1969 FORD MUSTANG oil

05-03-04
Clutch

05-03-04

bushings, position the clutch pedal and

bushings in the pedal support.

8. Install the retaining ring on the

clutch pedal shaft.

9. Position the assist spring in the

pedal support bracket and the assist

spring bracket. Rotate the assist

spring bracket clockwise until the

upper bolt holes line up and install the

bolt. Torque both the upper and lower

bolts to specification.

10.
Check the clutch pedal free

travel and adjust as required.

MUSTANG, COUGAR

1.
Disconnect the battery ground

cable.

2.
Remove the steering column.

Refer to Group 3 of this manual for

the procedure.

3.
Remove the two capscrews re-

taining the master cylinder or booster

to the dash panel. Then remove the

two capscrews retaining the pedal sup-

port bracket to the dash panel.

4.
Working inside the vehicle, dis-

connect the clutch pedal-to-equalizer

rod at the clutch pedal by removing

the retainer and bushing.

5.
Secure the clutch pedal against

the bumper stop with a small C-clamp

as shown in Fig. 6.

6. Disconnect the stop light switch

wires at the connector.

7.
Remove the switch retainer and

slide the stop light switch off the

brake pedal pin just far enough for

the switch outer hole to clear the pin.

Then lower the switch away from the

pin.
Remove the master cylinder push

CLUTCH PEDAL ASSIST SPRING
rod, bushing and nylon washer from

the brake pedal pin.

8. Remove the screw retaining the

pedal support bracket to the top inner

cowl bracket (Fig. 6).

9. Remove the two sheet metal

screws retaining the pedal support

bracket to the dash panel.

10.
Remove the two screws retain-

ing the pedal support bracket to the

upper cowl brace and lower the pedal

support bracket away from the steer-

ing column studs.

11.
Remove the pedal support

bracket assembly from the vehicle.

12.
Mount the bracket in a vise.

13.
Remove the small C-clamp se-

curing the clutch pedal to the bumper.

Slowly pivot the pedal away from the

bumper until the assist spring can be

lifted from its seat.

14.
Remove the retainer clip from

the clutch and brake pedal shaft.

Then, remove the clutch pedal and

shaft assembly, brake pedal assembly,

and bushings from the pedal support

bracket.

15.
Apply a coating of SAE 10 en-

gine oil to the bushings and locate all

bushings in their proper places on the

brake and clutch pedal assemblies.

16.
Position the brake pedal to the

pedal support bracket. Install the

clutch and brake pedal shaft through

the pedal support and brake pedal as-

sembly. Install the retainer.

17.
Install the clutch pedal assist

spring and pivot the pedal against its

bumper stop. Secure the pedal against

the bumper with a small C-clamp as

TOP INNER COWL-TO-BRACKET

RETAINING SCREW

C2057-A

FIG.
6—Clutch
Pedal —Mustang and Couga?
shown in Fig. 6.

18.
Position the pedal support

bracket assembly to the dash panel

and to the steering column retainer

studs.

19.
Align the pedal support bracket

holes with the holes in the dash panel

and install the two sheet metal screws.

20.
Install the two capscrews at-

taching the pedal support bracket to

the upper cowl bracket.

21.
Install the screw attaching the

support bracket to the top inner cowl

bracket (Fig. 6).

22.
Install the inner nylon washer,

bushing master cylinder push rod on

the brake pedal pin. Position the stop

light switch so that it straddles the

push rod with the switch slot on the

pedal pin and the switch outer hole

just clearing the pin. Slide the switch

completely onto the pin, and install

the outer nylon washer. Secure with

the self-locking pin.

23.
Connect the stop light switch

wires to the connector and install the

wires to the retaining clip.

24.
Connect the clutch pedal-

to-equalizer rod to the clutch pedal

assembly with the bushing and retain-

er and remove the C-clamp from the

bracket.

25.
Working from the engine side

of the dash panel, install the two cap-

screws attaching the pedal support

bracket to the dash panel. Then install

the two screws attaching the master

cylinder to the dash panel.

26.
Install the steering column.

Refer to Group 3 of this manual for

the procedure.

27.
Adjust the clutch pedal free

travel.

28.
Check the brake pedal free

height and travel measurements

(Group 2).

29.
Connect the battery ground

cable.

CLUTCH PEDAL AND/OR

BUSHING REMOVAL

AND INSTALLATION

MOM EGO, FALCON

FAIRLANF

1.
Remove the retaining clip (Fig.

2) that secures the equalizer rod to the

clutch pedal. Disconnect the rod from

the pedal.

2.
Remove the lower bolt retaining

the assist spring bracket to the pedal

support. Then, loosen the upper

bracket retaining bolt (approximately

4 turns) and disconnect the spring

from the clutch pedal and bracket.

3.
Disconnect the brake pedal push

rod from the brake pedal.procarmanuals.com

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

05-04-02

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

06-01-02
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

06-02-03
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

06-02-09
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

06-04-02

Specifications

06-04-02

TORQUE LIMITS(FT-LBS)

Extension Housing Bolts

Input Shaft Bearing Retainer-to-Transmission Case Bolts

Speedometer Cable Retainer-to-Transmission Extension

Transmission-to-Flywheel Housing Bolts

Gearshift Control Levers to Cam and Shaft Assembly Lock Nuts

Transmission Cover Bolts

Filler Plug-to-Case

Drain Plug-to-Case

Shift Fork-to-Shift Rail

Third and Fourth Shift Rail Detent Bolt

Gear Shift Control Assembly
to
Transmission Extension

Shift Selector Levers to Shift Rods

Gear Shift Control Support Bracket
to
Back Plate
3-Speed

Transmissions

42-50

30-36

3.0-4.5

37-42

18-23

14-19

10-20

20-30

10-18

-

8-12

10-20

-
4-Speed

Transmissions

42-50

19-25

3.0-4.5

37-42

18-23

14-19

10-20

20-30

10-18

10-18

8-12

10-20

8-13
® Inch-pounds

SPECIAL TOOLS
SPECIAL TOOLS (Continued)

Tool Numbers

T50T-100A

T59L-100B

Tool-1175AB

T53T-4621-Bor(4621-F)

T57L-4220-A4

T52L-7000-GAE

T63P-7025-A

T64P-7025-B

T53T-4621-C
Description

Impact Hammer-Long

Impact Hammer-Short

Grease Seal Remover

Drive Pinion Bearing Cone

Replacer Front
&
Rear

Differential Side Bearing Cone

Replacer
or
Input Shaft Bearing

Remover

Extension Housing Bushing and

Seal Remover

Output Shaft Bearing Remover

& Replacer

Output Shaft Bearing Remover

& Replacer

Drive Pinion Bearing

Cone Replacer
Tool Numbers

Tool-7025-B

Tool-7025-G

T64P-7111-A

T63P-7111-A

T64P-7140-A

T61L-7657-A

T57P-7697-B

T57P-7657-G

T67P-7341-A
Description

Rear Main Shaft Bearing Removei

Main Shaft Bearing Remover

& Replacer

Cluster Gear Roller Retainer Shaf

Cluster Gear Roller Retainer Shaft

Reverse Idler Shaft Remover

Transmission Extension Housing

Oil Seal Replacer

Extension Housing

Bushing Replacer

Extension Housing

Bushing Replacer

Shift Linkage Grommet

Replacerprocarmanuals.com