1969 FORD MUSTANG manual transmission

06-02-10
Ford Design Three Speed Transmission
06-02-10

bore.
On these 6 cylinder models, in-

stall a new expansion plug in the

countershaft bore at the front of the

case.

23.
Coat a new extension housing

gasket with sealer and position it on

the case.

24.
Install lock washers on the five

attaching screws. Dip the threads of

the cap screws in sealer. Secure the

housing to the case and torque the
cap screws to specification.

25.
Install the filler and drain plugs

(if equipped) in the case. Make sure

that the magnetic plug is installed in

the bottom of the case.

7.6. Place the transmission in gear.

Pour lubricant over the entire gear

train while rotating the input or out-

put shaft.

27.
Install the remaining detent
plug in the case. Install the long

spring (which is retained by the case)

to secure the detent plug.

28.
Coat a new cover gasket (Fig.

5) with sealer. Secure the cover with

cap screws. Torque the screws to spec-

ification.

29.
Check the operation of the

transmission in all of the gear posi-

tions.procarmanuals.com

06-03-01

Ford Design Four-Speed Transmission

06-03-01

PART
6-3
Ford Design Four Speed
Transmission

Trans-

mission

Model

RUG-ADI

RUG-AE1

RUG-AG

RUG-AH

RUG-AJ

RUG-AL

RUG-C2

RUG-D2

RUG-E3

RUG-JZ

RUG-M3

RUG-AK

RUG-VI

® Used with

© Used with
Engine

Model

390-4V-GT

428-4V-CJ

351-2V-4V

351-2V-4V

428-4V

390-4V-GT

390-2V-4V

351-2V-4V

302-2V-4V.351-2V-4V

390-4V-GT

390-4V

351-2V-4V

429-4V

3.75:1
and lower axle ratios

3.50:1
and higher axle ratios
Shift

Lever

Location

Floor

Floor

Floor

Floor

Floor

Floor

Floor

Floor

Floor

Floor

Floor

Floor

Floor
MODEL APPLICATION
All
Models
Ford

X
Mercury
Meteor
Cougar
X

X

X

X

X
Fairlane
X

X

X

X

X

X

X
Falcon
X

X

X

X

X

X

X
Montego
Mustang
X

X

X

X

X
Lincoln-
Continental
Thunderbird
Continental-
Mark
III

COMPONENT INDEX

COUNTERSHAFT GEAR BEARINGS

Removal and Installation

DESCRIPTION

GEAR SHIFT CAMS AND SEALS

Removal and Installation

GEAR SHIFT LINKAGE ADJUSTMENT

GEAR SHIFT CONTROL ASSEMBLY

Removal and Installation

INPUT SHAFT BEARING

Removal and Installation

INPUT SHAFTSEAL

Removal and Installation

REVERSE IDLER GEAR BEARING

Removal and Installation

SYNCHRONIZERS

Disassembly and Assembly

TRANSMISSION (Complete)

Cleaning and Inspection
See
Part 06-01

Disassembly and Overhaul

Removal and Installation

All
Models
03-06

03-02

03-04

03-02

03-05

03-06

03-04

03-06

03-06

03-03

03-02
procarmanuals.com

06-03-02
Ford Design Four-Speed Transmission

06-03-02

1 DESCRIPTION

DESCRIPTION

The Ford designed 4-speed trans-

mission
(Fig. 1) is of the
fully
syn-

chronized type with
all
gears except

the reverse sliding gear being
in con-

stant mesh.
All
forward-speed changes

are accomplished with synchronizer

sleeves.
All forward-speed gears
in the

transmission
are
helical-type, however,

the reverse sliding gear
and the
exter-

ior
of the
first-and second-speed
syn-

chronizer sleeve
are
spur-type gears.

The specifications
of
this section Part

6-4 lists
the
transmission model
num-

bers
and
vehicles
in
which they
are

used.

C 1765-B

FIG. 7—Four-Speed Transmission—Typical
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.

TRANS.
MODEL

O
RUG-C-2

10001
O

SERIAL NO.

C 2088-A

FIG. 2—Transmission

Identification
Tag

IN-VEHICLE ADJUSTMENTS
AND
REPAIRS

SHIFT LINKAGE ADJUSTMENT

1.
Loosen
the
three shift linkage

adjustment nuts. Install
a 1/4
inch
di-

ameter alignment tool through
the

control bracket
and
lever holes
as

shown
in Fig. 13.

An alignment tool
can be
made

from
1/4
inch diameter drill
rod
bent

to
an "L"
shape.
The
extensions
should
be 2 1/2
inch
and 3 3/4
inch

from
the
elbow. Short
end of
align-

ment
pin
should
be
inserted into
con-

trol bracket
and
linkage holes until
it

bottoms.

2.
Disconnect
the
reverse gear shift

rod from
the
shift lever.

3.
Shift
the
transmission into
re-

verse gear.
4.
Tighten
the 1-2 and 3-4
shift
rod

adjustment nuts.

5.
Connect
the
reverse gear shift

rod
to the
shift lever. Shift
the
reverse

lever
to the
neutral position
and
tight-

en
the
adjustment
nut.

6. Remove
the
alignment
pin.

7.
Check
the
gear shift lever
for a

smooth crossover.

REMOVAL
AND
INSTALLATION

REMOVAL

1.
Raise
the
vehicle
on a
hoist.

2.
Mark
the
driveshaft
so
that
it

may
be
installed
in the
same relative
position. Disconnect
the
drive shaft

from
the
rear U-joint flange. Slide
the

drive shaft
off the
transmission output

shaft
and
install
the
extension housing

seal installation tool into the extension
housing
to
prevent lubricant leakage.

See
Fig. 2,
Part
6-1.

3.
Disconnect
the
speedometer

cable from
the
extension housing.

4.
Disconnect
the
parking brakeprocarmanuals.com

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

cable from the equalizer lever and sep-

arate the lever from the crossmember.

5.
Remove the hairpin retainer se-

curing the cable to the transmission

rear support crossmember, and then

pull the cable assembly forward and

out of the crossmember.

6. Remove the retaining clip, flat

washer, and spring washer that se-

cures the shift rods to the shift levers.

7.
Remove the bolts that attach the

shift linkage control bracket to the ex-

tension housing and position the as-

sembly out of the way.

8. Support the engine with a trans-

mission jack and remove the extension

housing-to-engine rear support attach-

ing bolts.

9. Raise the rear of the engine high

enough to remove the weight from the

crossmember. Remove the bolts re-

taining the crossmember to the frame

side supports and remove the

crossmember.

10.
Support the transmission on a

jack and remove the bolts that attach

the transmission to the flywheel hous-

ing.

11.
Move the transmission and jack

rearward until the transmission input

shaft clears the flywheel housing. If

necessary, lower the engine enough to

obtain clearance for transmission re-

moval.

Do not depress the clutch pedal

while the transmission is removed.
INSTALLATION

1.
Make sure that the mounting

surface of the transmission and the

flywheel housing are free of dirt,

paint, and burrs. Install two guide

pins in the flywheel housing lower

mounting bolt holes. Move the trans-

mission forward on the guide pins

until the input shaft splines enter the

clutch hub splines and the case is posi-

tioned against the flywheel housing.

2.
Install the two upper transmis-

sion to flywheel housing, mounting

bolts snug, and then remove the two

guide pins. Install the two lower

mounting bolts. Torque all mounting

bolts to specifications.

3.
Raise the rear of the engine and

install the crossmember. Install and

torque the crossmember attaching

bolts to specifications, then lower the

engine.

4.
With the transmission extension

housing resting on the engine rear

support, install the transmission ex-

tension housing attaching bolts. Tor-

que the bolts to specifications.

5.
Position the shift linkage control

bracket to the extension housing and

install the attaching bolts.

6. Secure each shift rod to its re-

spective lever with the spring washer,

flat washer, and retaining pin.

7.
Guide the parking brake cable

assembly through the hole in the
transmission rear support crossmemb-

er. Secure the cable assembly to the

crossmember with the hair pin retain-

er.

8. 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.

9. Connect the speedometer cable

to the extension housing.

10.
Remove the extension housing

installation tool and slide the forward

end of the drive shaft over the trans-

mission output shaft. Connect the

drive shaft to the rear U-joint flange.

11.
Place both forward gear shift

levers and the reverse shift lever in the

neutral position and insert a 1/4 inch

diameter alignment tool in the shift

linkage alignment hole (Fig. 17). It

may be necessary to loosen the adjust-

ment nuts to install the alignment

tool. Adjust the linkage as necessary

and tighten the adjustment nuts to

specifications. Remove the alignment

tool.

12.
Fill the transmission to the

proper level with the specified lubri-

cant.

13.
Lower the car. Check tne shift

and crossover motion for full shift en-

gagement and smooth crossover oper-

ation.

MAJOR REPAIR OPERATIONS

DISASSEMBLY

1.
Mount the transmission in a

holding fixture and drain the lubri-

cant.

2.
Remove the cover attaching

screws from the case. Lift the cover

and gasket from the case.

3.
Remove the long spring that re-

tains the detent plug in the case (Fig.

4).
Remove the detent plug with a

small magnet.

4.
Remove the extension housing

attaching screws and lock washers.

Remove the housing and the gasket.

5.
Remove the input shaft bearing

retainer attaching screws. Slide the re-

tainer off the input shaft.

6. Support the countershaft gear

with a wire hook. Working from the

front of the case, push the counter-

shaft out the rear of the case as shown

in Fig. 3. Lower the countershaft to

the bottom of the case with the wire

hook. Remove the hook.
Tool-T64P-711hA

COUNTERSHAFT

C2073-A

FIG. 3—Removing Countershaft

From Case

7.
Place the first and second-speed

gear shift lever and the reverse shift

lever in the neutral position. Place the

third and fourth-speed gear shift lever

in the third-speed position.

8. Remove the attaching screw

from the third and fourth-speed shift

fork. Tap on the inner end of the shift

rail to unseal the expansion plug from
the front of the case. Then withdraw

the third and fourth-speed shift rail

from the front of the case. Do not

lose the interlock pin from the shift

rail.

9. Remove the set screw from the

first and second-speed shift fork.

Slide the first and second-speed shift

rail out the rear of the case.

10.
Remove the interlock plug and

the detent plug from the top of the

case (Fig. 4) with a magnet.

11.
On some models, remove the

snap ring that secures the speedometer

drive gear to the output shaft. Slide

the gear off the shaft, then remove the

speedometer gear drive ball. On mod-

els equipped with the new design re-

tainers, depress the tang on the speed-

ometer drive gear retaining clip and

slide the speedometer gear off the

shaft. (Fig. 5).

12.
Remove the snap ring that se-

cures the output shaft bearing to the

shaft.procarmanuals.com

06-03-04

Ford Design Four-Speed Transmission
06-03-04

13.
Remove the output shaft bear-

ing as shown in Fig. 6.

14.
Remove the input shaft and

bearing and the blocking ring from

the front of the case.

15.
Move the output shaft to the

right side of the case to provide clear-

ance for the shift forks. Rotate the

forks as shown in Fig. 7, then lift

them from the case.

16.
Support the thrust washer and

first-speed gear to prevent them from

sliding off the shaft, then lift the out-

put shaft assembly from the case as

shown in Fig. 8.

17.
Remove the reverse gear shift

fork set screw. Rotate the reverse shift

rail 90 degrees as shown in Fig. 9.

Slide the shift rail out of the rear of

the case. Lift the reverse shift fork

from the case.

18.
Remove the reverse detent plug

and spring from the case with a mag-

net.

19.
Remove the reverse idler gear

shaft from the case as shown in Fig.

10.

20.
Lift the reverse idler gear and

the thrust washers from the case. Be

careful not to drop the bearings and

the dummy shaft from the gear.

21.
Lift the countershaft gear and

the thrust washers from the case. Be

careful not to drop the bearings or the

dummy shaft from the counter-shaft

gear.

22.
Remove the snap ring from the

front of the output shaft. Slide the

third and fourth-speed synchronizer

(Fig. 11) blocking ring and the third-

speed gear off the shaft.

23.
Remove the next snap ring and

the second-speed gear thrust washer

from the shaft. Slide the second-speed

gear and the blocking ring off the

shaft.

24.
Remove the next snap ring.

25.
Remove the thrust washer, first

speed gear and blocking ring from the

rear of the shaft. The first and second

synchronizer hub is a press fit on the

output shaft. To eliminate the possi-

bility of damaging the synchronizer

assembly, remove the synchronizer

hub using an arbor press as shown in

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

remove or install the hub by hammer-

ing or prying.

PARTS REPAIR OR

REPLACEMENT

CAM AND

SHAFT SEALS

1.
Remove the attaching nut, lock

washer and the flat washer from each

shift lever and remove the three levers.

2.
Remove the three cam and shafts

from inside the case.
jjL
-SPRING
•
7234

if

Q-* 'DETENT PtUG 7C316

THIRD AND FOURTH

SPEED SHIFT FORK- 7230

SCREW. 377886 - S

DETENT PLUG-fr-fl

7C316 **

INTERLOCK PIN

7235
FIRST AND SECOND SPEED SHIFT RAIL

7240

fl-«-—
SCREW - 377386 • S

FIRST AND SECOND

SPEED SHIFT FORK • 7230

THIRD AND FOU

SPEED SHIFT RAIL

7241

EXPANSION

PLUG-74112-S

MAGNETIC DRAIN PLUG -373719-S

FIG. 4—Shift Rails and Forks Disassembled
C2074-A

SPEEDOMETER DRIVE

GEAR

SPRING CLIP

FRONT

C2052-A

# 5—Speedometer Drive Gear Installationprocarmanuals.com

06-03-05
Ford Design Four-Speed Transmission

06-03-05

DETAIL
4

FORD
AND
MERCURY

DETAIL
5

COUGAR. FAIRLANE,

FALCON,
MONTEGO,

AND MUSTANG
REVERSE SHIFT

RAIL

C1533-B

FIG. 6—Removing Output Shaft Bearing

3.
Remove
and
discard
the
O-ring

from each
cam and
shaft (Fig.
12).

4.
Dip the new
Orings
in
gear
lu-

bricant
and
install them
on the cam

and shafts.

5.
Slide each cam
and
shaft into
its

respective bore
in the
transmission

case.

6. Secure each shaft lever with
a

flat washer, lock washer
and nut.

GEAR SHIFT CONTROL

ASSEMBLY

1.
Remove
the
four screws attach-

ing
the
lower boot
to the
floor
pan.

2.
Remove the two bolts that secure

the gear shift lever
to
the shift control

assembly.

THIRD AND,

FOURTH

SPEED

SHIFT

FORK

FIRST
AND

REVERSE

SPEED

SHIFT

FORK
3.
Remove
the two
piece lock nuts

that secure
the
shift rods
to the
shift

levers.

4.
Remove
the
three bolts attaching

the control assembly
to the
extension

housing. Lower
the
control assembly

and boot
and
remove
the
control
as-

sembly from
the
boot.

5.
Remove the back-up light switch.

6. Remove
the
outer
nut
from
the

selector lever shaft
and
slide
the
shaft

from
the
control assembly.

7.
Lift
the
outer support bracket,

rubber washer, first-second,
and

third-fourth selector levers
off the as-

sembly (Fig.
13).

8. Remove
the two
bolts retaining

the inner support bracket
to the
back

THIRD
AND
FOURTH

SPEED SYNCHRONIZER

OUTPUT SHAFT MOVED

TO RIGHT SIDE
OF
CASE

C2075-A
C2077-A
Tool-T52T-

C2076-A

FIG. 9—Rotating Reverse

Shift Rail

plate. Lift
the
inner support bracket,

selector arm, and reverse selector lever

from
the
back plate.

9. Lubricate
all
mating surfaces

with lithium grease before assembly.

10.
Position
the
reverse gear selec-

tor lever, selector
arm and the
inner

support bracket
on the
back plate.

The reverse gear selector lever will

have
a
flat spot
on the
top
of
the lever

to distinguish
it
from
the
third-fourth

selector lever. Install the two retaining

bolts finger tight.

11.
Insert
a 1/4
inch gauge
pin

through
the
alignment holes
of the se-

lector levers
and
support brackets.

Line
up the
gauge
pin
perpendicular

to the back plate. Torque the two sup-

port bracket-to-back plate retaining

nuts
to
specification
and
remove
the

gauge
pin.

12.
Position
the
rubber washer,

first-second
and
third-fourth selector

levers
in the
outer support bracket.

Position this assembly against
the

inner support
so
that the selector lever

shaft holes
in the
selector levers
and

support brackets
are
aligned.

13.
Install
the
selector lever shaft

"~ REVERSE IDLER

GEAR SHAFT

Tool-T64P-7140

C2078-A

FIG. 7—Removing Shift Fork

From Case
FIG. 8—Removing Output

Shaft Assembly
FIG. TO—Removing Reverse Idler

Gear Shaftprocarmanuals.com

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

BEARING

7C
SPEEDOMETER

DRIVE GEAR

172

OUTPUT

SHAFT

SEAL

SNAP RING 7Aon

SPEEDOMETER GEAR

DRIVE BALL

353351•S

BLOCKING RING

7107

FIRST AND SECOND

SPEED SYNCHRONIZER

7124

SECOND SPEED GEAR

7102

THIRD AND FOURTH

SPEED SYNCHRONIZER

•7124

SNAP RING - 7109

FIG.
7
7—Output Shaft Disassembled

and torque the retaining nuts to speci-

fication.

14.
Install the back-up light switch

on the control assembly.

15.
Slide the lower boot over the

shift control assembly and attach the

entire assembly to the extension hous-

ing with the three bolts.

16.
Install the two bolts securing

the gear shift lever to the control as-

sembly.

17.
Pull the top lip of the lower

boot over the edges of the floor pan

and secure the upper boot to the lower

boot and floor pan with the four re-

taining screws.

18.
Position the shift rods in the se-

lector levers and install the retainers.

19.
Adjust the shift linkage as out-

lined previously in this section.

20.
Check the operation of the shift
mechanism for smooth

Adjust as required.
cross-over.

INPUT SHAFT BEARING

1.
Remove the snap ring that se-

cures the bearing to the shaft (Fig.

14).

2.
Press the input shaft gear out of

the bearing as shown in Fig. 15.

3.
Press a new bearing onto the

input shaft with the tool shown in Fig.

15.

4.
Secure the bearing with a snap

ring.

SYNCHRONIZERS

1.
Push the synchronizer hub from

each synchronizer sleeve (Fig. 16).

2.
Separate the inserts and insert

springs from the hubs. Do not mix the

parts of the first and second-speed
C1529-C

synchronizer with the third and

fourth-speed synchronizer.

3.
Position the hub in the sleeve,

making sure that the alignment marks

are properly indexed.

4.
Place the three inserts into place

on the hub. Install the insert springs

making sure that the irregular surface

(hump) is seated in one of the inserts.

Do not stagger the springs.

COUNTERSHAFT GEAR

BEARINGS

1.
Remove the dummy
sKo.ft,
two

bearing retainer washers, and the 21

roller bearings (Fig. 17) from each

end of the countershaft gear.

2.
Coat the bore in each end of the

countershaft gear with grease.

3.
Hold the dummy shaft in the

gear and install the 21 roller bearingsprocarmanuals.com

06-03-07
Ford Design Four-Speed Transmission

06 03-07

and a retainer washer in each end of

the gear.

REVERSE IDLER GEAR

BEARINGS

1.
Slip the reverse idler sliding gear

off the reverse idler gear (Fig. 18).

2.
Remove the dummy shaft, two

bearing retainer washers and the 44

roller bearings from the reverse idler

gear.

3.
Coat the bore in each end of the

reverse idler gear with grease.

4.
Hold the dummy shaft in the

gear and install the 22 roller bearings

and the retainer washer in each end of

the gear.

5. Install the reverse idler sliding

gear on the reverse idler gear making

sure that the shift fork groove is

toward the front (Fig. 18).

INPUT SHAFT SEAL

1.
Remove the seal from the input

shaft bearing retainer as shown in Fig.

19.

2.
Coat the sealing surface with lu-

bricant.

3.
Install the seal as shown in Fig.

20

ASSEMBLY

1.
Coat the countershaft gear thrust

surfaces in the case with a thin film of

lubricant and position a thrust washer

(Fig. 17) at each end of the case.

2.
Position the countershaft gear,

dummy shaft, and roller bearings in

the case.

3.
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.

4.
Place the case in a horizontal

position and check the countershaft

gear end play with a feeler gauge. The

end play should be 0.004-0.0018 with-

in specification. If not within these

limits,
replace the thrust washers.

5. 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.

6. Coat the reverse idler gear thrust

surfaces in the case with a thin film of

lubricant and position the two thrust

washers (Fig. 18) in place.

7. Position the reverse idler gear,

sliding gear, dummy shaft and the

roller bearings in place making sure

that the shift fork groove in the slid-

ing gear is toward the front of the

case.

8. Align the gear bore and thrust

washers with the case bores and install

the reverse idler shaft.

9. Measure the reverse idler gear
REVERSE GEAR CAM AND SHAFT-7C124

•
FIRST AND SECOND SPEED CAM AND SHAFT-7C124

O-RING-7288

THIRD AND FOURTH SPEED

CAMANDSHAFT-7C124
FIRST AND SECOND SPEED SHIFT LEiVER-7290

44727-S

34807-S

33800-S

THIRD AND FOURTH SPEED SHIFT LEVER-7285

44727-S'

34807-S 33800-S C1767-A

FIG. 12—Cam and Shafts and Shift Levers Disassembled

SELECTOR LEVER

SHAFT

INNER SUPPORT

BRACKET

OUTER SUPPORT

BRACKET

REVERSE SELECTOR LEVER

FIRST-SECOND

SELECTOR LEVER

C 2054.A

FIG. 13—Gear Shift Control Assemblyprocarmanuals.com