1969 FORD MUSTANG manual transmission

06-03-08
Ford Design Four-Speed Transmission
06-03-08

ROLLER BEARINGS

SNAP RINGS

FIG. 14—Input Shaft Gear Disassembled
C1802-
A

Hardwood

Block

Tool-7025-G

OR
7025-B

Detail
5

REMOVAL

FIG. 15—Replacing Input Shaft Bearing

INSERT SPRING
INSTALLATION

ETCH MARKS
C2079-A

INSERT SPRING

SLEEVE
HUB

FIRST AND SECOND SPEED SYNCHRONIZER

INSERT

INSERT SPRING

INSERT
SLEEVE

INSERT SPRING

HUMP

THIRD
AND
FOURTH SPEED SYNCHRONIZER

FIG. 16—Synchronizers Disassembled
GROOVE
TO
FACE

TOWARD FRONT

OF TRANSMISSION

C2080.A
end play with
a
feeler gauge. End play

should
be
within specification.
If the

end play
is not
within limits, replace

the thrust washers.
If the end
play
is

within limits, leave
the
reverse idler

gear installed.

10.
Position
the
reverse gear shift

rail detent spring
and
detent plug
in

the case. Hold
the
reverse shift fork
in

place
on the
reverse idler sliding gear

and install
the
shift rail from
the
rear

of
the
case. Secure
the
fork
to the
rail

with
the
Allen head
set
screw.

11.
Install
the
first
and
second-

speed synchronizer onto
the
front
of

the output shaft (Fig.
11)
making sure

that
the
shift fork groove
is
toward

the rear
of the
shaft.
The
first
and

reverse synchronizer
hub is a
press
fit

on
the
output shaft.
To
eliminate
the

possibility
of
damaging
the
synchro-

nizer assembly, install
the
synchroniz-

er
hub
with
the
teeth
end of the
gear

facing toward
the
rear
of the
shaft,

using
an
arbor press
as
shown
in
Part

6-2,
Fig. 20. Do not
attempt
to re-

move
or
install
the
hub
by
hammering

or prying.

12.
Position
the
blocking ring
on

the second-speed gear.

13.
Slide
the
second-speed gear

onto
the
front
of the
shaft, making

sure that
the
inserts
in the
synchroniz-

er engage
the
notches
in the
blocker

ring.

14.
Install
the
second-speed gear

thrust washer
and
snap ring.

15.
Slide
the
third-speed gear onto

the shaft with
the
synchronizer coned

surface toward
the
front.

16.
Place
a
blocking ring
on the

third-speed gear.

17.
Slide
the
third
and
fourth-

speed gear synchronizer onto
the
shaft

making sure that
the
inserts
in the

synchronizer engage
the
notches
in the

blocking ring.

18.
Install
the
snap ring
on the

front
of the
output shaft.

19.
Position
the
blocking ring
on

the first-speed gear.

20.
Slide
the
first-speed gear onto

the rear
of the
output shaft making

sure that
the
notches
in the
blocking

ring engage
the
synchronizer inserts.

21.
Install
the
heavy thrust washer

on
the
rear
of the
output shaft.

22.
Support
the
thrust washer
and

first-speed gear
to
prevent them from

sliding
off the
shaft
and
carefully

lower
the
output shaft assembly into

the.
case
as
shown
in Fig. 8.

23.
Position
the
first
and
second-

speed shift fork
and the
third
and

fourfh-speed shift fork
in
place
on

their respective gears
and
rotate them

into place.procarmanuals.com

06-03-09
Ford Design Four-Speed Transmission

06-03-09

24.
Place a detent plug (Fig. 5) in

the detent bore. Place the reverse shift

rail into neutral position.

25.
Coat the third and fourth-

speed shift rail interlock pin with

grease and position it in the shift rail.

26.
Align the third and fourth-

speed shift fork with the shift rail

bores and slide the shift rail into place

making sure that the three detents are

facing toward the outside of the case.

Place the front synchronizer into

third-speed position and install the set

screw in the third and fourth-speed

shift fork. Move the synchronizer to

the neutral position. Install the third

and fourth-speed shift rail detent plug,

spring and bolt in the left side of the

transmission case (Fig. 5). Place the

interlock plug (tapered ends) in the

detent case.

27.
Align the first and second-

speed shift fork with the case bores

and slide the shift rail into place. Se-

cure the fork with the set screw.

28.
Coat the input gear bore with a

thin film of grease, then install the 15

roller bearings in the bore. A thick

film of grease could plug the lubricant

holes and restrict lubrication of the

bearings.

29.
Position the front blocking ring

in the third and fourth-speed synchro-

nizer.

Place the input shaft gear in the

transmission case making sure that

the output shaft pilot enters the roller

bearings in the input gear.

30.
Place a new gasket on the input

shaft bearing retainer. Dip the attach-

ing bolts in sealer and install and

tighten them to specifications.

31.
Install the output shaft bearing

as shown in Fig. 21. Install the snap

ring to retain the bearing.

32.
On some transmissions, position

the speedometer gear iometer drive

gear retaining clip on the output shaft

with the lower tang in the retaining

hole.
Align the groove in the gear with

the clip and slide the gear forward

until the upper tang on the clip locks

the gear (Fig. 4).

33.
Place the transmission in a ver-

tical position as shown in Fig. 22.

Align the countershaft gear bore and

thrust washers with the bore in the

case.
Install the countershaft.

34.
Use a new gasket and secure

the extension housing to the case with

the attaching screws. Use a sealer on

the extension housing attaching

screws. Torque the screws to specifica-

tions.

35.
Install the filler plug and drain

plug (if so equipped) in the case if

they were removed. Make sure that
COUNTIERSHAFT

7111

RETAINER WASHER

378559 • S

THRUST WASHER -7119

THRUST

WASHER

7119
ROLLER BEARINGS- 7121(21)

COUNTERSHAFT GEAR - 7113

ROLLER BEARINGS'7121(21)

RETAINER

WASHER

378559 • S

FIG. 17—Countershaft Gear Disassembled
C2081-A

REVERSE IDLER

GEAR SHAFT

7140

ROLLER BEARINGS

7D271 22)

THRUST WASHER

7149

RETAINER

WASHER

351529 - S

REVERSE IDLER GEAR -7142

'REVERSE SLIDING GEAR • 7D223

•THRUST WASHER • 7149

FIG. 78—Reverse Idler Gear Disassembled
C2082-A

the magnetic plug (if so equipped) is

installed in the bottom of the case.

36.
Pour the specified lubricant

over the entire gear train while rotat-

ing the input shaft.

37.
Place each shift fork in all posi-

tions to make sure that they operate

properly.

38.
Install the remaining detent

plug in the case. Install the long

spring (which is retained by the case)
to secure the detent plug.

39.
Use a new cover gasket and in-

stall the cover. Coat the cover attach-

ing screws with sealer and install and

tighten them to specifications.

40.
Coat the third- and fourth-

speed shift rail plug bore with a sealer

and install a new expansion plug.

41.
If the extension housing bush-

ing and seal are to be replaced, refer

to Section 1.procarmanuals.com

06-03-10

Ford Design Four-Speed Transmission

06-03-10

INPUT SHAFT

BEARING RETAINER

C2083-A

FIG. 79—Removing Input Shaft Seal

Tool-T57P-77047-A

OR
70256-6B

C1144-B

FIG. 20—Installing Input Shaft

Seal
Tool-T64P-7025-B

DETAIL
1

DETAIL
4

FORD AND MERCURY

DETAIL
5

COUGAR, FAIRLANE,

FALCON,
MONTEGO,

AND MUSTANG

DETAIL
3

DETAIL
2

FIG. 21—Installing Output Shaft Bearing

OUNTERSHAFT

Tool-T64P-7111-A-

FIG. 22—Installing Countershaft
C1518-Bprocarmanuals.com

06-04-01
Specifications

06-04-01

PART
6-4
Specifications

TRANSMISSION IDENTIFICATION 3-SPEED TRANSMISSION

Car Model

Ford,
Mercury, Meteor

Ford,
Meteor

Ford,
Meteor
Engine

390-2V-4V

240-1V

302-2V
Trans.

Model

RAT-A2

RAN-A2

RAT-SI
Gear Ratios

1st

2.42

2.99

2.99
2nd

1.61

1.75

1.75
Rev.

2.33

3.17

3.17

Car Model

Fairlane, Montego

Cougar

Falcon

Mustang

Fairlane, Montego

Falcon

Fairlane, Montego
Engine

390-4V

390-4V

170-1V

302-2V

250-IV

200-lV,

351-2V-4V
Trans.

Model

RAT-B2, RAT-C2

RAT-N2

RAN-AN

RAT-U1

RAN-AL

RAT-AJ
Gear Ratios

1st

2.42

3.41

2.99

2.42
2nd

1.61

1.86

1.75

1.61
Rev.

2.33

3.51

3.17

2.33
Car Model

Mustang

Fairlane, Montego

Falcon

Mustang, Cougar
Engine

200-lV, 250-IV

302-4V

351-2V-4V
Trans.

Model

RAN-AM

RAT-T

RAT-AM
Gear Ratios

1st

2.99

2.42
2nd

1.75

1.61
Rev.

3.17

2.33

4-SPEED TRANSMISSIONS

Car Model

Montego,

Fairlane, Ranchero

Montego, Fairlane,

Ranchero

Fairlane, Ranchero

Montego GT

Mustang, Cougar

Mustang, Cougar

Fairlane, Montego,

Ranchero

Fairlane, Montego,

Ranchero
Engine

390-2V-4V

351-2V-4V

390-4V

390-4V, GT

428-4V-CJ

428-4V-CJ

390-4V-GT
Trans.

Model

RUG-C2®

RUG-D2®

RUG-J2®

RUG-ADI

RUG-AE1®

RUG-AJ
®

RUG-AL
®
Gear Ratios

1st

2.32
2nd

1.69
3rd

1.29
Rev.

2.32
Car Model

Mustang, Cougar

Mustang, Cougar

Mustang, Cougar

Fairlane, Montego,

Ranchero

Fairlane, Montego,

Ranchero

Ford,
Meteor

Fairlane,

Montego
Engine

351-2V-4V

302-2V-4V

390-4VGT

351-2V-4V

302-4V

351-2V-4V

351-2V-4V

429-4V

428-4V-

6V
Trans.

Model

RUG-E3®

RUG-M3®

RUG-AG

RUG-AH
®

RUG-AK
®

RUG-V1

RUG-AF
Gear Ratios

1st

2.78

2.32
2nd

1.93

1.69
3rd

136

1.29
Rev.

2.78

2.32

® With 3.25:1 and lower axle ratios.
©
With 3.50:1 and higher axle ratios.

CLEARANCES(INCHES)

Countershaft Gear End PI ay-3-and 4-Speed Ford 0.004-0.018

Reverse Idler Gear End PI ay-3- and 4-Speed

Ford...:

.0.004-0.018
MANUAL TRANSMISSION REFILL CAPACITIES

Manual Transmission

3-Speed

4-Speed
Approximate Capacity

U.S.

Measure

3-1/2 pts.

4pts.
Imperial

Measure

3 pts.

3 pts.procarmanuals.com

06-04-02

Specifications

06-04-02

TORQUE LIMITS(FT-LBS)

Extension Housing Bolts

Input Shaft Bearing Retainer-to-Transmission Case Bolts

Speedometer Cable Retainer-to-Transmission Extension

Transmission-to-Flywheel Housing Bolts

Gearshift Control Levers to Cam and Shaft Assembly Lock Nuts

Transmission Cover Bolts

Filler Plug-to-Case

Drain Plug-to-Case

Shift Fork-to-Shift Rail

Third and Fourth Shift Rail Detent Bolt

Gear Shift Control Assembly
to
Transmission Extension

Shift Selector Levers to Shift Rods

Gear Shift Control Support Bracket
to
Back Plate
3-Speed

Transmissions

42-50

30-36

3.0-4.5

37-42

18-23

14-19

10-20

20-30

10-18

-

8-12

10-20

-
4-Speed

Transmissions

42-50

19-25

3.0-4.5

37-42

18-23

14-19

10-20

20-30

10-18

10-18

8-12

10-20

8-13
® Inch-pounds

SPECIAL TOOLS
SPECIAL TOOLS (Continued)

Tool Numbers

T50T-100A

T59L-100B

Tool-1175AB

T53T-4621-Bor(4621-F)

T57L-4220-A4

T52L-7000-GAE

T63P-7025-A

T64P-7025-B

T53T-4621-C
Description

Impact Hammer-Long

Impact Hammer-Short

Grease Seal Remover

Drive Pinion Bearing Cone

Replacer Front
&
Rear

Differential Side Bearing Cone

Replacer
or
Input Shaft Bearing

Remover

Extension Housing Bushing and

Seal Remover

Output Shaft Bearing Remover

& Replacer

Output Shaft Bearing Remover

& Replacer

Drive Pinion Bearing

Cone Replacer
Tool Numbers

Tool-7025-B

Tool-7025-G

T64P-7111-A

T63P-7111-A

T64P-7140-A

T61L-7657-A

T57P-7697-B

T57P-7657-G

T67P-7341-A
Description

Rear Main Shaft Bearing Removei

Main Shaft Bearing Remover

& Replacer

Cluster Gear Roller Retainer Shaf

Cluster Gear Roller Retainer Shaft

Reverse Idler Shaft Remover

Transmission Extension Housing

Oil Seal Replacer

Extension Housing

Bushing Replacer

Extension Housing

Bushing Replacer

Shift Linkage Grommet

Replacerprocarmanuals.com

07-01-01

07-01-01

*.v:;V*>
-"^g&ly-

'y.y... -4^*:
GROUP

7

PART
7-1
PAGE

General Transmission Service
07-01-01

PART
7-2

C4 Automatic Transmission
07-02-01

PART
7-3

FMX Transmission
07-03-01
PART
7-4

C6 Automatic Transmission
....

PART
7-5

Specifications
PAGE

07-04-01

07-05-01

TRANSMISSION

CODE
TRANSMISSION

TYPE

AUTOMATIC
(C4)

U AUTOMATIC
(C6)

X AUTOMATIC
(FMX)

Z AUTOMATIC
(C6
SPECIAL)

D2040-A

FIG. 1—Typical Warranty Plate—Transmission Identification

PART
7-1
General
Transmission
Service

COMPONENT INDEX

AIR PRESSURE CHECKS

ANTI-STALL DASHPOT CLEARANCE

CHECK

(Engine Compartment)

CASE (Transmission)

Inspection

CONTROL PRESSURE CHECK

CONTROL VALVE BODY

Inspection

CONVERTER

Checking

Cleaning

DRAIN AND REFILL (Transmission)

ENGINE IDLE SPEED CHECK

EXTENSION HOUSING INSPECTION

FLUID AERATION CHECK
MODEL APPLICATION
All
Models

01-06

01-04

01-17

01-05

01-17

01-04

01-11

01-08

01-04

01-15

01-03
Ford
Mercury
Meteor
Cougar
Fairiane
Falcon
Montego
Mustang
Lincoln-
Continental
Thunderbird
Continental-
Mark
III

A page number indicates that the item
is for
the vehicle listed
at
the head
of
the column.

N/A indicates that the item
is not
applicable
to
the vehicle listed.
procarmanuals.com

07-01-02

General Transmission Service

07-01-02

COMPONENT INDEX

FLUID LEAKAGE CHECK

FLUID LEVEL CHECK

FRONT CLUTCH (Forward) INSPECTION

C4 Transmission

C6 Transmission

FMX Transmission

FRONT PUMP AND STATOR SUPPORT

Inspection

FRONT SERVO (Intermediate) INSPECTION

C4 Transmission

C6 Transmission

FMX Transmission

GOVERNOR INSPECTION

HYDRAULIC SYSTEM BENCH TESTS

(FMX)

Pressure Tests

Testing Tool Installation

MANUAL LINKAGE CHECKS

MANUAL SHIFT LINKAGE GROMMET

COLUMN SHIFT

Removal and Installation

NEUTRAL START SWITCH-COLUMN

SHIFT

Adjustment

Removal and Installation

OIL COOLER CLEANING

OIL COOLER TUBES

Removal and Installation

ONE-WAY CLUTCH INSPECTION

OUTPUT SHAFT AND PRIMARY SUN

GEAR

Shaft (FMX)

Inspection

PINION CARRIER, ONE-WAY CLUTCH

AND CENTER SUPPORT (FMX)

Inspection

PINION CARRIERS INSPECTION

C4 Transmission

C6 Transmission

PRESSURE REGULATOR (FMX)

Inspection

REAR CLUTCH (Reverse-High) INSPECTION

C4 Transmission

C6 Transmission

FMX Transmission

REAR SERVO (Low-Reverse) INSPECTION

C4 Transmission
MODEL APPLICATION
All
Models

01-03

01-03

01-16

01-17

01-04

01-11

01-08

01-17
Ford
01-16

01-16

01-16

01-17

01-17

01-17

01-08

01-07

01-11

01-09

01-10

01-12

01-15

01-15

01-15

01-17

01-16

01-16

01-16

01-17

01-17
Mercury
N/A

01-16

N/A

N/A

01-17

N/A

N/A

N/A

01-11

01-09

01-10

N/A

N/A

N/A

01-15

N/A

N/A

01-16

N/A

N/A

N/A
Meteor
01-16

01-16

01-16

01-17

01-17

01-17

01-08

01-07

01-11

01-09

01-10

01-12

01-15

01-15

01-15

01-17

01-16

01-16

01-16

01-17

01-17
Cougar
N/A

01-16

01-16

N/A

01-17

01-17

01-08

01-07

N/A

N/A

N/A

01-12

01-15

N/A

01-15

01-17

N/A

01-16

01-16

N/A

01-17
Fairlane
01-16

01-16

01-16

01-17

01-17

01-17

01-08

01-07

01-11

01-09

01-10

01-12

01-15

01-15

01-15

01-17

01-16

01-16

01-16

01-17

01-17
Falcon
01-16

N/A

N/A

01-17

N/A

N/A

N/A

N/A

01-11

01-09

01-10

N/A

N/A

01-15

N/A

N/A

01-16

N/A

N/A

01-17

N/A
Montego
01-16

01-16

01-16

01-17

01-17

01-17

01-08

01-07

01-11

01-09

01-10

01-12

01-15

01-15

01-15

01-17

01-16

01-16

01-16

01-17

01-17
Mustang
01-16

01-16

01-16

01-17

01-17

01-17

01-08

01-07

N/A

N/A

N/A

01-12

01-15

01-15

01-15

01-17

01-16

01-16

01-16

01-17

01-17
Lincoln-
Continental
N/A

01-16

N/A

N/A

01-17

N/A

N/A

N/A

01-11

01-09

01-10

N/A

N/A

N/A

01-15

N/A

N/A

01-16

N/A

N/A

N/A
Thunderbird
N/A

01-16

N/A

N/A

01-17

N/A

N/A

N/A

01-11

01-09

01-10

N/A

N/A

N/A

01-15

N/A

N/A

01-16

N/A

N/A

N/A
Continental-
Mark
III
N/A

01-16

N/A

N/A

01-17

N/A

N/A

N/A

01-11

01-09

01-10

N/A

N/A

N/A

01-15

N/A

N/A

01-16

N/A

N/A

N/A

A page number indicates that the item is for the vehicle listed at the head of the column.

N/A indicates that the item is not applicable to the vehicle listed.
procarmanuals.com

07-01-03

General Transmission Service

07-01-03

COMPONENT INDEX

FMX Transmission

REAR SUPPORT (FMX)

Inspection

SHIFT POINT CHECKS

STATOR ONE-WAY CLUTCH CHECK

STATOR TO IMPELLOR INTERFERENCE

CHECK

STATOR TO TURBINE INTERFERENCE

CHECK

TRANSMISSION CLEANING

TURBINE AND STATOR END PLAY

CHECK

VACUUM DIAPHRAGM ADJUSTMENT

Altitude Compensating Type

Non-Altitude Compensating Type

VACUUM UNIT CHECK

Altitude Compensating Type

Non-Altitude Compensating Type
MODEL APPLICATION
All
Models

01-06

01-12

01-12

01-12

01-11

01-12
Ford
01-17

01-16

N/A

01-08

N/A

01-05
Mercury
N/A

N/A

N/A

01-08

N/A

01-05
Meteor
01-17

01-16

N/A

01-08

N/A

01-05
Cougar
01-17

01-16

N/A

01-08

N/A

01-05
Fairlane
01-17

01-16

N/A

01-08

N/A

01-05
Falcon
N/A

N/A

N/A

01-08

N/A

01-05
Montego
01-17

01-16

N/A

01-08

N/A

01-05
Mustang
01-17

01-16

N/A

01-08

N/A

01-05
Lincoln-
Continental
N/A

N/A

01-09

N/A

01-06

N/A
Thunderbird
N/A

N/A

01-09

N/A

01-06

N/A
Continental-
Mark
III
N/A

N/A

01-09

N/A

01-06

N/A

A page number indicates that the item is for the vehicle listed at the head of the column.

N/A indicates that the item is not applicable to the vehicle listed.

Three different three-speed trans-

missions are used. The C4 Automatic,

C6 Automatic and the FMX Auto-

matic. Part 7-1 covers testing, com-
mon adjustments and repairs, and

cleaning and inspection for the three

types of transmissions. Where there
are differences in procedures or speci-

fications, the type of transmission af-

fected will be designated.

l
AUTOMATIC TRANSMISSION TESTS

When diagnosing transmission

problems, refer to the Ford Car and

Truck Diagnosis Manual for the de-

tailed information on the items that

could be causing the problem.

The following preliminary checks

should be made before proceeding

with other diagnosis checks.

TRANSMISSION FLUID LEVEL

CHECK

1.
Make sure that the vehicle is

standing level. Then firmly apply the

parking brake.

2.
Run the engine at normal idle

speed. If the transmission fluid is cold

run the engine at fast idle speed

(about 1200 rpm) until the fluid reach-

es its normal operating temperature.

When the fluid is warm, slow the en-

gine down to normal idle speed.

3.
On a vehicle equipped with a

vacuum brake release, disconnect the

release line and plug the end of the
line;
otherwise the parking brake will

not hold the transmission in any drive

position.

4.
Shift the selector lever through

all positions, and place the lever at P.

Do not turn off the engine during the

fluid level checks.

5.
Clean all dirt from the transmis-

sion fluid dipstick cap before remov-

ing the dipstick from the filler tube.

6. Pull the dipstick out of the tube,

wipe it clean, and push it all the way

back into the tube. Be sure it is prop-

erly seated.

7.
Pull the dipstick out of the tube

again, and check the fluid level. The

fluid level should be above the ADD

mark. If necessary, add enough fluid

to the transmission through the filler

tube to bring the level between the

ADD and FULL marks on the dip-

stick. Do not overfill the transmission.

Install the dipstick, making sure it is

fully seated in the tube.
8. Connect the vacuum brake re-

lease line if so equipped, and test it

for proper operation.

FLUID AERATION CHECK

A fluid level that is too high will

cause the fluid to become aerated:

Aerated fluid will cause low control

pressure, and the aerated fluid may be

forced out the vent.

Check the transmission fluid level.

Low fluid level can affect the opera-

tion of the transmission, and may in-

dicate fluid leaks that could cause

transmission damage.

TRANSMISSION FLUID

LEAKAGE CHECKS

Check the speedometer cable con-

nection at the transmission. Replace

the rubber seal if necessary.

Leakage at the oil pan gasket often

can be stopped by tightening the at-
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