1969 FORD MUSTANG manual transmission

06-02-02
Ford Design Three Speed Transmission

06-02-02

DESCRIPTION

DESCRIPTION

The RAN and RAT Model three-

speed transmission (Fig. 1) are used

on models having 170, 200, 240, 250,

302,
351 and 390 C.I.D. engines. The

specifications of this section, Part 6-4,

lists the transmission model numbers

and vehicles in which they are used.

A transmission service identification
tag is located on the right side of the

case at the front (Fig. 2). The first

line on the tag will show the transmis-

sion model and service identification

code when required. The second line

will show the transmission serial num-

ber. Additionally, a driveline compo-

nent identification tag is attached to

the upper right side of the transmis-

sion case.
This transmission is of the fully

synchronized type, with all gears ex-

cept the reverse gear and sleeve being

in constant mesh. All forward-speed

changes are accomplished with syn-

chronizer sleeves.

The forward-speed gears are

helical-cut and are in constant mesh.

Gears used in the reverse gear train

are spur-cut and are not synchronized.

C2O87-A

FIG.
1—Three-Speed
Transmission—Typical
TRANS.
MODEL

SERIAL
NO.

C 2089-A

FIG.
2—Transmission
Identification

Tag

IN-VEHICLE ADJUSTMENTS
AND
REPAIRS

GEAR SHIFT LINKAGE

ADJUSTMENT—COLUMN

MOUNTED

1. Place the gear shift lever in the

neutral position.

2.
Loosen the two gear shift rod

adjustment nuts.

3.
Check shift levers on transmis-

sion to be in neutral position.

4.
Insert a 3/16-inch diameter

alignment tool through the first and

reverse gear shift lever, the second and

third gear shift lever and both holes

in the lower casting (Fig. 3). An align-

ment tool can be made from 3/16

inch drill rod bent to an L shape.

The extensions should be 1 inch and 2

inches from the elbow. The short end

of the tool should be inserted into the

alignment holes.

5.
Tighten the two gear shift rod

adjustment nuts.

6. Remove the alignment tool from

the levers.

7.
Start the engine and shift the se-

lector lever to each position to make

sure it operates freely.
FIG.
3—Gearshift
Linkage Adjustment—Typicalprocarmanuals.com

06-02-03
Ford Design Three Speed Transmission

06-02-03

STOP
PIN

GROMMET

Tool -
T67P.7347.A

GROMMET

LEVER

CONTROL ROD REMOVAL
^S.
GROMMET INSTALLATION

SET STOP PIN SO THAT THE GROMMET

Tool
-
T67P.734LA
AND
SHIFT ROD ARE PROPERLY SEATED
OMMET—^

SEATED
\

CONTROL ROD INSTALLATION

CONTROL ROD

STOP
PIN

FIG. 4—Removing
or
Installing Shift Linkage Grommet

GEAR SHIFT LINKAGE

ADJUSTMENT—FLOOR MOUNTED

1.
Loosen
the
three shift linkage

adjustment nuts. Install
a 1/4
inch
di-

ameter alignment pin through the con-

trol bracket and lever alignment holes

shown
in Fig. 18.

2.
Tighten
the
three linkage adjust-

ment nuts
and
then remove
the
align-

ment
pin.

3.
Check
the
gear shift lever
for a

smooth crossover.

COLUMN-MOUNTED

SHIFT LINKAGE

GROMMET REMOVAL
AND

INSTALLATION

The column-mounted shift lever
as-
sembly incorporates
an oil
impregnat-

ed plastic grommet
in the
end
of
each

lever
arm. A
special tool T67P-

7341-A
is
required
to
install the grom-

met
in the
shift lever,
and to
install

the shift linkage
rod
into
the
grom-

met. Remove
and
install
the
grommet

as follows:

1.
Place
the
lower
jaw of the
tool

between
the
shift lever
and the
shift

rod.
Position
the
stop
pin
against
the

end
of the
shift
rod
(Fig.
4)
and force

the
rod out of the
grommet. Remove

the grommet from
the
shift lever
by

cutting
off the
large shoulder with
a

sharp knife. The groin met must
be re-

moved from
the
shift lever
and a new

one installed each rime
'he rod is
dis-

connected.

2.
Before installing
a
new grommet,
C 2090-A

adjust
the
stop
pin as
necessary
to

properly install
the
grommet and coat

the outside
of
the grommet with lubri-

cant. Then, place
the
grommet
on the

stop
pin and
force
it
into
the
shift

lever hole. Turn
the
grommeit several

times
to be
sure
it is
properly seated.

3.
Readjust
the
stop
pin to a
length

which
is
sufficient
to
install
the
shift

rod into
the
grommet
(Fig.
4).
If
the

pin height
is not
adjusted,
the
shift

rod
may be
pushed
too far
through

the grommet causing damage
to the

grommet retaining
lip.

4.
With
the pin
height properly
ad-

justed, position
the
shift
rod on the

tool
and
force
the rod
into
the
grom-

met until
the
groove
in the rod
seats

on
the
inner retaining
lip of
the grom-

met.

REMOVAL AND INSTALLATION

REMOVAL

1.
Raise
the
vehicle
on a
hoist.

2.
Mark
the
drive shaft
so
that
it

may
be
installed
in the
same relative

position. Disconnect
the
drive shaft

from
the
rear U-joint flange.

3.
Slide
the
front
of the
drive shaft
out
of the
transmission extension

housing
and off the
output shaft
In-

sert
the
tool shown
in (Fig. 2),
Part

6-1 into the extension housing
to
pre-

vent
the
lubricant from leaking
out of

the transmission.

4.
Remove
the cap
screw
and
lock

washer that secures
the
speedometer
cable retainer
to the
extension hous-

ing. Pull
the
speedometer cable
out of

the extension housing.

5.
On
vehicles equipped with
a

column-mounted gear shift selector,

remove
the
shift rods from
the
shift

levers
at
the transmission. On vehicles

equipped with
a
floor-mounted gearprocarmanuals.com

06-02-04

Ford Design Three Speed Transmission

06-02-04

shift selector, remove
the
shift selector

assembly from
the
extension housing.

6.
On
Ford, Mercury
and
Meteor

vehicles disconnect
the
parking brake

cable from the equalizer lever and sep-

arate
the
lever from
the
crossmember.

7.
On
Ford, Mercury
and
Meteor

models, remove
the
bolts that secure

the extension housing
to the
engine

rear support.

8. Raise
the
rear
of
the engine high

enough
to
remove
the
weight from
the

crossmember.

9. Support
the
transmission with
a

transmission jack
and
remove
the

transmission from
the
flvwheel hous-

ing.

10.
Move
the
transmission and jack

rearward until
the
input shaft
is
clear

of
the
flywheel housing.

11.
Remove
the
transmission from

the jack
and
mount
it in a
holding

fixture.

Do
not
depress
the
clutch pedal

while
the
transmission
is
removed.

INSTALLATION

1.
Make certain that
the
machined

surfaces
of the
transmission case
and

the flywheel housing
are
free
of
dirt,

paint,
and
burrs.
2.
Install
a
guide
pin in
each lower

mounting bolt hole.

3.
Start
the
input shaft through
the

release bearing. Align
the
splines
on

the input shaft with
the
splines
in the

clutch disc. Move
the
transmission

forward
on the
guide pins until
the

input shaft pilot enters
the
bearing
or

bushing
in the
crankshaft.
If the

transmission front bearing retainer

binds
up on the
clutch release bearing

hub,
work
the
release bearing lever

until
the hub
slides onto
the
transmis-

sion front bearing retainer. Install
the

two transmission-to-flywheel housing

upper mounting bolts
and
lockwash-

ers.
Remove
the two
guide pins
and

install
the
lower mounting bolts
and

lock washers.

4.
Raise
the
rear
of the
engine high

enough
to
provide clearance
for in-

stalling
the
crossmember. Bolt
the

crossmember assembly
to the
frame

side supports.

5.
On
Ford, Mercury
and
Meteor

models, lower
the
engine until
the ex-

tension housing just contacts
the
rear

support. Align
the
bolt holes
in the

extension housing with those
in the

support. Then lower
the
engine
and

remove the jack. Install the two exten-

sion housing-to-support attaching
bolts
and
lock washers.

6.
On
Ford, Mercury
and
Meteor

models, insert
the
parking brake front

cable
in the
equalizer
and
install
the

equalizer
in the
bracket
on the

crossmember. Secure
the
parking

brake rear cable
to the
equalizer.

7.
On
vehicles equipped with
a

column-mounted gear shift selector,

secure
the
shift rods
to the
shift levers

at
the
transmission.
On
vehicles

equipped with
a
floor-mounted gear

shift selector, attach
the
shift selector

assembly
to the
extension housing.

8. Insert
the
speedometer cable
and

driven gear
in the
extension housing

and secure
it
with
a cap
screw
and

lock washer.

9. Remove
the
tool shown
in
Fig.
2,

Part 6-1, from
the
extension housing.

Align
the
reference marks
and
slide

the front universal joint yoke onto
the

output shaft
and
into
the
extension

housing. Connect
the
rear universal

joint
to the
axle pinion flange
and tor-

que
the
nuts
to
specifications.

10.
Fill
the
transmission
to the

proper level with
the
approved lubri-

cant.

11.
Adjust
the
clutch pedal free

travel
and the
shift linkage
as re-

quired.

MAJOR REPAIR OPERATIONS

DISASSEMBLY

1.
Mount
the
transmission
in a

holding fixture and drain
the
lubricant

by removing
the
drain plug,
if so

equipped,
or the
lower extension hous-

ing bolt.

2.
Remove
the cap
screws that
at-

tach
the
cover
to
the case. Remove
the

COVER
cover
and the
gasket (Fig.
5)
from
the

case.

3.
Remove
a
long spring that
re-

tains
the
detent plug
in the
case (Fig.

9).
Remove
the
detent plug with
a

small magnet.

4.
Remove
the cap
screws
and
lock

washers that attach
the
extension

housing
to
the case. Remove extension

FRONT

BEARING RETAINER

C2069-A
and gasket from
the
case.

5.
Remove
the cap
screws
and
lock

washers that attach
the
front bearing

retainer
to the
case. Remove
the
front

bearing retainer
and
gasket from
the

case.

6. Remove
the
lubricant filler plug

from
the
right side
of the
case. Work-

ing through
the
plug opening, drive

the roll
pin out of the
case
and
coun-

tershaft with
a
1/4-inch
punch
(Fig.

6).

TERSHAFT'
#

PIN

C 1841-A

FIG. 5—Transmission Case
and
Related Parts—Typical
FIG. 6—Removing Countershaft

Roll
Pinprocarmanuals.com

06-02-05

Ford Design Three Speed Transmission

06-02-05

Dummy

Shaft

FIG. 7—Removing Countershaft

7.
On 6-cylinder vehicles with a

model RAN transmission except

Ford, tap the countershaft from the

rear of the case with a dummy shaft

to remove the expansion plug from

the countershaft bore at the front of

the case.

8. Hold the countershaft gear with

a hook and with the tool shown in

Fig. 7, push the countershaft out the

rear of the case.

The countershaft (cluster) gear and

thrust washers (Fig. 21) can be low-

ered to the bottom of the case. Re-

move the countershaft from the rear

of the case.

9. On some models, remove the

snap ring that secures the speedometer

drive gear on the output shaft. Slide

the speedometer drive gear off the

shaft. Remove the speedometer drive

gear lock ball from the shaft. If the

vehicle is equipped with the new de-

sign retainer, depress the tang on the

speedometer drive gear retaining clip

and slide the gear off the output shaft

(Fig. 10).

10.
Remove the snap ring that re-

tains the output shaft bearing on the
C2070 A

shaft. Remove the bearing from the

case and shaft as shown in Fig. 8.

11.
Place both shift levers in the

neutral (center) position.

12.
Remove the set screw that se-

cures the first and reverse shift fork to

the shift rail. Slide the first and rev-

erse shift rail out through the rear of

the case.

13.
Slide the first and reverse syn-

chronizer forward as far as possible,

and rotate the first and reverse shift

fork upward. Then lift it from the

case.

14.
Move the second and third-

speed shift fork to the second-speed

position to gain access to the set

screw. Remove the set screw from the

fork. Rotate the shift rail 90 degrees

as shown in Fig. 11.

15.
Lift the interlock plug (Fig. 9)

from the case with a magnet.

16.
Tap on the inner end of the sec-

ond and third-speed shift rail to re-

move the expansion plug (Fig. 9) from

the front of the case. Remove the shift

rail.

17.
Remove the second and third-

speed shift rail detent plug and spring

from the detent bore.
18.
Pull the input gear and shaft

forward until the gear contacts the

case,
and then remove the large snap

ring. It is necessary to move the gear

forward to provide clearance when re-

moving the output shaft assembly

from RAT model transmissions. On

all other models, the input shaft and

gear is removed from the front of the

case at this time.

19.
Rotate the second and third-

speed shift fork upward, and lift it

from the case.

20.
Carefully lift the output shaft

assembly out through the top of the

case.

21.
On an RAT model, work the

input shaft bearing and gear back

through the bore in the case and out

through the top. Remove idler gear

shaft, driving from the front of the

case.

22.
Lift the reverse idler gear and

two thrust washer (Fig. 12) from the

case.
Lift the countershaft gear, thrust

washer, and dummy shaft from the

case.

23.
Remove the snap ring from the

front of the output shaft, and slide the

synchronizer and the second-speed

gear (Fig. 13) off the shaft.

24.
Remove the next snap ring and

tabbed thrust washer from the output

shaft. Then slide the first gear and

blocking ring off the shaft.

25.
Remove the next snap ring

from the output 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, remove the synchro-

nizer hub using an arbor press as

shown in Fig. 21. Do not attempt to

remove or install the hub by hammer-

ing or prying.

C2071-A

FIG. 8—Removing Output Shaft

Bearing
SET SCREW
SCREW

MACHINED SURFACE

2ND AND 3RD SHIFT FORK

EXPANSION PLUG

1ST AND REVERSE

SHIFT RAIL

FIG. 9—Shift Rails and Forks Disassembled
C1798-Aprocarmanuals.com

06-02-06
Ford Design Three Speed Transmission

06-02-06

SPEEDOMETER DRIVE

GEAR

SPRING CLIP

FRONT

C2052-A

FIG. 10—Speedometer Drive Gear Installation—New Design

TOOL-T52T

6500-DJD

C1564-A

FIG. 11—Rotating Second and Third-Speed Shift Rail

PARTS REPAIR
OR

REPLACEMENT

SHIFT LEVERS
AND
SEALS

1.
Remove
the nut,
lock washer,

and flat washer that secure each shift

lever (Fig.
14) to the
lever
and
shaft
in
the transmission case. Lift
the
levers

off
the
shaft. Slide each lever
and

shaft
out of the
case. Discard
the CD-

ring from each shaft.

2.
Lubricate
the new
seals with

transmission lubricant
and
install

them
on the
shafts.

3.
Install
the
lever
and
shafts
in the
case.

4.
Position
a
shift lever
on
each

shaft
and
secure them with
a
flat

washer, lock washer,
and nut.

INPUT SHAFT BEARING

1.
Remove
the
snap ring securing

the input shaft bearing
(Fig. 15), and

press
the
input shaft
out of the
bear-

ing.

2.
Press
the
input shaft bearing

onto
the
input shaft with
the
tool

shown
in Fig. 16, and
install
the
snap

ring
on the
shaft.

SYNCHRONIZERS

1.
Push
the
sychronizer
hub
from

each synchronizer sleeve.

2.
Separate
the
inserts
and
insert

springs from
the
hubs.
Do not mix the

parts from
the
second
and
third-speed

synchronizer with
the
first
and
reverse

synchronizer (Figs.
17 and 18).

3.
Install
the
rear insert spring
in

the groove
of the
first
and
reverse
syn-

SHAFT AND LEVER

0-RING

SHIFT

LEVER

C 1845-A

FIG. 74—Shift Lever and Shafi

Disassembled

REVERSE

IDLER GEAR THRUST

WASHER ROLL
PIN

REVERSE IDLER

GEAR SHAFT

C1799-A

FIG. 72—Reverse Idter Shaft

Disassembled
BLOCKING RING SPEEDOMETER DRIVE GEAR

OUTPUT SHAFT

BLOCKING RINGS

SNAP RING

REAR BEARING

SYNCHRONIZER
THRUST WASHER
REVERSE GEAR

AND SLEEVE
C2072-A

FIG. 13—Output Shaft Disassembledprocarmanuals.com

06-02-07
Ford Design Three Speed Transmission

06-02-07

SNAP RINGS

FIG. 15—Input Shaft Gear Disassembled
C1802-
A

REMOVAL
INSTALLATION

C1O25-B

FIG. 76—Replacing Input Shaft

Bearing
chronizer
hub.
Make sure that
the

spring covers
all
insert grooves. Start

the
hub in the
sleeve making sure that

the alignment marks
are
properly
in-

dexed. Position
the
three inserts
in the

hub making sure that
the
small
end is

over
the
spring
and
that
the
shoulder

is
on the
inside
of the hub.
Slide
the

sleeve
and
reverse gear onto
the hub

until
the
detent
is
engaged. Install
the

front insert spring
in the hub to
hold

the inserts against
the hub. Be
sure

the spring humps
of the
rear spring

cover different inserts than
the
front

spring humps (Fig.
20).

BLOCKING RING

SLEEVE
AND

REVERSE GEAR

C1803-
A

FIG. 17—First
and
Reverse Synchronizer Disassembled

INSERT
HUB AND
SLEEVE ALIGNMENT MARKS

SPRING

BLOCKING m$ERTS

RING
INSERT SPRING

C1804-
A

FIG. 18—Second
and
Third Synchronizer Disassembled
4.
Install
one
insert spring (Fig.
18)

into
a
groove
of the
second
and
third

speed synchronizer
hub,
making sure

that
all
three insert slots
are
fully cov-

ered. With
the
alignment marks
on

the
hub and
sleeve aligned, start
the

hub into
the
sleeve. Place
the
three
in-

serts
on top of the
retaining spring

and push
the
assembly together.
In-

stall
the
remaining insert spring
so

that
the
spring ends cover
the
same

slots
as
does
the
other spring.
Do not

stagger
the
springs. Place
a
synchro-

nizer blocking ring
on
each
end of the

synchronizer sleeve.

COUNTERSHAFT GEAR

BEARINGS

1.
Remove
the
dummy shaft, fifty

roller bearings,
and the two
bearing

retainer washers from
the
countershaft

gear (Fig.
21).

2.
Coat
the
bore
in
each
end of the

countershaft gear with grease.

3.
Hold
the
dummy shaft
in the

gear
and
install
the
twenty-live roller

bearings
and a
retainer washer
in
each

end
of the
gear.

4.
Position
the
countershaft gear,

dummy shaft,
and
roller bearings
in

the case.

5.
Place
the
case
in a
vertical posi-

tion. Align
the
gear bore
and the

thrust washers with
the
bores
in the

case
and
install
the
countershaft.

6. Place
the
case
in a
horizontal

position
and
check
the
countershaft

gear
end
play with
a
feeler gauge.
The

end play should
be
within specifica-

tion.
If not
within specification,
re-

place
the
thrust washers.

7.
After establishing
the
correct end

play, install
the
dummy shaft
in the

countershaft gear
and
allow
the
gear

to remain
at the
bottom
of the
case

until
the
output
and
input shafts have

been installed.

GEAR SHIFT LEVER
AND

CONTROL ASSEMBLY

REMOVAL
AND

INSTALLATION—

FLOOR-MOUNTED

1.
Remove
the
four screws attach-

ing
the
lower boot
to the
floor
pan.

2.
Remove
the two
bolts attaching

the gear shift lever
to the
control
as-

sembly.

3.
Remove
the two
piece lock nuts

that connect
the
shift rods
to the con-

trol assembly.

4.
Remove
the
three bolts retaining

the shift control assembly
to the ex-

tension housing. Allow
the
back-up

light switch
to
hang free.procarmanuals.com

06-02-08
Ford Design Three Speed Transmission

06-02-08

FIRST-REVERSE

SELECTOR LEVER

SELECTOR LEVER

SHAFT

SUPPORT BRACKET

SECOND-THIRD

SELECTOR LEVER

C
2053-A

79—Gear Shift Control Assembly Disassembled—3-Speed
5.
Lower the control assembly from

the vehicle and remove the boot.

6. Remove* the nut from the selec-

tor lever shaft and remove the shaft

from the assembly. Then, llift the se-

lector arm and selector levers out of

the support bracket. Do not lose the

detent spring located between the

first-reverse selector lever and the se-

lector arm (Fig. 19).

7.
Lubricate all mating surfaces

with lithium grease before assembly.

8. Position the detent spring be-

tween the first-reverse selector lever

and the selector arm. Be sure the wide

base of the spring rests against the se-

lector lever. Position the second-third

selector lever against the selector arm

and insert the entire assembly into the

support bracket.

9. Install the selector lever shaft

through the support bracket and selec-

tor lever assembly and install the re-

taining nut.

10.
Slide the control assembly into

the boot and attach the entire assem-

bly to the extension housing. Do not

lose the spacer located inside the as-

sembly. Be sure the back-up light

switch is properly installed.

11.
Install the two bolts securing

the gear shift lever to the shift control

assembly.

12.
Insert a 1/4 inch diameter

alignment pin in the alignment holes

of the control assembly.

13.
Position the shift rods on the

selector levers and install the lock

nuts.

14.
Remove the alignment pin.

15.
Check the operation of the shift

mechanism for smooth cross-over and

adjust as required.

FRONT

REAR

C 1742-A

FIG.
20—First
and
Reverse Speed Synchronizer Insert Spring

Installation

iNEEDLE BEARINGS
(25
EACH
END

\

BEARING

RETAINER ROLL
PIN

. 27—Countershaft Gear Disassembled
BEARING

RETAINER

C1805-
A
ASSEMBLY

1.
Coat the reverse idler gear thrust

surfaces in the case with a thin film of

lubricant and position the two thrust

washers in place.

2.
Position the reverse idler gear

and dummy shaft in place. Align the

gear bore and thrust washers with the

case bores and install the reverse idler

shaft.

3.
Measure the reverse idler gear

end play with a feeler gauge. End play

should be within specification. If the

end play is not within specification,

replace the thrust washers. If the end

play is within limits, leave the reverse

idler gear installed.

4.
Lubricate the output shaft

splines and machined surfaces with

transmission lubricant.procarmanuals.com

06-02-09
Ford Design Three Speed Transmission

06-02-09

PRESS
RAM

OUTPUT SHAFT

SYNCHRONIZER
PRESS
RAM

OUTPUT SHAFT
Tool-T63P7025-A

SYNCHRONIZER

HUB

REMOVAL INSTALLATION c 1718-A

FIG. 22—Removing
and
Installing First
and
Reverse Synchronizer

5.
The
first
and
reverse synchroniz-

er
hub is a
press
fit on the
output

shaft.
To
eliminate
the
possibility
of

damaging
the
sychronizer assembly,

install
the
synchronizer
hub
with
the

teeth
end of the
gear facing toward

the rear
of the
shaft, using
an
arbor

press
as
shown
in Fig. 22. Do not at-

tempt
to
remove
or
install
the hub by

hammering
or
prying.

6. Place
the
blocking ring
on the

tapered machined surface
of the
first

gear.

7.
Slide
the
first gear onto
the out-

put shaft with
the
blocking ring

toward
the
rear
of the
shaft. Rotate

the gear
as
necessary
to
engage
the

three notches
in the
blocking ring with

the synchronizer inserts. Secure
the

first gear with
the
thrust washer
and

snap ring.

8. Slide
the
blocking ring onto
the

tapered machined surface
of the sec-

ond gear. Slide
the
second gear with

blocking ring
and the
second
and
third

gear synchronizer onto
the
mainshaft.

The tapered machined surface
of the

second gear must
be
toward
the
front

of
the
shaft. Make sure that
the

notches
in the
blocking ring engage

the synchronizer inserts. Secure
the

synchronizer with
a
snap ring.

9. Coat
the
bore
of the
input shaft

and gear with
a
thin film
of
grease.
A

thick film
of
grease will plug
the lu-

bricant holes
and
prevent lubrication

to
the
bearings. Install
the 15
bearings

(Fig.
15) in the
bore.

10.
If
working
on a RAT
model

transmission, install
the
input gear

and bearing through
the top of the

case
and
through
the
bore
in
front
of

the case.
On RAN
models,
me
input

shaft
is
installed through
the
front
of

the transmission. Install
the
snap ring

in
the
bearing groove.
11.
Position
the
output shaft
as-

sembly
in the
case. Position
the sec-

ond
and
third-speed shift fork
on the

second
and
third-speed synchronizer.

12.
Place
a
detent plug spring
and

a plug
in the
case
(Fig. 9).
Place
the

second
and
third-speed synchronizer
in

the second speed position (toward rear

of transmission). Align
the
fork
and

install
the
second
and
third-speed shift

rail.
It
will
be
necessary
to
depress
the

detent plug
to
enter
the
rail
in the

bore.
Move
the
rail inward until
the

detent plug engages
the
forward notch

(second-speed position).

13.
Secure
the
fork
to the
shaft

with
the set
screw. Move
the
synchro-

nizer
to the
neutral position.

14.
Install
the
interlock plug
in the

case.
If the
second
and
third-speed

shift rail
is in the
neutral position,
the

top
of the
interlock will
be
slightly

lower than
the
surface
of the
first
and

reverse shift rail bore.

15.
Move
the
first
and
reverse
syn-

chronizer forward
to the
first-speed

position. Place
the
first
and
reverse

shift fork
in the
groove
of the
first

and reverse synchronizer. Rotate
the

fork into position
and
install
the
first

and reverse shift rail. Move
the
rail

inward until
the
center notch (neutral)

is aligned with
the
detent bore. Secure

the fork
to the
shaft with
the set

screw.

16.
Install
a new
shift rail expan-

sion plug
in the
front
of the
case.

17.
Hold
the
input shaft
and
block-

ing ring
in
position. Then move
the

output shaft forward
to
seat
the
pilot

in
the
roller bearings
of the
input

gear.

18.
Tap the
input gear bearing into

place
in the
case while holding
the

output shaft
to
prevent
the
roller bear-

ings from dropping. Install
the
front
C1806-A

FIG. 23—Installing Output Shaft

Rear Bearing

bearing retainer
and new
gasket
mak-

ing sure that
the oil
return slot
is at

the bottom
of the
case. Install
and

torque
the
attaching screws
to
specifi-

cation.

19.
Install
the
large snap ring
on

the rear bearing. Place
the
bearing
on

the output shaft with
the
snap ring

end toward
the
rear
of the
shaft. Press

the bearing into place with
the
tool

shown
in Fig. 23.
Secure
the
bearing

to
the
shaft with
a
snap ring.

20.
On
some models, hold
the

speedometer drive gear lock ball
in

the detent
and
slide
the
speedometer

drive gear into place. Secure
the
gear

with
a
snap ring.
On
models equipped

with
the new
design retainer, install

the speedometer drive gear retaining

clip
on the
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. 9).

21.
Place
the
transmission
in the

vertical position. Working through
the

drain hole
in the
bottom
of the
case,

align
the
bore
of the
countershaft gear

and
the
thrust washers with
the
bore

of
the
case with
a
screwdriver.

22.
Working from
the
rear
of the

case,
push
the
dummy shaft
out of the

countershaft gear with
the
counter-

shaft. Before
the
countershaft
is com-

pletely inserted
in the
bore, make sure

that
the
hole that accommodates
the

roll
pin is
aligned with
the
hole
in the

case.
Drive
the
shaft into place
and in-

stall
the
roll
pin. On all 8
cylinder
ve-

hicles
and
Ford
6
cylinder models,
the

countershaft
is a
press
fit in the
case.

On
6
cylinder models with model

RAN transmissions there
is a
counter-

shaft-to-case clearance
of
0.020 inch

at
the
front bore
and 0.010 at the
rearprocarmanuals.com