Ford Falcon. Manual — part 272

308-03b-2

Manual Transmission — TR3650

308-03b-2

SPECIFICATIONS

General Specifications

Description

Nm

Description

Specification

Driveshaft flange to pinion flange bolt

112

Inspection Standards and Tolerances
Synchronizer blocking

0.5 mm

ring to conical face

runout
Assembly Standards
Input shaft end play

0.023 mm –

0.051 mm

Countershaft cluster gear

0.0 mm –

end play

0.076 mm

Output shaft end play

0.025 mm –

0.051 mm

Lubricant/Adhesive/Cleaner Specifications
Premium Long-Life

ESA-M1C75-B

Grease

XG-1-C, K or T
Threadlock and Sealer

WSK-M2G351-A5

E0AZ-19554-AA
Black Silicone Rubber

ESB-M4G92-A

D6AZ-19562-BA
Pipe Sealant with

ESR-M18P7-A

Teflon®

D8AZ-19554-A
Stnthetict MERCON®

MOBIL 1 SYNTHETIC

(ATF) Transmission Fluid

ATF (Dextron III ATF

E6AZ-19582-B

Alternative)

Lubricant Refill Capacities
Stnthetict MERCON®

3.8L (8.0 pt)

(ATF) Transmission Fluid

E6AZ-19582-B

Torque Specifications

Description

Nm

Gearshift lever to extension housing

25-40

bolt
Gear shift lever to gear shift stub shaft

37

bolt
OSS to case bolt

10

Reverse idler gear bolt

20-35

Fifth/reverse lockout bolt

20-35

Clutch housing to transmission main

25-40

case bolt
Extension housing to transmission

25-40

main case bolt
Drain plug

20-35

Reversing lamp switch

20-35

Fill plug

20-35

Transmission to engine bolt

75

Engine plate to transmission bolt

27

Crossmember to frame bolt

41

Crossmember to transmission support

58

bolt

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Manual Transmission — TR3650

308-03b-3

DESCRIPTION AND OPERATION

Manual Transmission

The TR3650 five-speed manual transmission features

the following:

The fifth speed gear functions as an overdrive

gear.
The forward gears are synchronized and helical

cut.
The reverse gear operates through a

constant-mesh, fully synchronized system.
The shift interlock system prevents the

engagement of more than one gear.
The countershaft is serviced as an assembly.
An aluminum main case, extension housing and

bell housing.

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Manual Transmission — TR3650

308-03b-4

DESCRIPTION AND OPERATION (Continued)

Transmission Internal Components — Disassembled View

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Manual Transmission — TR3650

308-03b-5

DESCRIPTION AND OPERATION (Continued)

Item

Description

Item

Description

1

Input shaft seal

38

Reverse gear synchronizer hub (part of

7124)

2

Shim

39

Reverse gear synchronizer insert (part of

3

Input shaft front bearing and cup

7124)

4

Input shaft

40

Reverse gear synchronizer sleeve (part of

5

Input shaft pocket bearing

7124)

6

Input shaft thrust bearing

41

Retaining ring

7

Input shaft thrust washer

42

Reverse needle bearing

8

Retaining ring

43

Reverse driven gear

9

Third/fourth gear synchronizer assembly

44

Reverse gear bushing

10

Third/fourth gear synchronizer blocking

45

Selector gate

ring

46

Mainshaft rear bearing and cup

11

Third/fourth gear synchronizer spring (part

47

Mainshaft fifth gear

of 7124)

48

Retaining ring

12

Third/fourth gear synchronizer insert (part

of 7124)

49

Output shaft speed (OSS) sensor

13

Third/fourth gear synchronizer hub (part of

50

Retaining ring

7124)

51

Shim

14

Third/fourth gear synchronizer sleeve (part

52

Countershaft front bearing and cup

of 7124)

53

Countershaft

15

Third gear

54

Countershaft rear bearing and cup

16

Third gear needle bearing

55

Thrust bearing

17

Third gear bushing

56

Countershaft fifth gear

18

Check ball

57

Countershaft fifth gear needle bearing

19

Thrust washer

58

Countershaft fifth gear bearing spacer

20

Second gear needle bearing

59

Retaining ring

21

Second gear

60

Fifth gear synchronizer assembly

22

First/second gear synchronizer inner cone

61

Fifth gear synchronizer blocking ring

23

First/second gear synchronizer outer cone

62

Fifth gear synchronizer spring (part of

24

Output shaft

7124)

25

Retaining ring

63

Fifth gear synchronizer hub (part of 7124)

26

First/second gear synchronizer assembly

64

Fifth gear synchronizer insert (part of

27

First/second gear synchronizer blocking

7124)

ring

65

Fifth gear synchronizer sleeve (part of

28

First/second gear synchronizer spring (part

7124)

of 7124)

66

Fifth gear clutch cone

29

First/second gear synchronizer hub (part of

67

Retaining ring

7124)

68

Reverse idler gear support

30

First/second gear synchronizer insert (part

69

Reverse idler gear shaft

of 7124)

70

Reverse idler gear

31

First/second gear synchronizer sleeve

71

Reverse idler gear needle bearing

(part of 7124)

72

Reverse idler gear bearing spacer

32

First gear needle bearing

33

First gear

34

Reverse clutch cone

35

Reverse gear synchronizer assembly

36

Reverse gear synchronizer blocking ring

37

Reverse gear synchronizer spring (part of

7124)

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