Ford Falcon. Manual — part 245

307-01-83 Automatic

Transmission 307-01-83

ASSEMBLY (Continued)

5. Align the C3 piston in the cylinder until the OD of

C3 Clutch, Reverse Sun Gear &

the piston enters the inside diameter of the

Forward Sun Gear Assembly

cylinder. Ensure that the piston ‘O’ ring

compression is adequate but not excessive.

Special Tool(s)

Assemble the spring and spring retainer on the

piston. Using tool 307-369 compress the spring

Clutch Compression Kit

sufficiently to enable the installation of the

retaining circlip. Ensure that the circlip is firmly

seated in the groove and remove the tool.

Fit the C3 wave plate to the C3 piston face with

one crest of the wave plate directly over one of

the piston orifices. Assemble the clutch plates and

discs into the cylinder in the following sequence:

Clutch Measuring Kit

1. Steel plate outer.

2. Friction disc inner.

3. Steel plate outer.

4. Friction disc inner.

5. Steel plate outer.

6. Friction disc inner.

Assembly

7. Steel plate outer.

C3 Clutch and Reverse Sun Gear

8. Friction disc inner.

Align and fit the pressure plate with the

counterbore facing away from the clutch

plates. Install the circlip.

6. Check the clutch clearance using special tool

307-370 in the following manner:

Forward sun gear and C3 clutch assembly

1. Check the orifices in the cylinder are clear. Check

the C3 cylinder bush outside diameter against the

centre support inside diameter. Coat the sealing

rings with automatic transmission fluid and fit into

the C3 cylinder grooves.

2. Check the reverse sun gear splines, grooves and

thrust face for condition. Coat the ‘O’ ring with

automatic transmission fluid and fit it to the groove 1. (weight only) Place the weight on the

and the reverse sun gear.

pressure plate and measure the distance from

3. Install the reverse sun gear in the C3 cylinder.

the end of the cylinder to the top of the

Ensure that the ‘O’ ring compression is adequate

pressure plate. Record this figure.

but not excessive.

2.

Remove

the

weight.

4. Coat the C3 piston ‘O’ rings with automatic

3. Lift the pressure plate up against the circlip

transmission fluid and fit the small ‘O’ ring to the

and measure the distance from the end of the

inner ring and the large ‘O’ ring to the outer ring of

cylinder to the top of the pressure plate.

the C3 piston. ‘O’ rings must not be twisted in

Record this figure.

grooves. Check that the bleed orifices of the

4. Subtract the second reading from the first

piston are clear.

reading to obtain the clutch pack clearance.

5. If new friction plates are being fitted, remove

the clutch pack and soak the friction elements

G73131 en

307-01-84 Automatic

Transmission 307-01-84

ASSEMBLY (Continued)

in automatic transmission fluid for a minimum

of five minutes prior to reassembly.

6. Clutch pack clearance must be taken before

the elements are soaked in automatic

transmission fluid.

7. Lubricate the needle thrust bearing assembly

No. 7 with petroleum jelly and fit the bearing

over the forward sun gear, thrust washer face

to gear.

8. Align and fit the C3 clutch assembly over the

forward sun gear.

9. Fit the thrust plate securely over the reverse

sun gear.

10. Lubricate the needle thrust bearing No. 6 with

petroleum jelly and fit it to the thrust plate.

Ensure the lugs on the OD of the bearing fit in

the thrust plate counterbore.

11. Align and fit the plastic thrust washer to the

thrust plate with petroleum jelly as illustrated.

Install the assembly over the foward sun gear

shaft against the No. 6 thrust bearing.

12. Place assembly to one side.

C3 Clutch Assembly Clearance

G73131 en

307-01-85 Automatic

Transmission 307-01-85

ASSEMBLY (Continued)

C1 Clutch Overdrive Shaft & Input

C1 Clutch Assembly Clearance

Shaft

Special Tool(s)

Clutch Measuring Kit

Assembly
1. Check the overdrive shaft grooves for any defect.
2. Coat the sealing rings, large and small, with

petroleum jelly and fit them to the overdrive shaft.

The sealing rings may be held in place with a

small amount of petroleum jelly.

3. Assemble the clutch plate and disc into the

cylinder in the following sequence:

1. Steel plate outer.

2. Friction disc inner.

3. Steel plate outer.

4. Friction disc inner.

5. Steel plate outer.

6. Friction disc inner.

7. Steel plate outer (selective).

8. Friction disc inner.

9. Steel plate outer (selective).

5. Check the fit of the C1 clutch hub on the overdrive

shaft. If it is loose, the hub and shaft assembly

10. Friction disc inner.

must be replaced.

4. Check the clutch pack clearance using special

6. Coat the small nylon thrust spacer with petroleum

tool 307-370. Use selective plates to achieve the

jelly and install it into the cylinder hub.

correct specification. If new friction plates are

being fitted, remove the clutch pack and soak the 7. Carefully fit the overdrive shaft into the C1

friction elements in automatic transmission fluid

cylinder so as not to damage the sealing ring.

for a minimum of five minutes prior to assembly.

8. Fit the small bronze C1 hub thrust washer in

Clutch pack clearance must be taken before

place with petroleum jelly.

elements are soaked in automatic transmission

9. Check the input shaft for any defect. Fit the input

fluid.

shaft into the cylinder and secure it with the

circlip. Ensure the circlip is completely seated in

the groove

10. Coat the front and rear sealing rings and the outer

‘O’ ring with petroleum jelly and fit the input shaft.

11. Assemble the C1/C2/C4 clutch assembly to the

C3 clutch and sun gear assembly.

12. Install thrust bearing No. 8 onto the overdrive

shaft with spigot into the forward sun gear.

13. Install this assembly in the transmission case.

G73133 en

307-01-86 Automatic

Transmission 307-01-86

ASSEMBLY (Continued)

Clutch

C1, C4, C2 Clutch

C1, C4, C2, C3 Clutch

G73133 en