Ford Falcon. Manual — part 269

308-03a-38

Manual Transmission — I6

308-03a-38

DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued)

3. Pull shifter shaft out of cover using a twisting

Assembly

motion.

1. Install a new O-ring seal.

2. If disassembled, assemble the shift forks, selector

arm plates and nylon inserts.

WARNING: Do not assemble the 3-4 shift

fork black nylon inserts or the selector arm

plate onto 1-2 shift fork.
NOTE: The narrow side of the C-shaped selector

interlock plate has to be positioned in the shift

cover slot. The control selector arm roll pin hole

has to be toward the rear of the cover.

4. Remove shift forks, roll pin and shift interlock from

shift cover.

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308-03a-39

Manual Transmission — I6

308-03a-39

DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued)

3. Install control selector arm and selector interlock

plate as an assembly.

CAUTION: Ensure the roll pin is installed

slightly below the selector arm surface. Failure to

4. Position shift forks in cover. Lubricate shifter shaft

countersink the roll pin may result in interference

with petroleum jelly. Slide shaft through shift cover

between the pin and the interlock plate during

and shift components until it stops against the

shifts.

front of the cover.
NOTE: The 1-2 shift fork is the larger fork. The

shift fork offset is to face the rear of the cover.

The 3-4 gear shift selector arm plate is to be

positioned under the 1-2 gearshift selector arm

plate.
NOTE: If on disassembly, the shifter shaft is

burred or nicked, remove to prevent damage to

the bush coating.

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308-03a-40

Manual Transmission — I6

308-03a-40

DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued)

5. Align the hole in shifter shaft and the control

2. Install end play shim and bearing race.

selector arm to install the roll pin using a 5mm

NOTE: If seal is being replaced as a part of a

(3/16-inch) pin punch.

transmission overhaul, do not install the end play

shim.

Bearing Retainer Seal — Front

Disassembly
1. Detach flywheel from transmission main case and

remove the end play shim.

2. Using a screwdriver, carefully pry seal from

flywheel housing.

Assembly
1. Using Differential Side Bearing Replacer install

new seal.

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308-03a-41

Manual Transmission — I6

308-03a-41

ASSEMBLY

3. Using a press and Cluster Gear Bearing installer

Transmission

and Remover Tube install countershaft rear

bearing to countershaft.

Assembly
1. Using a press, install front countershaft bearing

onto countershaft using Pinion Bearing Cone

Replacer.

4. Install rear countershaft bearing race onto

countershaft.

2. Position countershaft in case.

CAUTION: Failure to properly support the

countershaft can result in permanent

distortion of the case during bearing

installation.
NOTE: Support the countershaft using two pieces

of 7mm (1/4 inch) bar stock.

5. Install countershaft bearing retainer to

transmission housing with four 13mm bolts.
NOTE: This should be done initially without any

shims installed. Tighten bolts to 15-27 Nm (11-20

lb-ft).

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