Ford Falcon. Manual — part 262
308-03a-10
Manual Transmission/Transaxle — I6
308-03a-10
GENERAL PROCEDURES
12. Inspect the synchronizer blocking rings for
Transmission Cleaning
widened index slots, rounded clutch teeth, and
1. Wash all parts except ball bearings, O-rings and
smooth internal surfaces (must have machined
seals in a suitable cleaning solvent. Brush or
grooves). With the synchronizer blocking ring on
scrape all foreign matter from the parts. Be careful
the cone, the distance between the face of the
not to damage any parts with the scraper.
synchronizer blocking ring and the clutch teeth on
the gear must not be less than 0.5mm (0.020
CAUTION: Do not clean, wash or soak
inch).
transmission seals in cleaning solvents. Dry
13. Replace speedometer drive gear (where fitted) if
all parts with compressed air.
teeth are stripped or damaged. Make certain to
2. Rotate ball bearings in a cleaning solvent until all
install correct size replacement gear.
lubricant is removed. Hold bearing assembly to
14. Replace the output shaft if there is any evidence
prevent it from rotating and dry it with compressed
of wear or if any of the splines are damaged.
air.
15. Inspect bushing and seal in the extension
3. Lubricate bearings with Multi-Purpose Grease and
housing, and replace if worn or damaged. The
wrap them in a clean, lint-free cloth or paper until
bushing and/or seal should be replaced after the
ready for use.
extension housing has been installed on the
4. Clean the magnet in the bottom of the case with
transmission.
kerosene or mineral spirits.
16. Replace the seal in the input shaft bearing
retainer.
Transmission Inspection
17. Replace seals on the cam and shafts.
1. Inspect transmission case for cracks, worn or
damaged bearing bores, damaged threads, or any
other damage that could affect operation of the
transmission.
2. Inspect the front face of the case for small nicks
or burrs that could cause misalignment of the
transmission with the flywheel housing. Remove
all small nicks or burrs with a fine file.
3. Replace any cover that is bent or distorted. Make
sure that the vent hole in the cover is open.
4. Check the condition of the shift levers, forks, shift
rails, and the lever and shafts.
5. Inspect the bearings. Refer to Bearing Inspection.
6. Replace roller bearings that are broken, worn or
rough, and check their respective races.
Aluminium Transmission Case Service
7. Replace the countershaft (cluster) gear if the teeth
NOTE: If an aluminum transmission case thread is
are chipped, broken or worn. Replace the
damaged, service kits may be purchased from local
countershaft if it is bent, scored or worn.
jobbers. To service a damaged thread, the following
8. Replace the reverse idler gear or sliding gear if
procedures should be carefully followed.
the teeth are chipped, worn or broken. Replace
the idler gear shaft if bent, worn or scored.
1. Drill out the damaged threads, using the same
drill size as the thread OD. For example, use a
9. Replace the input shaft and gear if the splines are
16mm drill for a M16x1.5 thread.
damaged or if the teeth are chipped, worn or
broken. If the roller bearing surface in the bore of
2. Select the proper special tap and tap the drilled
the gear is worn or rough, or if the cone surface is
hole. The tap is marked for the size of the thread
damaged, replace the gear and the gear rollers.
being serviced. Thus, the special tap marked
M16x1.5 will not cut the same thread as a
10. Replace all other gears that are chipped, broken
standard M16x1.5 tap. It does cut a thread large
or worn.
enough to accommodate the insert, and after the
11. Check the synchronizer sleeves for free
insert is installed the original thread size
movement on their hubs. Make sure that the
(M16x1.5) is restored.
alignment marks (if present) are properly indexed.
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308-03a-11
Manual Transmission/Transaxle — I6
308-03a-11
GENERAL PROCEDURES (Continued)
3. Select the proper coil inserting tool. These tools
3. Clean the plug, inspect the gasket condition and
are marked with the thread size being serviced.
replace where necessary.
Place the insert on the tool and adjust the sleeve
4. Install the plug.
to the length of the insert being used. Press the
insert against the face of the tapped hole. Turn
Drain and Refill Transmission
the tool clockwise and wind the insert into the
1. Clean the area around the drain and filler plugs.
hole until the insert is one-half turn below the
2. Remove the drain and filler plugs.
face.
3. Clean the drain and filler plugs. (Apply pipe
4. Working through the insert, bend the insert tang
sealant with Teflon to the plug threads.)
straight up and down until it breaks off at the
notch.
4. Install the drain plug.
5. Improperly installed inserts can be removed with
5. With the vehicle on a level surface fill the
the extractor tool. Place the extractor tool in the
transmission to the bottom of the filler plug hole
insert so that the blade rests against the top coil
with the specified transmission oil.
one-fourth to one-half turn away from the end of
6. Install the filler plug.
the coil. Tap the tool sharply with a hammer so
that the blade cuts into the insert. Exert downward
pressure on the tool and turn it counterclockwise
until the insert is removed.
These tools are marked with the thread size being
serviced. Place the insert on the tool and adjust
the sleeve to the length of the insert being used.
Press the insert against the face of the tapped
hole. Turn the tool clockwise and wind the insert
into the hole until the insert is onehalf turn below
the face.
Taper Roller Bearings Inspection
NOTE: It is recommended to replace all bearings
during a major overhaul of the gearbox. The cost of
removing and disassembling transmissions is too high
to run the risk of bearing damage after they have
been put back together.
1. If it is desired to reuse bearings, the cone
assembly must not be removed from the
component. The bearings should be inspected for
the following damage:
Discolouration of surfaces by heat.
Excessive pitting and bruising caused by
foreign material.
Etching or corrosion.
Spalls from fatigue of metal.
Scoring of roller ends due to inadequate
lubrication.
Damaged bearing cage.
Gauges or nicks on bearing surfaces.
NOTE: The bearing should be replaced as a unit. Do
not replace cup or cone assembly only.
Fluid Level Check
1. Clean around the filler plug and remove the plug.
2. If lubricant does not flow from the filler hole, fill the
case with the specified lubricant until it is level
with the bottom of the filler hole with vehicle in a
level position.
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308-03a-12
Manual Transmission — I6
308-03a-12
REMOVAL AND INSTALLATION
Removal
Rear Extension Housing Oil Seal
1. Remove driveshaft. Refer to Section 205-01.
Special Tool(s)
WARNING: Failure to match marks when
re-assembling the driveshaft may induce
Impact slide hammer
driveline vibration.
100-001
NOTE: Before dis-assembly, mark the matching
points on slip yoke and transmission output shaft.
Mark the mating points on bolt, yoke flange,
companion flange, nut and balance nut (if fitted).
Re-assemble with matching points matched
± 1
spline, and all mating hardware in original hole.
Seal remover
NOTE: Do not hang the driveshaft from the
307-365
transmission extension housing as this may
damage the extension housing oil seal and/or
bush.
2. Remove oil seal from extension housing with
impact slide hammer and seal remover.
Extension housing seal replacer
308-260 (E9321)
Installation
4. Remove any contaminants from the driveshaft slip
yoke’s working surface before re-installingit into
1. Lubricate extension housing oil seal bore by
the transmission extension housing.
wiping with approved lubricant.
NOTE: During installation of the driveshaft into
2. Using seal replacer, push oil seal into extension
transmission, plunge the slip yoke the minimum
housing flush of housing rear face.
distance into the extension housing to avoid slip
3. Lubricate oil seal lips with approved fluid.
yoke radius damaging oil seal.
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308-03a-13
Manual Transmission — I6
308-03a-13
REMOVAL AND INSTALLATION (Continued)
3. Working through the console aperture remove the
one bolt and one nut securing the shift lever to the
transmission and remove the lever.
WARNING: Failure to match marks when
re-assembling the driveshaft may induce driveline
vibration.
NOTE: Before dis-assembly, mark the matching
points on slip yoke and transmission output shaft.
Mark the mating points on bolt, yoke flange,
companion flange, nut and balance nut (if fitted).
Re-assemble with matching points matched
± 1
spline, and all mating hardware in original hole.
Shift Lever and Boot Assembly
Removal
1. Unscrew the gearshift knob from the gear lever.
2. Gently prise the boot retaining panel from the
console and lift the boot and retainer from the
lever. For more information refer to Manual
Transmission Ecternal Control 308-06.
Item
Description
1
Lever Knob
2
Lever Locator
3
Bolt
4
Nut
5
Transmission Stalk Sleeve
6
Plate
7
Bolt Locator (with bolt stud)
8
Nut
9
Shift Lever
10
Boot Assembly
Installation
1. Position the shift lever on the left hand side of the
transmission lever, install and torque the bolts to
specification.
2. Push yellow
foam block down firmly over lever join
to its home position. Make sure the "L" printed on
foam block faces passenger side.
3. Locate the boot and retainer over the shift lever
and press the retainer lugs into the console.
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