Ford Falcon. Manual — part 270

308-03a-42

Manual Transmission — I6

308-03a-42

ASSEMBLY (Continued)

6. Measure end play using Dial Indicator with

9. If removed, apply Pipe Sealant with Teflon ® to

Bracketry. Remove retainer and install necessary

reverse positioning spring anchor pin threads.

shim(s) between countershaft retainer and rear

Install anchor pin and tighten to 8-15 Nm (6-11

countershaft bearing race. Verify end play is

lb-ft). Install Tizz bushing over anchor pin head by

within 0.013-0.102mm. After installing

tapping lightly into position with hammer.

countershaft retainer and shims, bend tabs on

10. Align fifth/reverse shift lever, reverse shift fork and

retainer over the four attaching bolts.

reverse positioning spring as shown.

7. Position reverse idler gear in case with shift lever

11. Lower assembly into case and install looped end

groove facing rear of case. Install reverse idler

of reverse positioning spring onto anchor pin.

shaft and rubber overtravel stop.

Install shaft from rear of case and position

overtravel stop between gear and shaft support.

12. Position reverse idler gear into the NEUTRAL

position and align reverse shift fork onto reverse

idler gear. Once aligned, push downward on shift

8. Using a 5mm (3/16-inch) pin punch, install

fork until fully engaged into reverse idler gear.

reverse idler shaft roll pin.

NOTE: Observe reverse positioning spring

rotation. Reverse positioning spring should rotate

counter clockwise into its installed position.

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308-03a-43

Manual Transmission — I6

308-03a-43

ASSEMBLY (Continued)

13. Install output shaft assembly.

16. Install fifth/reverse shift rail into transmission case

by aligning ball stud with slot in case and aligning

shift rail with reverse shift fork. Once ball stud

enters case, rotate shift rail clockwise and push in

shift rail until ball aligns with fifth/reverse shift

lever. Rotate shift rail counterclockwise until ball

stud fully engages shift lever.

14. Align notches in synchronizer blocking ring with

inserts in 3-4 synchronizer and install

synchronizer blocking ring.

17. Install fifth gear, synchronizer and shift fork as an

assembly.

15. Install output shaft rear bearing race. If necessary,

tap bearing race into position using a plastic

tipped hammer.

18. Install fifth gear synchronizer blocking ring,

Reverse Cone, spacer and snap ring.
NOTE: Ensure tabs on spacer engage splines of

countershaft and the tab on the reverse cone is at

the 12 o’clock position to assist when installing

the extension housing.

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308-03a-44

Manual Transmission — I6

308-03a-44

ASSEMBLY (Continued)

NOTE: Ensure lubrication funnel engages into end of

21. Install speedometer gear.

countershaft gear. Before installing the pivot pin,

NOTE: The tab on the retainer clip engages a

ensure the shift rail ball stud is fully engaged with the

hole in the output shaft.

shift lever.

19. Apply Pipe Sealant with Teflon ® to the pivot pin

threads and install the fifth/reverse shift lever pivot

pin.

Tighten pivot pin to 34-47 Nm (25-35 lb-ft) using a

T50 Torx ® driver. Apply Pipe Sealant with Teflon

® to the reverse light switch and install using a

22mm socket. Tighten to 27-47 Nm (20-35 lb-ft).

CAUTION: Do not apply silicone sealer to top

of transmission case surface under any

circumstances, as sealant could fall into

transmission and affect operation.
22. Apply 3.2mm (1/8-inch) bead of Silicone Sealer

RTV Silastic 1080 or equivalent to shift cover

assembly.

Position cover to filler plug side of transmission

and lower into position until shift forks engage

synchronizers. Continue lowering cover and move

into position to engage fifth/reverse shift lever.
NOTE: Ensure all synchronizers are in the

NEUTRAL position and that the shift forks in the

cover are in the NEUTRAL position.

23. Install shift cover retaining bolts. Tighten cover

retaining bolts to 8-11 Nm.

20. Using needlenose pliers, install C-clip on shift

lever pivot pin.

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308-03a-45

Manual Transmission — I6

308-03a-45

ASSEMBLY (Continued)

24. Apply a 3.2mm (1/8-inch) bead of Silicon Sealer

27. Press downward on bonded offset lever to

RTV Silastic 1080 or equivalent on the extension

compress detent spring and push lever and

housing mating surface. Apply Silicone Sealer

housing into position. Ensure the reverse cone tag

RTV Silastic 1080 or equivalent to the lubrication

is engaged in the recess in the housing.

funnel and install funnel into countershaft gear.

28. Install extension housing retaining bolts. Tighten

25. Coat detent spring with petroleum jelly and install

to 47- 61 Nm (30-45 lb-ft).

in offset lever. Lubricate detent plate and install

detent ball in neutral position on plate. Position

bonded offset lever in extension housing with

spring over detent ball.

26. Slide lever and extension housing into position as

an assembly.

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