Ford Falcon. Manual — part 265

308-03a-22

Manual Transmission/Transaxle — I6

308-03a-22

DISASSEMBLY (Continued)

12. Remove offset lever, roll pin, detent spring and

15. To remove shift cover, lift it slightly and slide to

detent ball from extension housing detent plate.

filler plug side of transmission. When shift

mechanism clears groove in fifth/reverse shift

lever, continue lifting cover.

13. Using a 10mm socket, remove shift cover

retaining bolts.

16. Support fifth/reverse shift rail assembly with a

block of wood and drive out roll pin from fifth gear

shift fork with a suitable pin punch.

14. Using a suitable pry bar, break cover-to-case seal

by prying carefully between cover and case.

17. Using snap ring pliers, remove fifth gear

synchronizer snap ring retainer, splined washer,

reverse cone and synchronizer blocking ring from

rear of countershaft.

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308-03a-23

Manual Transmission/Transaxle — I6

308-03a-23

DISASSEMBLY (Continued)

18. Remove fifth gear, synchronizer and shift fork as

22. Rotate fifth/reverse shift rail clockwise to

an assembly.

disengage ball stud from fifth/reverse shift lever.

Pull fifth/reverse shift rail rearward slightly and

rotate shift rail counter clockwise to align ball stud

with slot in case and remove shift rail.

19. Using long needlenose pliers, remove C-clip

retaining fifth/reverse shift lever to lever pivot pin.

23. Press downward on speedometer gear retaining

clip and slide gear off output shaft. Remove

retaining clip.

20. Remove fifth/reverse shift lever pivot pin with Torx

® bit driver. Do not remove the fifth/reverse shift

lever at this point.

21. Using a 22mm wrench, remove the backup lamp

24. Rotate input shaft until flat on 4th gear clutching

switch.

teeth aligns with countershaft. With input shaft

properly aligned, remove it from case.

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308-03a-24

Manual Transmission/Transaxle — I6

308-03a-24

DISASSEMBLY (Continued)

25. Remove fourth gear synchronizer blocking ring

28. Remove fifth/reverse shift lever, reverse shift fork

from the third/fourth synchronizer.

and reverse positioning spring from case by

NOTE: If the race sticks, it is probably misaligned

grasping lever and lifting straight up as an

in the case bore. To free the race, work the shaft

assembly. If case replacement is necessary,

back and forth in the case.

remove reverse positioning spring anchor pin by

removing the Tizz bushing from the anchor bolt

head and then removing the anchor bolt.

26. Remove output shaft bearing race from rear of

case. To partially remove bearing race, pull

29. Using a suitable pin punch and hammer, remove

rearward on output shaft until first gear stops

roll pin from reverse idler shaft.

against case.

30. Remove reverse idler shaft by sliding it out of

27. Tilt output shaft assembly upward and lift out of

back of case. Remove reverse idler gear and

case.

overtravel rubber stop from case.

NOTE: Observe location of shift lever, shift fork

and inhibitor spring prior to removal. Also observe

the rotation action of the reverse positioning

spring during removal. This will be helpful during

assembly.

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308-03a-25

Manual Transmission/Transaxle — I6

308-03a-25

DISASSEMBLY (Continued)

31. Using a hammer and Locknut Staking Tool flatten 34. Remove rear countershaft bearing race from

tabs on countershaft retainer at all four corners.

countershaft.
NOTE: If the race sticks, it is probably misaligned

in the case bore. To free the race, work the shaft

back and forth in case.

32. Using a T40 Torx® driver, remove four bolts from

countershaft retainer.

35. Install Front Hub Remover/Replacer and Bearing

Pulling Attachment or equivalent to the

countershaft with the jaws behind the countershaft

bearing, and remove bearing.

33. Remove countershaft retainer and shim(s).

36. Move countershaft rearward through bearing bore.

Tilt assembly upward and remove from case.

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