Ford Falcon. Manual — part 244

307-01-79 Automatic

Transmission 307-01-79

ASSEMBLY (Continued)

Extension Housing

Front Band

Assembly

Assembly

Extension Housing

1. Install the reaction anchor strut to the case.
2. Check the band for any cracks or damage along

1. Check the condition of the extension housing

its lining and metal backing.

bush, replace if necessary.

3. If fitting a new band, soak the band in automatic

2. Install a new seal to the extension housing.

transmission fluid for a minimum of 5 minutes

3. Position a new gasket to the extension housing.

prior to assembly.

NOTE: Do not use petroleum jelly to hold gasket

4. Install the front band into the transmission case

in position.

and ensure that it is properly seated in place.

4. Install the extension housing and torque the bolts 5. Position the reaction strut in its retaining clip and

to specification.

engage it with the band and anchor strut. Position

the apply strut in its retaining clip and engage it

Front Servo

with the band and the servo piston rod.

6. Band adjustment is to be backed off to aid

Assembly

installation of the clutch cylinder.

1. Lubricate the cover ‘O’ ring with automatic

transmission fluid and assemble to the cover.

C2/C4 Clutch

2. Lubricate the piston ‘O’ rings with automatic

transmission fluid and assemble to the piston.

Special Tool(s)

3. Fit the piston push rod assembly into the front

Clutch compression kit

servo cover ensuring that the ‘O’ ring

compression is adequate but not excessive.

4. Install the front servo assembly into the case.

Ensure that the cover ‘O’ ring compression is

adequate but not excessive.

5. Compress the servo cover and fit the servo cover

retaining circlip and ensure that it is completely

Clutch measuring kit 307-370

seated in its groove.

G73130 en

307-01-80 Automatic

Transmission 307-01-80

ASSEMBLY (Continued)

Assembly

12. Install the spring and spring retainer on the piston.

Using Tool 307-369 compress the spring until the

retaining circlip can be installed. Ensure that the

circlip is firmly seated in its groove and remove

the tool. The wire diameter of this spring is 5.26

mm.

13. Install the C2 wave washer in the cylinder with the

crest of one wave covering one of the bleed

orifices in the C2 piston.

14. Measure and record the thickness of the flange of

the C2 sleeve.

15. Install the C4 clutch plates and wave washer into

the C2 actuating sleeve, with the rounded edge of

the steel plates down, in the following sequence:

Steel plate

1. Check the C2 piston bleed orifices for obstruction.

Friction disc

Check the feed orifices in the cylinder bore.

Steel plate

2. Lubricate the ‘O’ rings with automatic

Friction disc

transmission fluid. Fit the small ‘O’ ring on the

Steel plate

inner groove and the large ‘O’ ring on the outer

groove of the piston. ‘O’ rings must not be twisted.

Friction disc

3. Check the C4 piston bleed orifices for obstruction.

Steel plate (selective)

Check the feed orifices in the cylinder bore.

Wave washer

4. Lubricate the ‘O’ rings with automatic

NOTE: Hold the cylinder horizontal and install the

transmission fluid and fit the small ‘O’ rings to the

sleeve and clutch plate assembly into the cylinder with

inner groove and the large ‘O’ rings to the outer

the crest of one wave of the washer in line with one of

groove of the piston.

the holes in the outside of the cylinder until the sleeve

5. Position the clutch cylinder with the C2/C4 cavity

contacts the C2 wave washer.

facing upwards.

16. Check the C4 clutch pack clearance using special

6. Fit the C4 piston into the C2 piston with the bleed

tool 307-370 as illustrated. Use selective plates to

orifices in alignment. Ensure that the C4 piston

achieve the correct specification. If new friction

outer ‘O’ ring compression is adequate but not

plates are being fitted, remove the clutch pack

excessive.

and soak the friction plates in ATF for a minimum

7. Install the C2/C4 piston assembly into the cylinder

of 5 minutes prior to reassembly. Clutch pack

with the piston bleed orifices aligned with the

clearance must be taken before the elements are

holes on the outside of the cylinder until the OD of

soaked in ATF. Reassemble the sleeve and clutch

the C2 piston enters the inner diameter of the

pack into the cylinder.

cylinder. Ensure the C2 piston outer ‘O’ ring

compression is adequate not excessive.

8. Assemble the piston return spring to the piston

and fit the spring retainer over the spring. The

wire diameter of this spring is 4.3 mm.

9. Using special tool 307-369 compress the spring

sufficiently to enable the installation of the

retaining circlip. Ensure that the circlip is firmly

seated in its groove and remove the tool.

10. Check the C1 piston check valves for correct

function and the cylinder feed orifices for

obstructions. Lubricate the ‘O’ rings with

petroleum jelly and fit to their respective grooves.

The ‘O’ rings must not be twisted in the grooves.

11. Position the cylinder with the C1 cavity upwards.

Install the piston into the cylinder until the OD of

the piston enters the inner diameter of the

cylinder.

G73130 en

307-01-81 Automatic

Transmission 307-01-81

ASSEMBLY (Continued)

C4 Clutch Pack Clearance

G73130 en

307-01-82 Automatic

Transmission 307-01-82

ASSEMBLY (Continued)

22. Align and fit the C4 hub to the C2 clutch and

C2 Clutch Pack Clearance

OWC assembly. Check the rotation of the C2 hub.

While holding the C4 hub, the C2 hub should

rotate in the clockwise direction and lockup in the

anti-clockwise direction when viewed from the C2

hub.

17. Fit the thrust plate over the inner hub.
18. Install the C2 clutch plates in the cylinder in the

following sequence.

Friction disc

23. Apply petroleum jelly to thrust bearing No. 5 and

Steel plate

fit it to the C4 hub.

Friction disc

24. Remove the C2 clutch plates from the clutch

Steel plate

cylinder.

Friction disc

25. Engage the C2/C4 clutch hub assembly in the C4

Steel plate (selective)

clutch plates.

Friction disc

26. Install the C2 clutch plates.

Steel plate (selective)

27. Install the C3 hub and secure it with the circlip.

Friction disc

Ensure that the circlip is firmly seated in its

groove.

19. Check the clutch pack clearance using the weight

only from tool 307-370 as illustrated. Use

selective plate to achieve the correct specification.

If new friction plates are being fitted, remove the

clutch pack and soak the friction plates in ATF for

a minimum of 5 minutes prior to reassembly.

Clutch pack clearance must be taken before the

elements are soaked in ATF.

20. Lubricate and fit the 3-4 OWC. Lubricate and fit

the C2 OWC and end caps to the C2 hub.

21. Align the tangs and fit the nylon thrust washer

onto the C4 hub as illustrated.

G73130 en