1969 FORD MUSTANG manual transmission

05-03-05
Clutch

05-03-05

4.
Remove the bolt that secures the

left air vent control cable bracket to

the instrument panel. Position the

control cable to one side.

5.
Remove the retaining clip and

flat washer from the clutch pedal

shaft. Then, remove the shaft, bush-

ing, clutch pedal and brake pedal

from the support.

6. Remove the bushings from the

pedal shaft, and transfer the pedal

pad.

7.
Lubricate the clutch pedal shaft

bushings and position them on the

shaft. Then, position the brake pedal

and clutch pedal in the pedal support.

8. Install the flat washer and re-

taining clip on the pedal shaft.

9. Position the assist spring to the

pedal and bracket. Pry the bracket

forward and install the lower bolt.

Torque the bolts to specifications.

10.
Position the master cylinder

push rod, bushing, and washers on the

brake pedal and secure with a retain-

ing clip.

11.
Connect the equalizer rod to

the clutch pedal and secure it in place

with a retaining clip.

12.
Position the air vent control

cable bracket to the instrument panel

and secure with the attaching bolt.

13.
Adjust the clutch pedal free

travel.

EQUALIZER BAR AND/OR

BUSHING REMOVAL AND

INSTALLATION

FORD, MERCURY

AND METEOR

1.
Raise the vehicle and disconnect

the clutch pedal-to-equalizer rod at

the equalizer bar (Fig. 1).

2.
Disconnect the return spring and

retaining spring at the release lever.

Separate the release lever rod from

the release lever.

3.
Remove the equalizer bar frame

bracket from the frame.

4.
Remove the equalizer bar from

the pivot on the flywheel housing.

5.
Remove the wire clip to replace

the outer bushing and the snap ring
from the inner pivot stud to replace

the inner bushing.

6. Position the flat washer, felt

washer and bushing on the inner and

outer pivots. Secure these parts with

the snap ring.

7.
Position the equalizer bar on the

inner pivot and bolt the equalizer bar

frame bracket to the frame. Torque

the attaching bolts to specification.

8. Install the clutch release rod, re-

turn spring and retaining spring.

9. Connect the clutch pedal rod to

the equalizer bar.

10.
Adjust the clutch pedal free

travel.

MUSTANG, COUGAR,

MONTEGO, FALCON,

FAIRLANE (EXCEPT

MONTEGO AND FAIRLANE

WITH 390 V-8)

1.
Disconnect the clutch pedal

equalizer rod at the equalizer bar

(Figs.
2 and 3).

2.
Raise the vehicle and disconnect

the release lever, return spring at the

lever.

3.
Remove the equalizer bar outer

bracket and bushing assembly.

4.
Remove the release rod from the

equalizer bar, and then remove the

equalizer bar. Remove the bushing

and washers from the inner mounting

stud.

5.
Position the equalizer bar, wash-

ers,
inner bushing, and retainer on the

inner stud.

6. After positioning the outer bush-

ing, install the outer bracket (with the

equalizer bar in place).

7.
Connect the release rod and the

release lever return spring.

8. Lower the vehicle. Connect the

clutch pedal equalizer rod to the

equalizer baY and secure with the re-

taining pin.

9. Adjust the clutch pedal free trav-

el as required.

MONTEGO AND

FAIRLANE—390 V-8

1.
Disconnect the clutch pedal
equalizer rod at the equalizer bar (Fig.

2).

2.
Raise the vehicle and disconnect

the return spring at the release lever.

Disconnect the release lever rod from

the equalizer lever.

3.
Remove the equalizer bar center

bolt.

4.
Separate the equalizer bar and

remove both sections from the vehicle.

5.
Remove the bolts retaining the

equalizer bar inner bracket to the fly-

wheel housing and remove the bracket

and bushing assembly.

6. Remove the equalizer bar outer

bracket and bushing assembly.

7.
Remove the snap ring, bushing,

and felt washer from each bracket as-

sembly.

8. Position a felt washer, and bush-

ing on each bracket assembly and se-

cure with the snap ring.

9. Install the outer bracket and

bushing assembly to the frame (Fig.

2).
Torque the bracket attaching bolts

to specifications.

10.
Position the outer section of the

equalizer bar on the outer bracket

pivot.

11.
Connect the two sections of the

equalizer bar. Insert the inner bracket

pivot into the equalizer bar and install

the assembly to the flywheel housing.

Torque the attaching bolts to specifi-

cations.

12.
Install the equalizer bar center

bolt and torque to specifications.

Make sure that both ends of the

equalizer bar are against the felt

washers.

13.
Connect the release rod and the

release lever return spring.

14.
Adjust the clutch pedal free

travel.

15.
Lower the vehicle. Connect the

clutch pedal equalizer rod to the

equalizer bar and secure with the re-

taining clip.

16.
Check the free travel at the

pedal for conformance to specifica-

tions.
Readjust if necessary.

REMOVAL AND INSTALLATION

CLUTCH REMOVAL

1.
Raise the vehicle on a hoist.

2.
Disconnect the drive shaft from

the rear U-joint flange. Then, slide the

drive shaft off the transmission output

shaft. Insert the appropriate tool over

the output shaft and into the extension

housing oil seal.
3.
Disconnect the speedometer

cable from the extension housing.

4.
Disconnect the gear shift rods

from the transmission. If the vehicle is

equipped with a four-speed transmis-

sion, remove the bolts that secure the

four-speed transmission, disconnect

the front brake cable from the cross-

member and remove the crossmem-
member from the vehicle.

5.
Remove the bolts that attach the

transmission to the flywheel housing.

6. Move the transmission rearward

until the input shaft clears the fly-

wheel housing, then remove it from

the vehicle.

7.
Disconnect the clutch release

lever retaining spring from the release

lever.procarmanuals.com

05-03-06
Clutch

05-03-06

8. Remove the starter cable then

remove the starter motor from the fly-

wheel housing.

9. Remove the bolts that secure the

engine rear plate to the front lower

part of the flywheel housing.

10.
Remove the flywheel housing

lower cover (390 CID housing only).

11.
Remove the bolts that attach

the housing to the cylinder block.

12.
Move the housing back just far

enough to clear the pressure plate,

then move it to the right to free the

pivot from the clutch equalizer bar. Be

careful not to disturb the linkage and

assist spring.

13.
Loosen the six pressure plate

cover attaching bolts evenly to release

the spring tension. If the same pres-

sure plate and cover is to be installed

after the clutch is overhauled, mark

the cover and flywheel so that the

pressure plate can be installed in the

same position.

14.
Remove the pressure plate and

the clutch disc from the flywheel.

CLUTCH INSTALLATION

1.
Install the clutch release lever if

it was removed.

2.
Place the clutch disc, and pres-

sure plate assembly in position on the

flywheel. Start the cover attaching

bolts to hold the pieces in place, but

do not tighten them. Avoid touching

the clutch disc facing, dropping the

parts or contaminating them with oil

or grease as clutch chatter may result.

3.
Align the clutch disc with the

tool shown in Fig. 7, and alternately

tighten the bolts a few turns at a time

until they are all tight. Then torque

the six pressure plate cover attaching

bolts to specification before removing

the tool.
4.
Apply a light film of grease

(C3VY-19586-A) to the outside diam-

eter of the transmission front bearing

retainer. Apply a light film of grease

(C3VY-19586-A) to both sides of the

release lever fork where it contacts the

release bearing bore spring clips.

Apply a light film of grease to the re-

lease bearing surface that contacts the

pressure plate release fingers. Fill the

grease groove of the release bearing

hub with lithium base grease (C3VY-

19586-A). Clean all excess grease

from inside the bore of bearing hub.

Excess grease will be forced onto the

spline by the transmission input shaft

bearing retainer and will contaminate

the clutch disc. Also, place the release

bearing and hub on the release lever.

5.
Make certain that the flywheel

housing and the cylinder block mount-

ing surfaces are clean. Position the

felt washer on the pivot in the fly-

wheel housing. Slip the pivot into the

clutch equalizer shaft being careful

not to disturb the linkage and at the

same time position the housing on the

dowels in the cylinder block. Install

and torque the attaching bolts to spec-

ification.

6. Install the starting motor and

connect the cable.

7.
The mounting surfaces of the

transmission and the flywheel housing

must be free of dirt, paint, and burrs.

Install two guide pins in the flywheel

housing lower mounting bolt holes.

Move the transmission forward on the

guide pins until it is tightly positioned

against the flywheel housing.

8. Install the two upper mounting

bolts.
Then, remove the guide pins

and install the two lower mounting

bolts.
Torque all the bolts to specifica-

tion.

9. Raise the rear of the engine and
install the crossmember. Install and

torque the crossmember attaching

bolts to specifications, then lower the

engine.

10.
Install the extension housing-

to-engine rear support attaching bolts.

Torque the bolts to specification.

11.
Remove the transmission jack

and connect the parking brake cable.

12.
If the vehicle is equipped with a

four-speed transmission, connect the

gear shift linkage control bracket to

the extension housing.

13.
Connect the gear shift rods to

the transmission. Adjust the shift link-

age as required.

14.
Connect the release lever retain-

ing spring. Install the flywheel housing

cover (390 CID housing only).

15.
Remove the tool from the

transmission output shaft and install

the drive shaft.

16.
Check the clutch pedal free

travel.

CLUTCH ARBOR CLUTCH DISC

PRESSURE PLATE

C 1788-A

FIG. 7—Installing Clutch Disc —

Typicalprocarmanuals.com

05-04-01
Specifications

05-04-01

PART
5-4
Specifications

CLUTCH IDENTIFICATION

Car Line

Ford

Meteor

Ford

Ford

Meteor

Ford

Meteor

Mercury

Ford

Falcon

Fairlane

Falcon

Montego

Fairlane

Montego

Falcon

Mustang

Mustang

Cougar

Fairlane

Montego

Fairlane

Montego

Mustang

Cougar

Fairlane

Montego

Mustang

Cougar

Fairlane

Montego

Mustang

Cougar
Engine

240-IV

240-IV

302-2V

390-2V,

4V

429-4V

170-1V

200-IV

250-1V

302-2V

200-IV

250-1V

302-2V

390-2V,

4V

390-4V GT

351-2V,

4V

428-4V
Transmission

3-Speed

3-Speed

Heavy Duty

3-Speed

3-Speed

4-Speed

4-Speed

3-Speed

3-Speed

3-Speed

4-Speed

3-Speed

3-Speed

4-Speed

3-Speed

4-Speed

3-Speed

4-Speed

3-Speed

4-Speed

4-Speed
Pressure Plate

Diameter

(Inches)

9.5

11

10

11

11.5

9

9

10

9

10

11

11.5

11

11.5
No.
of

Springs

6

9

9

9

12

6

6

9

6

9

9

12

9

12
Color Identification

(Paint Daub)

Pressure Plate-No Color

Cover—Green

Springs—Aluminum

Pressure Plate-White

Cover-Pink and Blue

Springs
8-Green

Pressure Plate-Green

Cover-White

Springs-White
on
Bronze

Pressure Plate—Orange

Cover-Black

Springs-Aluminum

Pressure Plate-Yellow

Cover-Black

Springs-Green

Pressure Plate-Orange

Cover—Purple

Springs-Aluminum Stripe

Pressure Plate-Orange

Cover-Purple

Springs-Aluminum Stripe

Pressure Plate—Green

Cover-White

Springs-Bronze

Pressure Plate—Orange

Cover—Purple

Springs—Aluminum Stripe

Pressure Plate-Blue

Cover—Purple

Springs—Bronze

Pressure Plate-Green

Cover-Purple

Springs-Purple

Pressure Plate-Green

Cover-Purple

Springs-Purple

Pressure Plate-Blue

Cover-Yellow

Springs-Silver

Pressure Plate-Yellow

Cover-Black

Springs—Green
Disc

Diameter

(Inches)

9.5

11

10

11

11.5

9

9

10

9

10

11

11.5

11

11.5
No.
of

Springs

6

8

12

12

10

6

6

12

6

6

8

8

8

10
Color Identification

(Paint Daub)

Clutch-Yellow

Springs—2 Purple (Small)

4 Aluminum (Large)

Clutch-No Color

Springs—4 Aluminum

4 Pink

Clutch-Blue

Springs-6 Orange (Small)

6 Pink (Large)

Clutch-Pink

Springs-6 Green (Small)

6 Orange (Large)

Clutch-Gray

Springs—5
Red
Stripe (Small)

5
No
Color (Large)

Clutch-Pink

Springs—Blue

Clutch-Pink

Springs-Blue

Clutch-Blue

Springs-6 Pink

6 Orange

Clutch-Blue

Springs—Blue

Clutch-Green

Springs-Orange

Clutch-Pink
and
Orange

Springs—Aluminum

Clutch-Pink and Orange

Springs—Aluminum

Clutch—Pink and Orange

Springs—Aluminum

Clutch-Gray

Springs-Red Stripe

CLUTCH-DRIVELINE ADJUSTMENTS (INCHES)

Release Lever
Rod
Adjusting
Nut to
Swivel Sleeve

Ford,
Mercury Meteor
0.194

Fairlane, Montego, Falcon, Mustang, Cougar
ex.
with

390,
428
engine
0.136

390,
428
Engines
0.178
*

Clutch Pedal Free Travel (Engine Running)
7/8"-l
1/8"

Clutch Housing Alignment
If
Dia-L-lgner reading
0.014

is greater than that indicated,
the
clutch

housing alignment
is
unacceptable.

Maximum Shim to Correct Alignment
0.010procarmanuals.com

05-04-02

Specifications

05-04-02

TORQUE LIMITS (FT-LBS)

Description

Lower Access Clutch Cover Pan to Flywheel Housing Bolts (Cast Iron Housing)

Transmission Assembly to Flywheel Housing Bolts

Pressure Plate and Cover Assembly to Flywheel Attaching Bolts

Clutch Release Equalizer Frame Bracket Bolts

Clutch Pedal Free Travel Adjustment Nut

Flywheel Housing to Cylinder Block Bolts
6-Cylinder

8-Cylinder

Clutch Pedal Assist Spring Bracket to Brake Pedal Support Bracket
Meteor

Ford,
Mercury

17-20

37-42

12-20

15-24

15-20

_

12-17
Mustang,
Cougar

Fairlane, Montego, Falcon

-

-

12-20

15-24

15-20

23-33

40-50

12-17

SPECIAL TOOLS

Tool No.

A-37H

T61L-7657-Aor B

T57L-7657-A

T64P-7657-A
Description

Clutch Disc Aligner-Universal

Transmission Extension Housing Oil Seal

Replacer
Tool No.

CJ91B

T64L-6392-A

T49P-7580-A
Description

Universal Joint Bearing Replacer

Dia-L-lgner Gauge

Clutch Release Bearing Replacerprocarmanuals.com

06-01-01

06-01-01

ual Shift
GROUP

6

PART
6-1
PAGE

General Transmission Service
06-01-01

PART 6-2

Ford Design Three-Speed

Transmission
06-02-01
PART 6-3

Ford Design Four-Speed

Transmission

PART
6-4

Specifications
PAGE

.06-03-01

.06-04-01

Part 6-1 General
Transmission
Service

COMPONENT INDEX

REAR SEAL

Removal and Installation

REAR BUSHING AND SEAL

Removal and Installation

TRANSMISSION

Cleaning

Inspection

Lubrication
MODEL APPLICATION
All
Models
Ford

01-02

01-02

01-02

01-02

01-02
Mercury
01-02

01-02

01-02

01-02

01-02
Meteor
01-02

01-02

01-02

01-02

01-02
Cougar
01-02

01-02

01-02

01-02

01-02
Fairlane
01-02

01-02

01-02

01-02

01-02
Falcon
01-02

01-02

01-02

01-02

01-02
Montego
01-02

01-02

01-02

01-02

01-02
Mustang
01-02

01-02

01-02

01-02

01-02
Lincoln-
Continental
N/A

N/A

N/A

N/A

N/A
Thunderbird
N/A

N/A

N/A

N/A

N/A
Continental-
Mark
III
N/A

N/A

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.

COMMON ADJUSTMENTS
AND
REPAIRS

54E
M IB I2H 33
CODE

1

5

6
TRANSMISSION

THREE-SPEED

FOUR-SPEED (WIDE RATIO)

FOUR-SPEED (CLOSE RATIO)

C2086-A

FIG.
1—Typical
Warranty Plate—Transmission Identification
procarmanuals.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

06-01-03

General Transmission Service

06-01-03

chipped, broken or worn.

11.
Check the synchronizer sleeves

for free movement on their hubs.

Make sure that the alignment marks

(etched marks) are properly indexed.

12.
Inspect the synchronizer block-

ing rings for widened index slots,

rounded clutch teeth and smooth in-

ternal surfaces (must have machined

grooves). With the blocker ring on the
cone,
the distance between the face of

the blocker ring and the clutch teeth

on the gear must not be less than

0.010 inches.

13.
Replace the speedometer drive

gear if the teeth are stripped or dam-

aged. Make certain to install the cor-

rect size replacement gear.

14.
Replace the output shaft if

there is any evidence of wear or if any
of the splines are damaged.

15.
Inspect the bushing and the seal

in the extension housing. Replace

them if they are worn or damaged.

The bushing and/or seal should be re-

placed after the extension housing has

been installed on the transmission.

16.
Replace the seal in the input

shaft bearing retainer.

17.
Replace the seals on the cam

and shafts.procarmanuals.com

06-02-01
Ford Design Three Speed Transmission

06-02-01

PART 6-2 Ford Design Three Speed
Transmission

Trans-

mission

Model

RAN-AL

RAN-AM

RAN-AN

RAN-AZ

RAT-AJ

RAT-AM

RAT-A2

RAT-B2

RAT-C2

RAT-N2

RAT-SI

RAT-T

RAT-U1
Engine

Model

200-IV, 250-IV

200-IV, 250-IV

170-1V

240-IV

351-2V-4V

351-2V-4V

390-2V-4V

390-4V-GT

390-4V-GT

390-4V

302-2V

302-2V-4V

302-2V
Shift

Lever

Location

Column

Floor

Column

Column

Column

Floor

Column

Floor

Column

Floor

Column

Column

Floor
MODEL APPLICATION
All
Models
Ford

X

X

X
Mercury
X

X
Meteor
X
Cougar
X

X
Fairiane
X

X

X

X

X
Falcon
X

X

X
Montego
X

X

X

X

X
Mustang
X

X

X
Lincoln-
Continental
Thunderbird
Continental-
Mark
III

COMPONENT INDEX

COUNTERSHAFT GEAR BEARINGS

Removal and Installation

DESCRIPTION

GEAR SHIFT CONTROL ASSEMBLY—

Floor Mounted

Removal and Installation

GEAR SHIFT LEVERS AND SEALS

Removal and Installation

GEAR SHIFT LINKAGE ADJUSTMENT

Column Mounted

Floor Mounted

INPUT SHAFT BEARING

Removal and Installation

SYNCHRONIZERS

Disassembly and Assembly

TRANSMISSION (Complete)

Cleaning and Inspection See Part 06-01

Disassembly and Overhaul

Removal and Installation

AH
Models
02-07

02-02

02-07

02-06

02-02

02-03

02-06

02-06

02-04

02-03
procarmanuals.com