Ford Falcon. Manual — part 264

308-03a-18

Manual Transmission — I6

308-03a-18

REMOVAL (Continued)

16. Move the transmission rearward until the input

shaft clears the pressure plate housing, then

lower the jack and remove the transmission.
NOTE: Removal of transmission from vehicle is

easier if the front of the engine is jacked up

carefully to tilt the transmission down at the rear.

Item

Description

1

Bolt (M8) x2

2

Bolt (M10x50) x4

3 Screw

(M10x50) x4 (Trilobial)

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308-03a-19

Manual Transmission — I6

308-03a-19

INSTALLATION

the markings on the CV joint and companion

Transmission

flange mate up.

Finally, bolt the centre-bearing bracket to the

Installation

centre-bearing cross member. Torque all bolts to

1. Place the transmission on a transmission jack.

specification. Ensure any shims are re-used in

NOTE: The CSC, CSC hydraulic line,

original location.

transmission damper and transmission cross

13. Attach the exhaust to the mounting bracket on the

member must be attached to the transmission

transmission damper, via the rubber isolator.

before installation can proceed.

14. Connect the exhaust to the outlet manifold. The

2. The engine must be tilted down before the

exhaust should not be fitted prior to the CSC

transmission can be moved into position. Raise

being reconnected and bled otherwise brake fluid

the vehicle’s bonnet before tilting the engine. The

will drip down onto the catalyst converter.

engine can be tilted by either:

15. Lower the vehicle.

1. jacking up the front end or

16. From inside the vehicle, install the gearshift lever,

2. using a harness to pull down the rear of the

insulator foam and boot.

motor.

3. Using a jack, raise the transmission and move it

forward until the flywheel housing locates on the

engine guide pins, ensuring that the spline on the

input shaft slides through the hub on the clutch

disc and the end of the shaft locates in the spigot

(pilot) bearing in the crankshaft.
NO T E : Installation of transmission

into the vehicle

is easier if the front of the engine is jacked up

carefully to tilt the transmission down at the rear.

4. Install the flywheel housing to engine bolts.

Torque all bolts to specification.

5. Connect the wiring to the reversing light switch

and, where necessary, the speedometer

transducer.

6. Install the starter motor and mounting bolts.

Torque to specification.

7. Raise the transmission using the jack until the

transmission cross member rests against the

chassis.

8. Install the bolts securing the transmission cross

member to the chassis. Torque to specification.

9. Remove the transmission jack.
10. Attach the CSC hydraulic clutch line to the firewall

and charge the clutch system with fluid according

to the procedure set out in Section 308-01.

11. Remove any contaminants from the driveshaft slip

yoke’s working surface before re-installing it into

the transmission extension housing.
NOTE: During installation of the driveshaft into

transmission, plunge the slip yoke the minimum

distance into the extension housing to avoid slip

yoke radius damaging oil seal.

12. Install the driveshaft. Ensure that the markings on

the transmission output shaft and slip yoke line

up, before sliding the slip yoke over the

output shaft and that the centre bearing bracket

mates up with the centre bearing cross member.

Once the driveshaft is connected to the

transmission, bolt the rear CV joint to the

differential pinion companion flange, ensuring that

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308-03a-20

Manual Transmission/Transaxle — I6

308-03a-20

DISASSEMBLY

4. Using a 12-mm double-hex head socket remove

Transmission

the four main case-to-flywheel housing bolts and

detach the transmission from the flywheel

Disassembly

housing.

1. Mount the transmission (with flywheel housing

attached) in a bench-mounted holding fixture or

equivalent.

2. Using a 3/8-inch drive ratchet and extension,

remove the drain plug located on the right hand

side of the transmission case.

3. Remove the CSC unit as Removal of Concentric

Slave Cylinder in Chapter Section 308-01.

Remove the four integral flywheel housing-to-main

case bolts located between the CSC mounting

bosses.

WARNING: Using an 11mm spanner,

restrain the steel female fitting in the CSC

whilst undoing the mating tube fitting to avoid

damaging the CSC

NOTE: The input shaft bearing carrier is integral

within the flywheel housing. Removal will result in

partial disassembly of the transmission main case.

5. Remount the transmission in the holding fixture.
6. Using a 13mm socket, position shift lever in

NEUTRAL position and remove turret cover

retaining bolts.

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308-03a-21

Manual Transmission/Transaxle — I6

308-03a-21

DISASSEMBLY (Continued)

7. Using a suitable pry bar, break turret

9. Using a 15mm socket, remove the eight extension

cover-to-extension housing seal by prying

housing retaining bolts.

carefully between housing and cover. Remove

turret cover.

CAUTION: Do not attempt to remove the

bonded offset lever while the extension

housing is bolted in place. A lug, located at

the bottom of the bonded offset lever, meshes

with the detent plate preventing enough

rearward movement of the bonded offset lever

to allow removal.

10. Using a suitable pry bar, break extension

housing-to-case seal by prying carefully between

housing and case.

8. Using a suitable pin punch and hammer, remove

roll pin retaining bonded offset lever to shifter

shaft.

11. Remove extension housing and bonded offset

lever as an assembly by sliding rearward away

from case.

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