Ford Falcon. Manual — part 281

308-03b-38

Manual Transmission — TR3650

308-03b-38

DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued)

2. Using the special tool, install the main shift rail

3. Position the gearshift fork on the shift rail. Align

bearing.

the split pin hole and install a new split pin.

CAUTION: Support the shift rail to

prevent damage to the parts.

Gearshift Rail and Fork

Disassembly

4. Install the gear shift fork inserts.

1. Using a 5/32-inch drift and a hammer, remove

and discard the split pin. Slide the shift fork from

the shift rail.

2. Remove the gearshift fork inserts.

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308-03b-39

Manual Transmission — TR3650

308-03b-39

ASSEMBLY

NOTE: If a new rear output shaft bearing was

Transmission

installed or a new rear countershaft bearing is being

used, install new bearing cups.

Special Tool(s)

3. Install the rear countershaft bearing cup and the

Dial Indicator Gauge with

rear output shaft bearing cup.

Holding Fixture

Lubricate the bearing cups and the shift rail

100-002 (TOOL-4201-C) or

bearing with petroleum jelly.

equivalent

Holding Fixture, Transmission

307-003 (T57L-500-B)

Remover/Installer, Bearing

Tube

308-024 (T75L-7025-B)

4. Install the rear countershaft bearing.

Replacer/Adapter

308-239 (T96P-7025-A)

Installer, Transmission

Extension Housing Oil Seal

5. Install the reverse idler gear bearings and spacer

on the shaft.

1. Lubricate all components with transmission fluid

during assembly.

2. Attach the clutch housing to the special tool.

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308-03b-40

Manual Transmission — TR3650

308-03b-40

ASSEMBLY (Continued)

9. Install the front input shaft bearing cup and the

6. Install the reverse idler gear on the shaft.

front countershaft bearing cup. Do not install the

shims at this time.

Install the transmission main case.

7. Install the reverse idler gear into the case.

10. Install the input shaft.

8. Install a new seal on the reverse idler bolt, then

install the bolt in the transmission case.

11. Install the shift rails and shift forks on the

mainshaft.

NOTE: If a new front input shaft bearing or front

countershaft bearing was installed, install new bearing

cups.

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308-03b-41

Manual Transmission — TR3650

308-03b-41

ASSEMBLY (Continued)

14. Install the case with two opposing bolts.

12. Install the mainshaft onto the clutch housing.

The notches on the shift rail should be

pointing upward.
Align the shift rails in the bores.

15. Using a dial indicator gauge, measure the input

shaft end play by applying an upward load on the

output shaft. Record the measurement.
NOTE: Rotate the transmission so that the input

shaft is pointing upward.
NOTE: Rotate the input shaft to seat the bearings.

13. Install the countershaft.

Lift the mainshaft upward, tilt the countershaft

and install.

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