1969 FORD MUSTANG oil level

04-02-19
Rear Axle — Removable Carrier Type
04-02-19

POINTER RESTING ON

PINION NUT

E 1505-B

FIG.
44
— End Play Indicator

Installation

pinion shaft as shown in Figs. 37 and

38.

2.
Slide the correct spacer over the

pinion shaft against the rear bearing.

3.
Position the bearing retainer and

cup assembly on the pinion shaft and

install the front bearing cone and rol-

ler. Press the front cone and roller

into position, as shown in Fig. 46.

4.
Lubricate a new O-ring with axle

lubricant and install it in the groove

provided in the pinion retainer. Be

careful not to twist the O-ring. Install

it by snapping it into place.

5.
Place the proper shim on the

carrier housing and install the pinion

and retainer assembly, being careful

not to pinch the O-ring (Fig. 41).

6. Install the pinion retainer bolts.

Torque the bolts to specification.

7.
Place the slinger over the pinion

shaft and against the front bearing.
Tool - 4858-
E

E 1197-D

FIG. 46—Installing
U-Joint
Flange

8. Install a seal in the bearing re-

tainer, (Fig. 47).

9. Start a new integral nut and

washer on the pinion shaft.

10.
Hold the companion flange with

the tool shown in Fig. 20 or 22 and

torque the pinion nut to specifications

(200 ft-lbs).

11.
With a new seal installed pin-

ion bearing preload should now read

17 to 32 in-lbs for new pinion bearings

and new seal, or 8 to 14 in-lbs for ori-

ginal bearings and a new seal.

ASSEMBLY AND

INSTALLATION OF

DIFFERENTIAL CASE

Conventional

Differential Case

1.
Place a side gear and thrust

washer in the differential case bore

E 1506-B

E 1629-A

FIG. 45— Checking Pinion End

Play
FIG. 47—Installing Oil Seal
(Fig. 48). Lubricate all differential

parts liberally with axle lubricant dur-

ing assembly.

2.
With a soft-faced hammer, drive

the differential pinion shaft into the

case only far enough to retain a pin-

ion thrust washer and pinion gear.

3.
Place the second pinion and

thrust washer in position, and drive

the pinion shaft into place. Carefully

line up the pinion shaft lock pin holes.

4.
Place the second side gear and

thrust washer in position (Fig. 48),

and install the cover on the differen-

tial case. Install the pinion shaft lock

pin. A pinion or axle shaft spline can

be inserted in the side gear spline to

check for free rotation of the differen-

tial gears.

5.
Insert two 7/16 (N.F.) bolts two

inches long through the differential

case flange, and thread them three or

four turns into the ring gear as a

guide in aligning the ring gear bolt

holes.
Press or tap the ring gear into

position.

6. Install and tighten the ring gear

bolts and washers evenly, and torque

them alternately across the gear to

specification.

7.
If the differential bearings have

been removed, press them on as

shown in Figs. 49 and 50.

8. Wipe a thin coating of lubricant

on the bearing bores so that the dif-

ferential bearing cups will move easily.

9. Place the cups on the bearings.

If the gear set is of the non-hunting or

partial non-hunting type, assemble the

differential case and ring gear assem-

bly in the carrier so that the marked

tooth on the pinion indexes between

the marked teeth on the ring gear as

shown in Fig. 51.

In almost every case of improper

assembly (gears assembled out of

time),
the noise level and probability

of failure will be higher than they

would be with properly assembled

gears.

When installing the hunting type

gear set (no timing marks), assemble

the differential case and ring gear as-

sembly in the carrier without regard

to the matching of any particular gear

teeth.

10.
Slide the assembly along the

bores until a slight amount of back-

lash is felt between the gear teeth.

11.
Set the adjusting nuts in the

bores so that they just contact the

bearing cups. The nuts should be en-

gaged about the same number of

threads on each side.

12.
Carefully position the bearing

caps on the carrier. Match the marks

made when the caps were removed.procarmanuals.com

04-03-05
Rear Axles — Integral Carrier Type

04-03-05

6. Using the tool shown in Fig. 10,

remove the pinion U-joint flange.

7.
Using the tool shown in Fig. 7,

remove the drive pinion oil seal.

8. Clean the oil seal seat.

9. Pinion oil seals have pre-applied

oil resistant sealer. Install the seal in

the retainer using the tool shown in

Fig. 11.

10.
Check splines on the pinion

shaft to be sure they are free of burrs.

If burrs are evident, remove them by

using a fine crocus cloth, working in a

rotational motion. Wipe the pinion

shaft clean.

11.
Apply a small amount of lubri-

cant to the U-joint splines.

12.
Align the punch mark on the

U-joint flange with the mark on the

end of the pinion shaft, and install the

flange.

13.
Install a new integral nut and

washer on the pinion shaft. (Apply a

small amount of lubricant on the

washer side of the nut.)

14.
Hold the flange with the tool

shown in Fig. 9 while tightening the

nut.

15.
Tighten the pinion shaft nut,

rotating the pinion occasionally to in-

sure proper bearing seating, and take

frequent preload readings (Fig. 6)

until the preload is at the original rec-

orded reading established in step 3.

16.
After original preload has been

reached, tighten the pinion nut slowly,

until an additional preload of 6 to 12

in-lbs has been added.

The preload should not exceed the

amount indicated above, or bearing

failure may result. Under no circum-

stances should the pinion nut be

backed-off to lessen preload. If this is

done, a new pinion bearing spacer

must be installed. In addition, the U-

joint flange must never be hammered

on, or power tools used.

17.
Remove the oil seal replacer

tool from the transmission extension

housing. Install the front end of the
drive shaft on the transmission output

shaft.

18.
Connect the rear end of the

drive shaft to the axle U-joint flange,

aligning the punch marks made on the

drive shaft end yoke and the axle U-

joint flange (Fig. 14).

19.
Check the lubricant level. Make

sure the axle is in running position.

Add whatever amount of specified lu-

bricant is required to reach the lower

edge of the filler plug hole, located in

the carrier casting or the housing

cover.

REMOVAL AND INSTALLATION

OF THE ORIGINAL U-JOINT

FLANGE

Use procedure as outlined under

drive pinion oil seal replacement.

Tool-T53T-4857-A

or
4851 -A

E1223-B

FIG. 10—Typical Drive Pinion

Flange Removal

El 906A
Tool-T55P-4676-A

or 4676-G

E1907A
INSTALLATION OF A NEW

UNIVERSAL JOINT FLANGE

1.
Raise the vehicle and install safe-

ty stands. Remove both rear wheels

and brake drums.

2.
Disconnect the drive shaft from

the axle U-joint flange. Be careful to

avoid dropping the loose universal

joint bearing cups. Hold the cups on

the spider with tape. Mark the cups so

that they will be in their original posi-

tion in relation to the flange when

they are assembled. Remove the drive

shaft from the transmission extension

housing. Install an oil seal replacer

tool in the transmission extension

housing to prevent transmission fluid

leakage. Refer to the transmission

group for the appropriate tool.

3.
Install an in-lb torque wrench on

the pinion nut Fig. 6. Record the tor-

que required to maintain rotation of

the pinion shaft through several revo-

lutions.

4.
While holding the flange with the

tool shown in Fig. 9, remove the inte-

gral pinion nut and washer.

5.
Clean the pinion bearing retainer

around the oil seal. Place a drain pan

under the seal, or raise the front of

the vehicle higher than the rear. Syn-

thetic seals must not be cleaned,

soaked or washed in cleaning solvents.

6. Using the tool shown in Fig. 10,

remove the U-joint flange.

7.
Check splines on the pinion shaft

to be sure they are free of burrs. If

burrs are evident, remove them by

using a fine crocus cloth, working in

rotational motion, then wipe clean.

Apply a small amount of lubricant

to U-joint splines.

8. Install the U-joint flange using

the tool shown in Fig. 12.

FIG. 9—Removing or Installing

Drive Pinion Nut
FIG.
11
— Typical Drive Pinion

Flange Seal Installation
FIG. 12—U-Joint Flange

Installationprocarmanuals.com

04-03-06

Rear Axles — Integral Carrier Type

04-03-06

9. Install a new integral nut and

ivasher on the pinion shaft. (Apply a

small amount of lubricant on the

washer side of the nut.)

10.
Hold the flange with the tool

shown in Fig. 9 while the nut is being

tightened.

11.
Tighten the pinion shaft nut,

rotating the pinion occasionally to in-

sure proper bearing seating, (Fig. 6)

and take frequent preload readings

until the preload is at the original rec-

orded reading established in step 3.

12.
After original preload has been

reached, tighten the pinion nut slowly,
until an additional preload of 6 to 12

in-lbs has been added.

The preload should not exceed the

amount shown above, or bearing fail-

ure may result.

Under no circumstances should the

pinion nut be backed off to lessen pre-

load. If this is done, a new pinion

bearing spacer must be installed. (In

addition, the U-joint flange must

never be hammered on, or pneumatic-

-tools used.)

13.
Remove the oil seal replacer

tool from the transmission extension
housing. Install the front end of the

drive shaft on the transmission output

shaft.

14.
Connect the rear end of the

drive shaft to the axle U-joint flange,

aligning the scribe marks made on the

drive shaft end yoke and the axle U-

joint flange (Fig. 14).

15.
Check the lubricant level. Make

sure the axle is in running position.

Add whatever amount of specified lu-

bricant is required to reach the lower

edge of the filler plug hole, located in

the carrier casting or housing cover.

REMOVAL AND INSTALLATION

REAR AXLE HOUSING

REMOVAL

1.
Raise the vehicle and support it

with safety stands under the rear

frame member.

2.
Drain the lubricant from the

axle.

3.
Make scribe marks on the drive

shaft end yoke and the axle U-joint

flange to insure proper position of the

drive shaft at assembly (Fig. 14). Dis-

connect the drive shaft at the drive

pinion flange.

4.
Disconnect the lower end of the

shock absorbers.

5.
Remove the wheels, brake drums

and both axle shafts as outlined in the

foregoing Section 2.

6. Remove vent hose front vent

tube (Corbin clamp) and remove vent

tube from brake tube junction and

axle housing.

7.
Remove the hydraulic brake T-
fitting from the axle housing. Do not

open the hydraulic brake system lines.

Remove the hydraulic brake line from

its retaining clip on the axle housing.

8. Remove both axle shaft oil seals

with the tools shown in Fig. 8.

9. Remove both brake backing

plates from the axle housing and sus-

pend them above the housing with me-

chanic's wire. The hydraulic brake

SCRIBE MARKS

5/16-24

4 REQ'D.

12-15
LB.
FT.

U-BOLT - 4529 2 REQ'D.

E 1783-A

FIG. 14—Drive Shaft-to-Axle

U-Joint
Connection

El231-A

FIG. 73—Rear Axle Installation—Typical
lines and the parking brake cables are

still attached to the brake carrier

plates.

10.
Support the rear axle housing

on a jack, and then remove the spring

clip nuts. Remove the spring clip

plates (Fig. 13)

11.
Lower the axle housing and re-

move it from under the vehicle.

12.
If the axle housing is being re-

placed, transfer all the differential and

pinion parts to the new housing. See

Section 4, Major Repair Operations.

INSTALLATION

1.
Raise the axle housing into posi-

tion so that the spring clip plates can

be installed. On a Montego or Fair-

lane,
position the spring upper insula-

tors and retainers between the axle

housing and springs and install the

lower insulators. Torque the spring

clip nuts to specification.

2.
Place the brake backing plates in

their normal position on the axle

housing. Use new gaskets on each side

of the brake backing plates.

3.
Install new axle shaft oil seals

with the tool shown in Fig. 8. Soak

the new seals in light weight engine oil

(SAE 10) for 1/2 hour before install-

ing them. Installation without use of

the proper tool will distort the seal

and cause leakage. Coat the outside

edges of the new oil seal with a non-

hardening type of sealer such as Per-

matex No. 2 or its equivalent.

4.
Install the axle shafts, brake

drums and wheels as outlined in Sec-

tion 2.

5.
Attach the hydraulic brake line

T fitting to the axle housing, and se-

cure the hydraulic brake line in its re-

tainer on the axle housing.

6. Install vent tube to brake tubeprocarmanuals.com

04-03-10
Rear Axles
—
Integral Carrier Type

04-03-10

in
the
case. Drive
the
shaft into place

and install
the
lock
pin
(Fig.
21).

6. Place
the
ring gear
on the
differ-

ential case
and
install
the
bolts.
Tor-

que
the
bolts
to
specification.

7.
If the
differential bearings have

been removed, press them
on as

shown (Fig.
24).

INSTALLATION
OF
DRIVE

PINION
AND
DIFFERENTIAL

CASE

1.
Place
the
shim
and
pinion rear

bearing cone
on the
pinion shaft.

Press
the
bearing
and
shim firmly

against
the
pinion shaft shoulder (Fig.

19).

PRESS RAM

Tool T54P-3044-A

Detail
7
2.
Place
a new
pinion bearing
pre-

load spacer
on the
pinion shaft.

3.
Lubricate
the
pinion rear bearing

with axle lubricant.

4.
Lubricate
the
pinion front bear-

ing cone
and
place
it in the
housing.

5.
Install
a new
pinion
oil
seal
in

the carrier casting (Fig.
11).

6. Insert
the
drive pinion shaft

flange into
the
seal
and
hold
it
firmly

against
the
pinion front bearing cone.

From
the
rear
of the
carrier casting,

insert
the
pinion shaft into
the
flange.

7.
Start
a new
pinion shaft
nut.

Hold
the
flange with
the
tool shown
in

Fig.
9 and
tighten
the
pinion shaft

nut.
As the
pinion shaft
nut is
tight-

ened,
the
pinion shaft
is
pulled into

the front bearing cone
and
into
the

flange.

As
the
pinion shaft
is
pulled into

the front bearing cone, pinion shaft

end play
is
reduced. While there
is

still
end
play
in the
pinion shaft,
the

flange
and
cone will
be
felt
to
bottom.

This indicates that
the
bearing cone

and flange have bottomed
on the col-

lapsible spacer.

From this point,
a
much greater

torque must
be
applied
to
turn
the

pinion shaft
nut,
since
the
spacer must

be collapsed. From this point, also,

the
nut
should
be
tightened very slow-

ly
and the
pinion shaft
end
play

checked often,
so
that
the
pinion bear-

ing preload does
not
exceed
the
limits

(Fig.
6).

FIG. 24—Differential Bearing

Installation
If
the
pinion shaft
nut is
tightened

to
the
point that pinion bearing
pre-

load exceeds
the
limits,
the
pinion

shaft must
be
removed
and a
new
col-

lapsible spacer installed.
Do not de-

crease
the
preload
by
loosening
the

pinion shaft
nut.
This will remove
the

compression between
the
pinion front

and rear bearing cones
and the col-

lapsible spacer
and may
permit
the

front bearing cone
to
turn
on the pin-

ion shaft.

&
As
soon
as
there
is
preload
on

the bearings, turn
the
pinion shaft
in

both directions several times
to set the

bearing rollers.

9. Adjust
the
bearing preload
to

specification. Measure
the
preload

with
the
tool shown
in Fig. 6.

10.
Apply
a
thin coating
of
lubri-

cant
on the
bearing bores
so
that
the

differential bearing cups will move

easily.

11.
Place
the
cups
on the
bearings

and
set the
differential case assembly

in
the
carrier casting (Fig.
17).

If
the
gear
set is of the
non-hunting

or partial non-hunting type, assemble

the differential case
and
ring gear
as-

sembly
in the
carrier
so
that
the

marked tooth
on the
pinion indexes

between
the
marked teeth
on the
ring

gear
as
shown
in Fig. 25.

In almost every case
of
improper

assembly (gears assembled
out of

time),
the
noise level
and
probability

of failure will
be
higher than they

would
be
with properly assembled

gears.

When installing
the
hunting type

gear
set (no
timing marks), assemble

the differential case
and
ring gear
as-

sembly
in the
carrier without regard

to
the
matching
of any
particular gear

teeth.

12.
Slide
the
case assembly along

the bores until
a
slight amount
of

backlash
is
felt between
the
gear teeth.

Hold
the
differential case
in
place.

13.
Set the
adjusting nuts
in the

PAINT MARKING INDICATES POSITION
IN
WHICH GEARS WERE LAPPED

E 1335-B

FIG. 25—Typical Gear
Set
Timing Marks
7oo/—T60K-4067-A or 4067 E

E1916A

FIG. 26—Backlash
and
Bearing

Pre-Load Adjustmentprocarmanuals.com

04-04-09
Rear Axle — Ford Light-Duty (WER)
04-04-09

case several revolutions in each direc-

tion while the bearings are loaded to

seat the bearings in their cups. This

step is important.

5. Again loosen the right nut to re-

lease the preload. Check to see that

the left nut contacts the bearing cup.

Using the dial indicator set-up shown

in Fig. 13, Part 4-1, adjust the preload

to 0.008 to 0.012 case spread for new

bearings or 0.005 to 0.008 for the

original bearings, if re-used.

6. Check the runout of the differen-

tial case flange with a dial indicator.

If the runout does not now exceed

specifications, install a new ring gear,

if the runout still exceeds specifica-

tions,
the ring gear is true and the

trouble is due to either a defective

casting or worn bearings.

7.
Remove the differential case

from the carrier and remove the side

bearings from the case.

8. Install new bearings on the case

hubs,
and again install the differential

assembly in the carrier without the

ring gear.

9. Check the case runout again with

the new bearings. If the runout is now

within limits, the old bearings were

excessively worn. Use the new bear-

ings for assembly. If the runout is still

excessive, the case is defective and

should be replaced.

ASSEMBLY OF AXLE

Refer to Part 4-1 of this Shop

Manual for Cleaning and Inspection

procedures before starting assembly

operations.

ASSEMBLY OF

DIFFERENTIAL CASE

1.
Place the ring gear on the differ-

ential case. Install the retaining bolts

and torque them to specification.

2.
If the differential bearings were

removed, press them on as shown in

Fig. 17.

3.
Insert the pinion gear shaft lock

bolt into the case (loosely).

INSTALLATION OF DRIVE

PINION AND

DIFFERENTIAL CASE

1.
Place the shim(s) and pinion rear

bearing cone on the pinion shaft.

Press the bearing and shim(s) firmly

against the pinion shaft shoulder (Fig.

18).

2.
Place a new pinion bearing pre-

load (collapsible) spacer on the pinion

shaft.
REAR BEARING

CONE AND

ROLLER
Press Ram

FIG. 18—Drive Pinion Bearing

Installation

3.
Lubricate the pinion rear bearing

with axle lubricant.

4.
Lubricate the pinion front bear-

ing with axle lubricant. Lubricate the

pinion front bearing cone and place it

in the carrier housing.

5.
Install a new oil seal in the car-

rier casting (Fig. 19).

6. Insert the drive pinion shaft (U-

joint) flange into the pinion seal and

hold it firmly against the pinion front

bearing cone. From the rear of the

carrier casting, insert the pinion shaft

into the flange.

7.
Apply a small amount of lubri-

cant to the washer side of the flange

nut and start the nut. Use a new nut.

Hold the flange with the tool shown in

Fig. 12 and tighten the pinion shaft

nut. As the pinion shaft nut is tight-

ened, the pinion shaft is pulled into

the front bearing cone and into the

flange.

As the pinion shaft is pulled into

the front bearing cone, pinion shaft

end play is reduced. While there is

still end play in the pinion shaft, the

flange and cone will be felt to bottom.

This indicates that the bearing cone

and flange have bottomed on the col-

lapsible spacer.

From this point, a much greater

torque must be applied to turn the

pinion shaft nut, since the spacer must

be collapsed. From this point, also,

the nut should be tightened very slow-

ly and the pinion bearing preload play

checked often, so that the pinion bear-

ing preload does not exceed the speci-

fied limits.

If the pinion shaft nut is tightened

to the point that pinion bearing pre-

load exceeds the limits, the pinion

shaft must be removed and a new col-

lapsible spacer installed. Do not de-

crease the preload by loosening the
/
Tool
-
T58L-4676-A

/ E
1581-A

FIG. 19—Installing Pinion Seal

E 1582-A

FIG. 20—Checking Pinion Bearing

Preload

pinion shaft nut. This will remove the

compression between the pinion front

and rear bearing cones and the col-

lapsible spacer and may permit the

front bearing cone to turn on the pin-

ion shaft.

8. As soon as there is preload on

the bearings, turn the pinion shaft in

both directions several times to seat

the bearing rollers.

9. Adjust the bearing preload to

specification. Measure the preload

with the tool shown in Fig. 20.

10.
Apply a thin coating of lubri-

cant on the bearing bores so that the

differential bearing cups will move

easily.

11.
Place the cups on the bearings

and set the differential case assembly

in the carrier casting.

If the gear set is of the non-hunting

or partial non-hunting type, assemble

the differential case and ring gear as-

sembly in the carrier so that the

marked tooth on the pinion indexes

between the marked teeth on the ring

gear as shown in Fig. 49, Part 4-2.

In almost every case of improper

assembly (gears assembled out of

time),
the noise level and probability

of failure will be higher than they

would be with properly assembled

gears.

When installing the hunting type

gear set (no timing marks), assembleprocarmanuals.com

06-01-02
General Transmission Service

06-01-02

REAR SEAL REPLACEMENT

1.
Remove the drive shaft.

2.
Remove the seal from the exten-

sion housing with the tool shown in

Fig. 2.

3.
Install the new seal in the exten-

sion housing with the tool shown in

Fig. 3.

4.
Install the drive shaft.

.REAR OIL SEAL

Tool-T61L-7657-A

EXTENSION HOUSING

C 1830.A

FIG. 3—Installing Extension

Housing Seal
Too/-7J75-AB

Tool-TSOT-lOO-A

FIG. 2—Removing Extension Housing Seal

EXTENSION HOUSING

Tool-T52L-7000-GAE

or 7000-G

C1O28-D

FIG. 4—Removing Extension

Housing Bushing and Seal
EXTENSION HOUSING
D
1927. A

Tool—T57P-7697-B

57-G

BUSHING

C 1832.A

FIG. 5—Installing Extension

Housing Bushing

REAR BUSHING AND SEAL

REMOVAL AND INSTALLATION

1.
Remove the drive shaft from the

vehicle.

2.
Insert the tool shown in Fig. 4

into the extension housing until it

grips on ihe front side of the bushing.
3.
Turn the screw clockwise until

the seal and the bushing are free of

the housing.

4.
Drive a new bushing into the ex-

tension housing with the tool shown in

Fig. 5.

5.
Install a new seal in the housing

as shown in Fig. 3.

6. Install the drive shaft.
LUBRICATION

Lubricant level should be even with

the bottom of the filler hole at the

right side of the transmission case.

CLEANING AND INSPECTION

CLEANING

1.
Wash all parts, except the ball

bearings and seals in a suitable clean-

ing solvent. Brush or scrape all foreign

matter from the parts. Be careful not

to damage any parts with the scraper.

Do not clean, wash or soak transmis-

sion seals in cleaning solvents. Dry all

parts with compressed air.

2.
Rotate the ball bearings in a

cleaning solvent until all lubricant is

removed. Hold the bearing assembly

to prevent it from rotating and dry it

with compressed air.

3.
Lubricate the bearings with ap-

proved transmission lubricant and

wrap them in a clean, lint-free cloth

or paper until ready for use.

4.
Clean the magnet welded to the

bottom of the case with kerosene or

mineral spirits.
INSPECTION

1.
Inspect the transmission case for

cracks, worn or damaged bearings

bores,
damaged threads or any other

damage that could affect the opera-

tion of the transmission.

2.
Inspect the front face of the case

for small nicks or burrs that could

cause misalignment of the transmis-

sion with the flywheel housing. Re-

move all small nicks or burrs with a

fine stone.

3.
Replace a cover that is bent or

distorted. Make sure that the vent

hole in the cover is open.

4.
Check the condition of the shift

levers, forks, shift rails and the lever

and shafts.

5.
Examine the ball bearing races

for cracks, wear or roughness. Inspect

the balls for looseness, wear, end play
or other damage. Check the bearings

for looseness in the bores. If any of

these conditions exist, replace the

bearings.

6. Replace roller bearings that are

broken, worn or rough.

7.
Replace the countershaft (clust-

er) gear if the teeth are chipped, brok-

en or worn. Replace the countershaft

if it is bent, scored or worn.

8. Replace the reverse idler gear or

sliding gear if the teeth are chipped,

worn or broken. Replace the idler

gear shaft if bent, worn or scored.

9. Replace the input shaft and gear

if the splines are damaged or if the

teeth are chipped, worn or broken. If

the roller bearing surface in the bore

of the gear is worn or rough, or if the

cone surface is damaged, replace the

gear and the gear rollers.

10.
Replace all other gears that areprocarmanuals.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-
procarmanuals.com