
Chapter 1 Engine 
: Part B: 3.0 litre engine 
General 
) 
rr 
T ype  .. Bore Slroke 
Cubic capacoly .... Compression 111100 
cylinde r block Bo,e dlnmCler mrn (In): $wndMd urnelcs. A B.CllndD DverSilC {)Inel!} A 
Cranksh aft Endllonl  mrll (III) .. 
Camshaft ThruSI plate  tlllckness mm (III) EnclllO;1! 111m (In) . 
Piston s Clearances III bore mm (111) nlllg gap mm (tn) Top .. Cenue BOllom .. 
Connecting rods Blg·end hea,ony running clearance mm (In) 
Valves Seill :myle . V,llve  clearance (cold) mm (m) Inlel .. E~h

7 
Chapter  1 Engine 
Fig . 1.1 8 R ear oil sen I ilnd ildaptcr pliltc (Sec 84) 
84 Renr oil se;1i ,,,,(I lIywheel  - rc fitti"u 
1 I'll the ()n!J"I(~ .r,," ,,(1"1'10' pla1<:1 and s(:clIre ,I wllh 'I S IIv(: holls. 2 Smenr  en\J1ne  (ld OlltO  the CI,mkshah '''".  Smear 0,1 on the lip 01 the sea l tlnd pos(( lon tlon ';".11 on th e  cran hha ll. 3 Align the seil l c;""er holos wllh Ihose 011 the cylrnd(:, hlock . Insell the loul bolts and 11!lhlCll Ihem 10 the SpeCifIed 10lqUfl 4 F it the  flywher.:l . or dllveplalc on au lOlllallC  lwnsrnis sion Illodels. 
InSerll h e  six holl S ;",d u\llole rllhem 10  Ihe  10 lque w rench sell"'U  Uiven in lhe Speclllcm'olls 
8 5 Sump -rciiuill!) 
En~",,, lh;ol  Ill" ru,rI "'!)  ',u.l,u :e s  01 hoth IllI.! Slimp a"d t h e  c(,1nkcilsc ,lie cl ea" ,mol IIi,1I n", '.""I",!)  SlIrJ ,u;e 01 the Sli mp IS not d'S lo lte d. 2 Apply IO" ,I,,,!! c"'''pollnd 1 0  the  pOUltS wllel(~ Ihe l"llllll) cover ablilS  lhu ,;yir r"lr" 1,Io ck .lIId where Ihe rea' 001 $u,,1 carr.(:r "dIOIllS  II 3 Pln ce  tloo \J,,~k"l '" fJo~.t.on, lIt  tlo"  SlIm l} ,'Ild IIlS(). 1 lhe r0Io1111il1l) 
bolts ImUO I tl!lhl 4 PrO!lres~lvely 1I!llIt,," llw sump holt s 011 opposIte I'ilr ts lIllt,1 all 0 1 
t
hem ,H" il l tl", ~ 1"":lllI"d IOlllUU , 5 FII ,1 now w;,~h", 10 Ihe ~Ul1lp II"'UI pili!) , IIlscrl  lhe dl,lIll pllll) and 
t ,uhlen ,t 
8 6 Cylinder h e"ds re;rssernbly 
L~y the cylrnd" r h",.\! on .IS s Ide. luhrrcnt e cvcry valve Uu ide with eng;l1(! oil. ,lilt! ,"~,,"t the valves 11110 the \Ju, dc Irom whIch lh ey wele remov(:d 2 To ,WOld d
lhero.s dilnlJC'  oltl1<.: ~I""IU rcW""C' dillllil\)IIlU tllC villve SHlm 011 sen l 
G Ahcr "lsert")!J tit" ~pllt collets. r eleilSo  the spllny compressor (111(1 
rcmove II 7 C hcc k th"t lh..: ~pl'l cull":IS hilve seilled properly and t
Fi g.  1.1 9 Tightening sequenc e for cylinde r head bolts on the 3.0 litre enuine (Sec 8 7) 
a Repe"l liln pruccdwn orven III p;ua!Jrnphs 1 to 7 o n the (CmJlnlllU 
v,llv"s 
87 Cylinder heads - re fitt;nu 
11 the tappels w ere rcmoved.  luiJricnle  lhe  lilppets nnd I heu hores wnh enoine orl nnd insor t thOlll wilh lhc;, d Ished cnds uppermost Ensule lha l every tappet ,s rclltlcd Into lhe hore hom whIch II wns 
t nkcl1 
2 Mak e  sure  tha t Ihe rna t"'!1 surlaccs o f lhe cylinder block.  cyl lndor henrJs  ;Uld 1111,,1 Ill,lIlIlold ;lIe de;"l. then plnce new cyhndcr head \Ja~kets ove, the Wildes un thn cylrmh"  block. Tho cyirnder head \I,,~k ~IS beilr  thO malkln\! TOP f:nON T ilnd nced to h e  pOSII,oned 
cOII(:ct ly . 
3 Low ul  Ille cyl ""lcr he,1ds ov"r the" posl tlonrngst u(!s, Although t he cyhlld\~r headS ,"0 Id entlc;,I,  they should h,lVe  been Illtlrke d when remuved ilnd should be lehllUd III  thcrr ()IIUinal positions t1 Inse rt  the cyirndcf 11I)"d boilS f"'!I(:r t.!Jh l then tIghten  lhelll prUglC SSlv(: ty OIl the olde, shown III r,U I l!J and III llle  stnucs",s U iven 
m the SpcelirC;lt'OnS 
88 Rocker arms and cover
s -refiUing 
Ensure Ihm "II Ihe  puslllOlls ,lie ,nselwd I!ltO the" p'llpor placos ;II1
)olt S nntl lighten them t o  the spec ,f led torque. 
89 Valve clearnnees -checking nnd adjustment 
R eier 
to SeC!lon 3 5 
90 Engine ancillaries -refitting 
R eier 10 Sec tIon 46 and ref, t lhe  I. ste d componenlS w,th refercnce 
to th e Chaptels ind,cilte(f 
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Chapter 5 
Contents 
CIUICh il$scmhty '"SIJoCcl'Qn . Clu\(;11 assembly 'Urn!!ll!) Clutch llsscmhly  lemOY," C lutc h cilhle  .efluwal._ 
Clutch 
Clutch !Jedal rClllovnl illld ,cflltl"U 
Specifictions 
Genera l Type ..... Clutch (lise  (hamClcr lining tlnckncss Clutch  pedal hcc "
Gene.al description 
, 
5 3 1 8 
All manu:!1 transmission madllis covered by this manual  nrc lilted Wilh a singlo dl3phrilgll  SpllJlg clutch. The unit COlllt)riscs il steel cover which is dowelled and bolted to  the tear lace of the lIywheci ilnd conla i.lS the pressure  plnte. diaphragm  spring and  fulCrum  .ings . The  clutc h " iClio n disc is 
ee to slice  along the splineJ  gearllox 
Inpu t Shillt and is held in  posi t,on  between  the flywheel  and the pressure  plate by  the pressure of the  pressure plate spring , Friction linIng  materiill is riveled 10 the d,sc and II has a  spring cushioned hull to absorb transmission shocks and to  help  ensure  a smoo th take oft. The circular  diaphrilUm  spring is mounted on shoulder  pins ilnd 
'Ield in place in the cover b.,. two fulcrum rings . The spring is also held ,0 th e  pressure platc by three spling steel clips which are rive ted in 
posi tion . 
The 
clu tC h ,s aCluated b.,. a cable  controlled b.,. the clulCh  pedal. 
Clutch '0Ie,150 bCilfl"U -remova' and wl,u,"g Filult  (ioilU"OS'S -clutch Generill descllptlon . noutlilc rn,untenanco  . 
SlIlgle (Iry plate.  dlill)hragm sprong. cilhle ·ope.ated 241,3 rnm (95 Ill) 381 nun (0 15 In) 27.01 40mm (1.OG:i 0 .16,n) 
No. Ib l It 16 to 20 12 10 15 
G 9 1 2 
The  clutch release  mechanism  consists 01 a .elease leve. and  a bearing which conwcts the lelease  Imgers on  the pressure plilte assembl.,..  The eHect of an.,. wear of the  friction ma terial in  the  clutch is adjuSled  out b.,. means 01 a cable adjuster at the lowel end 01 the  cable  where  it 
passes  through  the bell housing . 
Dep.ess lng the clutch pedal  actuates the clutch release leve. b.,. means  of  the  cable . The lelease  level pushes the lelease bearing 
forward to bear against thO release l ingels so moving  the centre  of the diaphf()gm sprong within  the annular  rings which act as fulcrum points. 
A s  th e centrO of thO spring is pushed in. the  outside of the Spling is pushed OUI. so Illoving Ihe pressure plme  backward  and disengaging the p.essu.e  plate flom the /tielion disc . When the Clutch  pedJI is Icleased.  the diaptllaglll spring torces the plessule plate  into  contac t w ith  the  frictIon  linings on the d,sc and at the saIne t,me  pushes  it a  flactlon 01 an InCh fOlward on I\S splines . The 
disc is now fuml.,. sandwic h ed  between  the plcsswe plnte Dnd the 
flywheel.  so the d.ive IS laken up. 
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) 
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 COI1~1
!'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
ig. 7. 1 Two-piece propeller shaft showing tubular section (Sec 1) 
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Chapter 8 Rear axle 
Contents 
Axle rear cover .. lemoval and .etliling Axlosha!! bearing -renewal Adcshah -removal and refltllng . Fnul1 diilgllosis -re3.  ,1xle Gcncr
Gel \cra' Axle dcsI\)n
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 
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 I
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
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m 
) 
Chapter 8 Rear axle 135 
Fig 8 .8 Drilling the beMing rf!t
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 . t
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
propeller sha h to ttt() flool I I 
J m 
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• 
Chapter 8  Rear axle 139 
ci,cumS«"Ulces mny only one pmt of the two be renewed. fnspect the dllfe,enti,ll pinions nnd side gems for signs of pitting. score mMks. Chipping nnd general wem. Obtain new gears  as necessa,y . Inspect the th,ust washers lor signs of weM or deep sco,ing. Obwin new thrust wnshe,s as necessary. Once the pinion o il  senl  has been disturbed it must be discMded and a new one obtained. 20 When new pnrts  have been obwined ns required. reassembly  cnn begin. First lit the thrust washers to the side gems and place them in position in the differential housing. The ground side of the thrust washers IllUSt lace the side gC.Jrs. 21 Place tile thrust wilshers behind the dillelentini pinion genrs  i1nd mesh these twO Oems with the Side  gears through the tWI) ilpertores in the lilllerentlill housing. Milke sure they ilre diametlicilily opposite 10 each other. RO«l!e the clillerent'i11 pinion gears through 90' so brinUlI1\j them into line with the pinion genr shnlt bore 111 the housinlt 22 Insert the pinion genr shnft with the lock In!) p'n hole III line with the pill hole. 23 Usinu leeler  1),IU!Jcs.  measure the en{lll(",t 01 ench s,de Be,,,. II the speclficd h\Jure IS excecrt"d. IU!W tl"u~t washlllS mu"t he  olJt,uned 
-omnlllie the a~~el)lhly ,lg,llll ,trld ht new thll,st wa:,lu'
28 Using soitable diameter tubes.  fit the two Wper roller bearing cones into the finnl dlive housing. making sure that they ale litted the correct way round. 29 Slide the shim and spncer onlO the pinion shalt and insert inlo t he final drive housing. 30 Relit the second and smaller diameter wper loller bea,ino onto the end of the pinion shaft lind 101i0w Ihis Wilh a new oil seal. Sefore Ihe senl is nctually fitted. apply some grense to the inner Ince between the two lips of the seal. 31 Apply n little jOinting compoond to the outer Ince of the seD I. 32 Using n tuhulilr dllft 01 suitable  dinmeter,  carefully drive the oil seal into the fillal (hive housinlJ. Make quite sore thnt it is lilted squarely and flush with the housinU. 33 Refn the drive pinion IInnge nnd hold securely in n bench vice. It II fixed lenIJth  spncCl is Itlted. fit ilnd tighten the pinion nut 10 the spec ,lied lorque. If a collapsihle spnce r is f,tte d. follow the prOCedlHe 
g iven in Section 7 paragraph 14. setting the pinion turning to'que to hetween 25 nnd 2.7 Nnt (1.810 2 0 Ihf It) which includes 0.2 to 0.<1 Nm (0.15 10 0.30 Ibl It) lor the ndriitional friction of the new oil senl  II new hea,inns h~ve heen filted. logether With  n li~e(l len(Jth  SP,lCer. check thm the tOrlllllg torque is bel ween the limits just stmed. If not. a longer or shorter spilcer must he I,tted until the setting IS correct 34 Fit the healing cones to the cf,fierenllal houslIlg heallll(Js and carefully ease the housing Into posilion in the finill drive housmg 35 Relit the be,IIII'!J  CilpS in thell originnl pOSitions.  Srnc,ll n httle JOlntmg compound on the threilcfs 01 each cnp secuIII'O bolt nnd fit 11110 position. When ,111 low halts have bcen rein ted tiUhten these up in a (h"IJonal and progresSive milnne, to the speCi fied torque. 36 I I pOSSIble.  1Il00nt n dlnl in(licntor onu(Je so thnt the probe IS resting on one of the teeth of the crownwheel and determine the backlash hetween the clownwheel and pillion. The bileklash may be vMicd by elecreasll'\) the thickness of the shims bellind one beilling nnd incrensing the thickness of shirns behind the othcr. thus moving the crownwheel ;nlO or out ofmcsh as requi,ed.  The tOt.llthlckness 01 the shims must not be  chnn\)ed. 37 The hesl check the do·it·yourself owner cnn make to aSCerta", the correct meshinu of the crownwheel ilnd pinion is to smear  ,I htt le engineer's blue onto the crownwheel and pinion iJnd then lot"te the pinion. The con1
_ 
t Heavy conWCl 0" huel. at 100lh  !,leu Move p'",on lowa,ds crownwhcd u:.!:.crt:1 3nd c,ownwhuel towards p,n,on 
.~\;!~" •. ,;.';,;,"",.,=,"--
l ' Fig. 8.17 CrownwheeJ and pinion setting chart (Sec 8) 
, , 
, , 
" 
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Chapter 8 Rear axle 141 
lings apm! and compress the clutch plntes. The nction is varinble. depending  on the power npplied. so tlMt under full power the dIfferential will lock completely nlld full torque will be appl;ed to both 
11 Fa ult diagnosis -rear axlo 
Symptom 
NOIse 
"Clonk· Oil nccelera tlon nnd deceh:ontlun 
,... Ilenka\Je 
) 
renr wheels . Under  coasting  or overrun  conditions  the differential will operate as a normal stnndard unit. The unit incorpora tes four different;nl pinions 
Worn axleshaft bearing Insufficient luhricant 
Worn dlfferentinl houSIng bearings Worn crown wheel and pinion Incorrect crown wheel nnd pinion mush 
Worn 1I. leshalt splrnes Excessive crownwheel nluJ pinIon bncklnsh 
Pm ion oil senl Icnkrng ReM cove r gasket leaklllg 011 seal on 
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