Ford Falcon. Manual — part 260

308-03a-2

Manual Transmission — I6

308-03a-2

(Continued)

Synchronizers . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...308-03a-36

Shift Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 308-03a-37

Bearing Retainer Seal — Front . . . . . . . . . . . . . . . . . . . . . . .308-03a-40

ASSEMBLY

Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .308-03a-41

308-03a-3

Manual Transmission — I6

308-03a-3

SPECIFICATIONS

General Specifications

Description

Nm

Gear Ratios

CSC to Pipe Fitting

14

XR6 T

I6 & XR6

CSC Bleed Screw

8

First

2.95:1

3.35:1

Case to Flywheel Housing (retainer M8

21

bolts)

Second

1.94:1

1.92:1

Case to Flywheel Housing (M12)

75

Third

1.34:1

1.29:1

Fourth

1.00:1

1.00:1

Fifth

0.73:1

0.72:1

Reverse

2.76:1

3.15:1

Specified Clearances

Component

Specification (mm)

Preload output shaft

0.01-0.1

1st Gear

0.18-0.33

2nd Gear

0.23-0.66

3rd Gear

0.23-0.58

5th Gear

0.13-0.86

Cluster shaft

0.013-0.102

Lubricant

I6 & XR6

XR6 T

Capacity

2.2 litre

Specification

ESR-M2C-163A CASTROL

(DEXRON II)

SYNTRANS B

(Ford R1-36)

2.05 litre

Oil Additive

LubrizoI 7906

N/A

(150 ml)

Shift Turret

Colour

Type

Vehicle

Black

Standard throw

All I6 except

XR6 T

Gold

Short throw

XR6 T

Tightening Torques

Description

Nm

Lower Boot Retainer

2

Shift Lever Bolts

37

Reversing Light Switch

37

Insulator to Extension Housing

50

Insulator to Crossmember

50

Crossmember to Body

50

Muffler Inlet Pipe Flange

35

Filler Plug

35

Extension Housing to Case

50

Reverse Spring Anchor Bolt

35

Flywheel Housing to Engine

65

Shift Lever Pivot Pin to Case

45

Shift Cover

10

Shift Turret to Ext. Housing

27

CSC to Flywheel Housing

9

G34500 en

308-03a-4

Manual Transmission — I6

308-03a-4

DESCRIPTION AND OPERATION

Manual Transmission

Manual Transmission

Three variants of the BTR T5 (M57) transmission are

used on the 6-cylinder BA Falcon range. The ABS &

non ABS standard I6 transmission models use a carry

over gearset (except for input shaft) and a standard

throw shifter turret is used. On the ABS model, the

speedo gear/tranducer ass’y is no longer required

and the signal is via the ABS sensor

s. The XR6 Turbo

model features a heavy-duty gearset, a short throw

shifter turret and a high performance transmission

lubricant.
On all BA 6-cylinder models the flywheel/clutch

housing incorporates the input bearing retainer into

the housing casting. A Concentric Slave Cylinder

(CSC) is mounted and bolted to the flywheel housing

supports. On the shifter turret, the gear shift lever bolt

mounting arrangement has been revised for all

models.
The M57 is a 5-speed manual transmission with 5th

speed as an overdrive gear. The 1st through 4th

gears and reverse gear are meshed within the case.

The 5th speed gear and synchronizer are located on

the back of the case in the extension housing where

the reverse brake is installed. The floor mounted shift

lever operates a shift rail which extends from the

extension housing turret to the shift cover. The

1st/2nd and 3rd/4th shift forks are mounted in the

cover. The 5th speed synchronizer and reverse sliding

gear are shifted through an intermediate lever

mounted on a pivot pin.

G34501 en

308-03a-5

Manual Transmission — I6

308-03a-5

DESCRIPTION AND OPERATION (Continued)

Item

Description

Item

Description

5

Boot

1

Plug, Fill/Drain

6

Vent Cap

2

Screw

7

Vent & O-Ring Assy.

3

Control Lever & Housing Assy.

G34501 en