1974 FORD CAPRI wheel

104 Chapter 6 Manual g earbox and autom ati c transmission )
PART 1, MANUAL GEARBOX
Gener"l description
The nl The reverse Ilear all the l.1ynenr has St,nluht·cut sp'" teeth which dllve Ihe 1 st/2"d synchrOlliser huh via the reverse Idler IJeM when I(~velse geiu IS (J1l\Jilge Ge;u$ "re ell!J 2 ROlltine Illainten,lIlce
At the "It,,"v "cc k Yf.'ilfbux oillevul
J.1ck up th,! C;lr amI SUPpO'{ on a xle s!;lIlds. m;lklll\j sure lh"lll 'S levI,1 Alt""l.ltlvely PO~III()n Ihe Cill over .111 "lsfH:r.IIUIl I"l 01 on lamps
) US"'~J ,I s\III, II,le SqLl,lIU key. un~r:",w IllI< hiler pili" f'O'l1 Ilw Idt h;1I1d ~I(h, of Ih(, oe"rI)Ox (pholo) Not" Ihm Oil Ihc lo"r-sp<:ed 11".101)0 the hll", ph,O IS 101: 4 Make UP" piece of bent w ire to Ihe d"llells'ons shown III r-'!I G] lhen IIlSCll II ,II1d ,eSl Ihe ho.ilOntal seetlO'l 011 Ihe tllIca(is of the pIli\! hole. Remove the wire and check Ih e all level On all lour-speed
\Jearhoxes . ,11l(1 f,ve·speed ge.1rhoxes m.1nufactlltud ,,(w, M"y 191;1S (!wlld code FIl) the 011 should be level with (]I a milx"num of 5 0 111111 (02 Ill) helow Ihe iJottOIll edne of the ph)~J hole. I: or ('ve-speed !1(;"'IJ()XI!~ m;lIlufactured liP t o Ap,,1 1984 (Iwlld co(ie EG) Ihe 011 "'list I,,, I"v'" W ill, 11,,; bOllom of Ihe plUH hoi" On I,ve· speed Ilca,hox cs "h"nda<:tu,,,,II,(,twe,)Il M"y 198<1 ,IIld 1\.11111 1985 (Iall sulf,x (,n(iIlHI II'
E) the o'("ltI~1 h" ""'w""" 1 0 0 ""d 150 """ (0 <1 alld 0 G 'n) 1,,;low 110" I)()UDl Il "d~I'! of Ihe I'lu~1 hoi,!
G WI",,,! "'";"s~.,,y top "I' l h " lev,,! with II", ~1'(!<:I(oed !jI;I(),., 0 1 001 (phulo)
" n,,(ot and "!Ih,,,n Ihn fill", plu!) Ihen lowe, Ihe "II to lloe ~)lolllHf
-;;e.1l'lJox -rmll()val ancl .efiuinu
If the IJ"ilrl,ox IS to he 'emov"d from Ih e Cill wllhcHJI romovlIIU Ihe ""II"l(J, Ih" !1'''"j,UX IS rumov,!d Irom heneallo lloe car Jnd il (,IIUe wound cle.11le. support It securely on hlocks 0' stands ,1nll chock the wheels 2 O'SCOIU10Ct the ha tlery
Fig. 6,1 four-spoed \Joarhox (Sec 1)
Fi\J. 6,2 Five-speed !Jcarhox (Sec 1)
I.e , ..
-~
t 25 W II I !
t A • I I I 15 I
7 (11) no I I ~
~-
" I /
~ 10\,
· ... 1--=" ...
Fig. 6 .3 Wire dimensions for IlHlking a geilrhox oil level dipstick (Sec 2)
All dUllet/SIOIIS J/l IIUn A File lIole/n's
:; .
.. ~ .. -,.' . • <
! ,,;
'r '
,j/
' I
live-speed 25 TopP lng'up the gearbox oil 3 ,4 A On the lIve -spee d UOilfhox remove the pack,n g
procarmanuals.com

)
Chapter 7 Propeller shaft
Contents
Cenl,C be"wl(J rCl1<,w,,1 !':HlII d'''!I(lOSIS 1',01'"11,,, Shill, Gel,..,,;!1 li('SCIIIIIIO"
Specifications
Type
Torque wrench settings C{:II(,,, I,/!,,, ,,,! )
(',op"lll:r shall (" "',II i,xlc I I,moO]
Cello!',,1 duscriptioll
3 , ..
o"V() IS lI"Il~""w,d 110m III!: HP.;uh<)x 10 thCIVill ,"xlc hy mpdns "r " r",,!ly 1)"I,lIlted two 1''',Co) tuhul;1I p,opcli.:r ~hafl The u 'Hv""Si,1 JOlin ;" 1he 1'0111 of tile ,hilh IIH:()rpOI,lICS;) sphno"r yoke winch IS,' ~hd"'!II'1 Oil Iliu \lUilllJu x "''''''SIHlft A (w Illel lIIuvcrs"r lUll)! ,11 11'0 leill uf the f.Il,1f1 IIl(;orpOr;\I(!s iI [lill1lter! yoke which IS holled to the Ie", ,1xle drive !lilll\IC The honl ,111<1 "."" sh"hs illU cOIll"'cl(,d vIa a COI1~1ody .
!'wpldlc, ~h;!h ,ctl1()v;)1 ,md rcf,UIIlU l)n,v,,,,,,II'''''IS '""pectln!) 2 .,
TWO'IHCCll tl1l>\lI., •. w llh lwo HMdy,Splcer type uillvelsitl 10lols an d 01'(' COIISWII1 V"loc,ly (CV) ccnl.e 10"'1. CC"lIC SUppO' 1 IUI;II">!)
NIIl 1 B 10 23 (;0 hI tj~
'1)111 13 10 17 114 10 48
II", 1110) ",11." ,hol!1 ,,,uv,,,s;r ) )OUlls C;IP"lOl hc ICllewed wllhoul ,purloll "'l"'Pllh:ll1 hcciI",e Ihe )01111 s pldels ;IIC sl"ke(1 11110 Ihe yokes ,n i> I'OSl1l011 dUWln)lnud dUlln9 elccl ,olHC h;>l;lI1cin\j When 101111 we;u IS dd,'Cit,d (seu SectIon 11). "ilher .1 new IHopelh;. sh~1t should he ohl;"""d. 01 lilt) cOlllpl{,tc plopelle. shah shQuld he p;rss~d to;> SIIII.IUly
equI pped el1!).necIIt>\j wOlkshop lor I~pn"
2 Propeller sh Chock hOlh IIonl wheels Ihen ) F
ig. 7. 1 Two-piece propeller shaft showing tubular section (Sec 1)
procarmanuals.com

Chapter 8 Rear axle
Contents
Axle rear cover .. lemoval and .etliling Axlosha!! bearing -renewal Adcshah -removal and refltllng . Fnul1 diilgllosis -re3. ,1xle Gcncr Speci fic", iOl1s
Gel \cra' Axle dcsI\)n Hallo . uhllei'ml C"llilClly •• I>IIC;1I11 type. O ,lIcnmll.1I sIde 90;u ('"dllo;u 1'''''011 turning torque (~ell"llJ) Crown wheel and pill 1011 backlilsh
Torqu e w re nch settings Bc,uinu (31) \0 axle Cilsing Cover \0 axle caSing CrOWllwheel Axlcshalt bearmg retainer /backplate . Drove pinion nut ....... ....... .. Rear 51),ing U·boh Stabilise. bar clamp boll _. Propeller shnfl 10 lear General descrilHion
6 !i ,
11 1 10
The rear axle IS of the hypol(f seml·floallnO tYI)oO and is located hy semi·elliptic ro~d springs, In conjunction with a smhlliser har. The dilJerel11inl is intogral Wllh the axle hOUSing and Ihe rear axlo
InuSt he removed to carry out ilny rePil" S to the dll1erellt,,,, wh,ch milY hecorne necessary . J The drive pinion runs in two lapered roller UeiltlllgS, which are "reloaded by a spacer . Early a.l"s have a ',xed lengltl Slh'lcer and Isible spacer (F'{ls 8.1 and 8 2). Both IYlleS of SI>aCer are InlOrchangeable. but c nle lhO The COrfeCI deplh of me~h 0 1 the p,nion in the crownwheel is
PUlIon 0.1 so,, , renew"l . fie;]! .1x10 ove.h;wl Ilear axle ,emOYil. and refIlling f1ollll!w 1ll00intCIHlIlCC • Wheel siud renewal,"
() (Sahshury)
7 8 3 2 ,
Ilypo,d. sem,·flo,lIU1!), onteorill dolle/ent",', limited-slip dollelenl,')1 on 28 Speciill 300.1
I I loire (1.0 l)il11) SAE 90 015 mill (0006 'n) 2510 2 7 N,,, (I 8 to 2.0 IIlI tt) 010 to 020 ,nm (0004 to 0008 in)
Nm 60 10 68 35 to 45 801087 27 10 31 100tol20 25 to 36 401050 60 to 65
Ibl It 44 to 50
26 1033 501064 20 to 23 74 to 89 18 to 27 301037 44 10 48
obwined by Ihe use of selected shims inserted belween Ihe pin ion and rear t end 0 1 Ihe axle housing . Ove.hauling ehe lear axle requires a variely of spedallools and it is no! recommended Ihal any allernpl should be made tfJ do Ihis unless these lools ~re d
procarmanuals.com

1 Chapter 8 Rear axle 133
Fig. 8 .1 CrOSS-Sl!ction o f cnrlv rCilr ;1xlo (Sec 1)
A Fixed /ellglh SIJ.1C(!f B Pinion slum
2 Routino mnintcnoncc
C Dd1clCII1.11 S/II"'$
At lhe uHerv"ls specIfIed 111 the HOlltmc M.111l1cn;mc c SCCllon III the 110111 0 1 the mnnu;1I c""y oul the following p,uccdw(!.
Check fcar axle oil level 1 Jilek lIlllhc IvaI of the Cil! ;uHf suPPOtl on axle ~I"nds T o C!lSI'''') li1,'l Ihe Cilr is lellel ;,150 Ii!xnmun ul 100 mill (0 39 Ill) belo w the holo 4 II necessmy top Ull wllh I he euoree! \)I;lde 01 011 ;IS !Jlvcn '" 'Rceommcmlt'd !"brle,',,'s ImrllhUfls' 00 no! ovcllill thc .em ,nle. o th e.wise thc 011 will ove.he;ll ;111(1 he IO~1 Ihl oUll h Ih e b.e;Ith e. vent 5 Rcht ilnd tiuhten thu hUu. plu\1 Ihen lowe. Ihe eM 1 0 the lJ'ound
3 R e Jack up the le,lI olth e cm ;Jnd sUPPOl1 wllh axl a stan ds 0' hl oc ks
posi tioned lIancnlh the sid(Hllemhe.s . Cho ck thc tronl wheels and rcmove the .ear wheelS . 2 Mark thc p.ol>elle. sh;J1! ilnd .eil' ha. insc 4 D is connect the h,mdlllilkc ti.lIle and. whe.e .1pphC;Jblc. tha
t'ansverse ,od from the .ea. (Ide wl,h refalCnce 10 Chal >!el 9
5 CI 10 reduce any fl u id loss and also plug the disco nnecte d hose 6 Jack up the ,ca. ilxle a few Inc heS Ihen unsc.ew and rem ove the sh oc k ab so,be, lowe. moun.,n g lIo115. Prise Ihe shock abso,lIers horn lhe b.ack (lIS on Ih e rca. aKle.
COUAPS'8ll -----i--i!~e"'.!i SPACH'
,
Fig. 6 .2 Cross·sc ction of I"ter rear Ilxle (See 1)
Fig. 6.3 Removing the rear ax le fillo r 1)lug (Sec 2)
Fig. 8.4 Flexible brake hose connection to the .ear axle­arrowed (Sec 3 )
procarmanuals.com

1
134 Chapte r 8 Rea r axl e
FiO. 8.5 Discorlllccti!l9 the rcar sI"biliser Iwr (Sec 3)
7 U~"'!I u"ps (FlU 8 5) I)UU rile s1.1h,l,s(lI b.ll 10 lilt:! lCol. while unstocwIIlIJ the mOlllllnlU I)oIIS from the Ie;)' ;l~II!. flcl110vc the C!JIllI'S 8 W,lh the rC:II Ildc sUlt,lbly SUIlI>o.ICd. lIIlSCICW rhe nulS hom the hallom 01 the U-bolts i1rld reOlOlle rhe lowel S I)llrlU p l;lrcs .. ",t! 1115 .. 1<11015. 9 Wllh rhe help of an asslSlilnt. hft the rem a~lc over the "~ 13 I O.:.lt!"! the ul~"''''o.s 1m!! lowe. SP""1J pl~ws all the sp rin!jS thclI "1 Ihn 1)·llo\1s. W!IClhc. wilh Il/!W sld/.locklll\) lIutS T'!Jhlf:l1 thc IHII S l"o!Jlnsslvuly 10 Ihe spo{;lf ,/!(IIOIQUC. III 1')<;,lIe Ihc CI;1I1IP~ 011 liIe Slilhd,scr bilr "'0\I1111\1 tubhers tlrCII pull 1 hili IlltO poslllon WIllI thl) grips l1~ 10 the S IICclllI .. '(l toIlIUI) . • ,. j , Ihe" I/.ac ket s. In se'l Ihe nloum"lU bolts and tlghlel1 the nUI S. H i Ilelll Ihe lIexll/le b.,lko hose and lIuhten the nuts. 17 Rel1lovc the hoso cl,lrn p or polythene sh eet then blcL,{/ Ihe hr t 8 nelll t he h 1 AxleshMt -removal ilnd refilting
Chock Ihe front wheels then jack up the re,lr of the c~r ilnd support with onle stilnds. Remove the .ear wheel 2 Ilelea se the hilndb.nke and .emove Ihe brake drum.
3 USIng a socket through the special holes in the drive lI.::tnge. unsc'ew the bollS secu.ing the b.::tckp late and bearing ,el.::tinor to tho a~le cilSln g (pholo). 11 Withdraw tho a~leshnft. together with the bearing. " it is tight due 10 tho oulor Ir 1 0 the dtive lIange. or ,1Iternil1ively sc rew two long baits th.ough Ihe jng al diametlicaUy opposite pOInts (FIg. 8 .7) and lighten them I,·...rply a liule Illhium based glease both 1 0 the casing and bear ing outer !rack . F
ig. 8
.6 RelHoving t h o Mdeshalt .e l'l ining hoits (Soc 4)
If
I
/1
II
I
\,
Fig 8 .7 U sing long bolls to ""ithdra"" tho a~leshaft (Sec 4)
cd
procarmanuals.com

m
)
Chapter 8 Rear axle 135
Fig 8 .8 Drilling the beMing rf!t 6 ju sen the ilxlesh.1h "nd CIl!jol\JC the spl"u,d end of Ilu) ~h;,ft Wit I! the ulHcrcnliJI side gC;II, TilP tile shnft wllh fully entered III the c .. sing. 7 Align the backplilW ,md be,1"'}!) rC1 ground. 9 Check the 'Cilt axle 0,1 level and lOp up II necess ary,
5 AxlcshiJft homing -renewal
Noto: A SfJL'CI.1f 1001 IS "Hlliller! /0 n'III1:''''''[1 (,0111 lilt' axles/mIl (s,:c Fly 89) 1 Remove the ;,xlushalt as ,h:sG"hcd 1(' St;CIl0n 1 2 Usin\J all 8 mill (0.31 In) dldl, 1Il;,kc a hole III the he,Hlnt! ,etauun\1 119 . tt 11 ;1{;II)SS tho hole with a sholp pllJ (;h,sel. RUlllove tlH~ ""9 hom the shafl ·1 PIC'SS th e l>earinIJ oH the shall lJSIIl\) " sUlt"hl,~ jllJllcr or press. The specil1l Ford tool is shown '" FlU 89. 5 Remove lhe I>e,'''''o ,eiJll1e,
G Cleiln the l1xlcshnf1. be,non\) ,,,t;WlC' ,Hld "xle C.,1511l\) 7 Locl1le the loe1ll1ll9 HIWlIlel 011 the l1xleshl1lt. followed uy tho new uoa,ing wIth the 001 sel1l [l1CIll\) l1WilY ['om the l1~leshaft Hallge. 8 Slide on the new hea'lIl\) rcta"lIn\) '1119 and pr ess J fully 11\l111l1st tile hearing inner IWck. uSIng a slJItJIJle puller or J ICWlth oftuue. 9 Re fIt Ihe l1xleshalt wllh refe'ence to S ectIon <1
6 Axle reM cover relllov,,1 ilnd refitting
Chock the hont wheels then lilck up the re,l( o f the Cl1r il'l(l SOPPOI1 on axle stands.
2 Cl em1 the reM cover .Jnd surroundIng .Jre" (photo) 3 Remove the hllmlbr"ke relay le ver lind seco nd.Jry cable. or
transverse ,od (as ;;Jpplicilblc) with reletCnce to Ch"pter 9. <1 Place a suitable container helle~th the reM "x Ie to c~tch the oil as the rear cover is removed.
5 Undo and remove t he ten IJOlt s and sprinU washers lhilt securo the reill cover to the llIl,l l drive housillg LIlt aWilY th e re"r cover and its
\Jasko!. ~ Before refitting the ,oar cover Illilke sure thm the mating fJces ilre free of th() old Uaskct or 10nlting compound.
7 FIt a new uasket Jnd then the lea, cover and secure wIth the ten bolts and spring washers. The cover bolts protrude IntO the fillal drive hOUSor1U so it is important that a SUlwble oll·resist.Jr1t scaling
... __ ro*
Fig. 8.9 Usill(J the special Ford tool to removc the axlesllilfl henring (Sec 5)
r;olllpoulid IS SlIll:ilr() d onto lioe Ihro,'ds of each boll bef ore it IS [,twd. 8 TIUhwll tllr: cover secu,,"!.! holls 10 lhe spec,[,ed torque Wfl:IICh
se ttln\)
9 ReCOlillect
Iht! h,lndbr,l~e components with re ference to ChJp ter 9. 10 R efil l ti,e 1e;1I ,ule with the correct 9rJde 01 oil then lower the C,lr to
the UIOUIl(i
G
2 Axle reM cover
7
Pinion oil seal -re"cw,,1
This ope r,ltion may be performed WIth the rear axle in position or on
the benc h
2 Undo ~nd remove the two holts. sprinU Jlld plain washers that secure lhe centre bearing support to the under51(fe of the body (reler to
Chapter 7) 3 With a sc"ber 0' fde. Ill positions <1 UndO ~nd remove the four bolts Jnd sprinu washers secu"n9 the propeller shalt and rear a~le dlivOllg flanges and carefully lower the
propeller sha h to ttt() flool I I
J m
procarmanuals.com

Chapter 8 Rear axle 136 )
5 C~rellJlly cle~n Ihe Ir Oll 1 01 the Im,ll d"ve housinU ~s there will Ilroll 10lque w.ench. check and . ecor d the lurnrng IOrque of the pillion. On eally models lilted wllh ~ tl~ed longlh spacer (see SectIon 1) lI11S procedure is nOt neceSS .,1 "\10 Ihe l ,n ,11 dllv!! hOllslnu unto! Ihl~h w'lh Ihe cas",o 13 Ilcfo1 Iho 1(';;1' "xlo p""nl1 fI.1IlUc ilnd on,:o "!I'"n hold sqll;,,,:ly wllh til" luol 0' wrench. 1~ SClew on " ncw s"II·I()c~"lll I1l1t IJIlIII Illl: (,ndllo,,1 ,s III~I dlll"n.llcd . II"", l'Uh h,n Iho nUL .1 1,;,,:11011 ill;r I"'h' whll" du":k"'!lII,,, prmO" lumlnu lor fixed ICllnth type "nd I he nul should be tIghtened lurthor WhIle domu Ih,s cheC k Ih"l Ihe pimon lurnrnn lorque doos not mcre;;lse. 15 flelll the h",ke 1" ,,"d l O p up II 1\",:eS~lIly
P ReM axle -o verh;;lul
Note: Mosl ymilycs wtlf Ilft'h" 10 If.'IWW Iflt' comfllelC IC,ll ,Jxfc ,15 .1 111111 d II IS WOII! ,.II/IC' I/Ioll! 10 rf,SllliI",fc Ille UII/I 10 lel/t·w '''IV r/;/11I.Jycd 01 WOIII poll Is ro do tlw ,ob correclly Icquires Ifle usc 01 spccial <111(1 cxpellsive loofs willch tin' "'",u/lly of y"WY"'S do 1/01 h,lVl' The P"n1 , le lccl,v e Pol.l ) then IllS besllo Ilu.ch"se "II e~ch;lnHe bUIlt UJl le;;l. ilxl/! 01" Uoad secon (lh,lnd Uillt 1 Remove the rO;;lr "xle I,orn the ,:,1r (S(.'(;t,on 3) illld tha,oughly cleiln
,' . 2 Remove the a xlesh;;lhs (Sec lIon 4) "nd the;lxle ,e". covel (Secllon 6) . If rleceSS;;Jry remove lire !H" ke !liIckpl;,ws 3 WOlk,n!) inside IIlI! axle casUlU . undo .lnd .emove Ihe four bolts th" t hold Ihe IWO U'Shill>cd dlllerentl,ll be"rmg CilPS III the Cilsing. 4 W,lh a sc.iber. m i h a dlffl!renliiJl casrny (Illd. uS"'IJ the lea, cove. 1;;Jr.:e o f thl! Irnal drrvo asing as" lu lc ,um. CDielully leve , Ihe (Mle.entlal asS(!mbly I.om the Ilna l d"ve housrng.
15 Froni I'll Im 7 1I'lls IIfJcess,lIY la ",move th e Iwo (hffelenlral casc l1'-'alll'gs Ihese
",.IY I,,, ",move(1 Ih:xl uSlnU " ulllvers,,1 two·leuged puliCI and sui! 111111'.1 1,.ld C"rfully uase e;lch bca'"'IJ Irom liS local ron . necovor Ihe ~IIOIII p.IO:k s hom hehmll e"ch be"rrnu nOlmU from whIch SId e Ihey (.,rlOr'! 8 thou!] a sCflhcr. m;;lrk Iho relative positions of Ihe crawnwhee l ilnd ,hU",,"rtl.,llrousinu so that the oownwhcelmay be f,tte d on rts origin al p"~H'OII. unless ,t .s to be lenewed. 9 Undo ,11", r enlo ve the eruht holtS thai secure Ihe crownwheello the ,hl,,,""'11:11 hOllS"'II. U S1nll a solt·faced h"n""cl. I,ll! 0\11 Iho cllJwllwhuci Irom liS locillion on Ih e d,ffe,enl,,,1 housin!) I 0 lJ~III\1 ;r sU I\(Ih l{) (i"unete. parallel pIn pmch. lap 0\11 Ihe pin Ihal Iud , ... Ilu, rI,'lcrelll,;,1 Illnial1 gea. Shilll 10 the dlftmrmll.11 housrnlJ.
NOLI! : 1 hu h"le 11110 willch thc peu Irts IS shghlly "'I>c.ed. lind the I>pl''''.'I'! "",1 may he IrIJhLly peelH)d over ;'Iml should he r.:!e;rned with a ·.u,I.II,I" ,".11111;1". ,tr,ll 11 th'''!1 a ... "It IIlI;t.11 dllfl. "'i> out Ihe drllelenli"l p"uon Ue", slr"h. 1.011 .Iw.ly tlr" d,lh;u!Oltl;r1 pinian ue,us. sido {leMS "lid IhruSI was hers; IA"'!l':,"" 10 ell::ure Ih"t the th,usl washe.s ",e lell wllh Ihe ir relative
liP,"" 12 1'",1"~"If)f .. ,1 Il1te.s (It Ihe ,)carrn!) CUllS. These mUSI nOl be used wllh new beallngs. 18Th" Ilnal UIIV(! assembly rs now drSl1lilllllod and should ho washed ,,,,,I d,u,d wrth PinU and uene'ill weal. If a c.ownwheel ami pinIon is .equllt.-d. a mated c.ownwheel and p inion muSI be II1I..,d and undor no
procarmanuals.com