installation Tool
bleed screw may result in damage to CSC.
(Countershaft)
Attachment for E7511-A
9. Remove the starter motor bolts and remove the
Handle
motor.
E9322
Dial Indicator Mounting
10. Support the engine and transmission assembly
Rod
with a transmission jack.
E1673P or E1673MT
Puller (Use with
11. Remove the bolts securing the transmission
E1673U15A)
cross-member to the body.
E7511A
Countershaft Bearing
12. Lower the transmission jack until the rear of the
Installer (Handle)
engine rests against the bulkhead.
E9321
Extension Housing
13. Disconnect the reversing light switch and, where
necessary, the speedometer transducer.
T30
Torx Bit (CSC)
14. The engine must be tilted down at the
Transmission
transmission and before removing the flywheel
housing-to-engine bolts. Raise the vehicle’s
Removal
bonnet before tilting the engine or else the bonnet
1. Unclip the console cover to access the gear
may be damaged. The engine can be tilted by
shifter prior to removing the gearshift boot,
either:
insulating foam and lever.
1. jacking up the front end or
2. From inside the vehicle, remove the gearshift
2. using a harness to pull down the rear of the
boot, insulating foam and lever.
motor.
3. Raise the vehicle on a hoist.
15. Remove the flywheel housing-to-engine bolts.
4. The exhaust should be removed from the outlet
WARNING: Do not seperate transmission
manifold and unbolted from the vehicle.
from vehicle engine by removing the 4
5. Detach the exhaust from the hanger bracket on
transmission case bolts.
the transmission damper.
6. After removing the exhaust, drain the clutch
reservoir of all fluid into a container. This is to
stop any change of the fluid dripping on to the
exhaust when it is re-installed into the vehicle.
7. Mark the driveshaft so that it may be installed in
the same relative position.
Disconnect the shaft at the centre bearing mount,
by detaching the centre bearing bracket from the
centre bearing carrier (cross member) and detach
the rear CV joint from the diff pinion companion
flange, by undoing the bolts. Slide the driveshaft
backwards, until the slip yoke slides off the output
shaft. Install a dust cover or extension housing
seal replacer into the extension housing to
prevent lubricant leakage.
G34518 en
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