Ford Falcon. Manual - part 239

 

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Ford Falcon. Manual - part 239

 

 

307-01-59 Automatic 

Transmission 307-01-59

REMOVAL AND INSTALLATION (Continued)

6.  If the extension housing is to be removed mark

97 LE (V8)

the driveshaft and pinion flange alignment and

remove the driveshaft.
NOTE: When disconnecting or removing the

driveshaft it is essential that the position of the

slip yoke relative to the output shaft and position

of the companion flange hardware be identified as

illustrated. Failure to return all parts to their

original position may induce driveline vibration.

7.  Separate the park brake cable at the cable joiner.
8.  Remove the speedometer transducer (non-ABS

vehicles only).

9.  Loosen the extension housing bolts to drain the

fluid.

10. Remove the extension housing bolts and

withdraw the extension housing. Discard the

gasket.

Installation
1.  Install a new gasket on the extension housing.
2.  Install the extension housing.
3.  Install the speedometer transducer (non-ABS

vehicles only).

4.  Position the mass damper and insulator

assembly.

5.  Install the insulator bolts then the mass damper

bolts.

6.  Install the cross member.
7.  Remove the transmission jack.
8.  Install the drive shaft aligning the mating marks.

Item

Description

9.  Connect the park brake cable joiner.

1

Nut  M8

10. Lower the vehicle.

2

V8 AutomaticTransmission Extension

11. Check the transmission fluid level.

Housing

NOTE: All hardware must be correctly installed

3

Extension Housing adapter

and torqued to specification.

4

Support Bracket

5

Bolt M10x25

Speedometer drive gear (Non-ABS

6

Transmission Support

vehicles only)

7

Lock Nut M10

Removal

8

Bolt M10x50

1.  Remove the extension housing.

9

Cross Member

2.  The speedometer drive gear is retained to the

10

Bolt M8X46

output shaft by a spring clip. Depress the tang of

11

Bolt M10x89

the clip and slide the gear from the shaft.

Installation

Removal

1.  Position the retaining clip on the shaft with the

1.  Raise the vehicle.

flanged end towards the case.

2.  Support the transmission with a jack.

2.  Slide the gear over the clip. Ensure that the

3.  Remove the transmission cross member.

retaining leg of the clip prevents the gear from

4.  Remove the insulator from the extension housing.

moving rearwards.

5.  Remove the bolt/s securing the mass damper to

3.  Install the extension housing with a new gasket.

the rear of the extension housing one bolt

4.  Check the fluid level.

securing the mass damper bracket on the side of

the extension housing. Remove the damper.

G73106 en

307-01-60 Automatic 

Transmission 307-01-60

REMOVAL AND INSTALLATION (Continued)

2.  Place a drain pan under the transmission.

Extension housing seal

Remove the screws at the rear of the oil pan.

Loosen the remaining screws and allow the fluid

Removal

to drain.

1.  Raise the vehicle.
 

1.  Mark the driveshaft and pinion flange

 CAUTION: The fluid will be very hot if the

alignment and remove the drive shaft.

transmission has just been operated.

 

2.  Prise the seal from the housing.

3.  Remove the remaining screws and lower the pan

carefully, it will still contain a quantity of fluid.

Installation

Discard this fluid and the oil pan seal.

1.  Using the seal replacing tool, drive the seal until

4.  Unclip the oil filter assembly. Remove the filter.

the seal seats.

Installation

2.  Lubricate the seal and the driveshaft yoke with

MIC75B grease and install the driveshaft aligning 1.  Thoroughly clean the oil pan, filter assembly and

the marks on the shaft and pinion flange.

the seal face of the transmission.

3.  Lower the vehicle.

2.  Check the condition of the ‘O’ ring seal on the oil

filter spigot and replace if necessary.

Extension housing bush

3.  Position the filter assembly on the valve body and

install the retaining clip.

Removal

4.  Check the location of the oil pan magnet.

1.  Remove the extension housing.

5.  Place a new seal on the oil pan and install the

2.  Prise the seal from the housing.

pan. Torque to 4.5 Nm.

3.  Using the bush removing tool press the bush from

6.  Fill the transmission with approved fluid.

the housing.

7.  Lower the vehicle.

Installation

8.  Check for leaks.

1.  Place a new gasket on the extension housing and

install the housing.

Valve Body Assembly

2.  Align the lubrication hole in the bush with the rib

along the upper inner surface of the housing.

Removal

3.  Using the bush replacing tool, drive the bush into

1.  Raise the vehicle and remove the oil pan.

the housing until it is flush with the inner edge of

2.  Remove the filter assembly.

the seal recess. Lubricate the bush.

3.  Disconnect the solenoid wiring at the solenoids.

4.  Drive the seal into the housing with the seal

4.  Remove the manual valve lever to manual valve

replacing tool.

link.

5.  Lubricate the seal and the driveshaft yoke with

5.  Remove the screws securing the valve body

MIC75B grease and install the driveshaft.

assembly to the case and lower the valve body.

Oil Pan and Filter

Installation
1.  Ensure that the locating pin is correctly

Removal

positioned. Offer the valve body assembly to the

1.  Raise the vehicle.

case. Ensure the z-link is connected to the

manual valve and detent lever. Fit the long end of

the link to the manual valve first.

2.  Install the screws. Torque the screws in the

specified sequence.

G73106 en

307-01-61 Automatic 

Transmission 307-01-61

REMOVAL AND INSTALLATION (Continued)

Tightening Sequence Valve Body to Case

NOTE: All hardware must be correctly installed and

Installation

torqued to specification.

1.  Check the condition of the piston, push rod and

cover ‘O’ ring seals and replace if necessary.

3.  Check the alignment of the detent roller in the

manual lever detent quadrant.

2.  Lubricate the ‘O’ rings with automatic

transmission fluid and install the servo piston in

4.  Connect the solenoid wiring.

the case. Ensure that Band struts are correctly

5.  Lubricate the ‘O’ ring seal on the filter spigot and

seated and located in push rod and anchor strut

carefully install the filter assembly on the valve

and that shim is correctly retained.

body. The spigot must not lean on one side while

3.  Install the retaining circlip.

being fitted. Install the retaining clip.

4.  Adjust the band with correct shims.

6.  Clean the oil pan and install a new seal on the

pan.

5.  Install valve body, filter and oil pan.

7.  Install the oil pan. Torque to 4.5 Nm.

6.  Lower the vehicle.

8.  Fill the transmission with approved transmission

7.  Check the fluid level, top up as necessary.

fluid.

8.  Check for leaks.

9.  Lower the vehicle.

Rear Servo

10. Check for leaks.

Removal

Front Servo

1.  Raise the vehicle. Remove the oil pan, filter and

Removal

valve body as previously described.

1.  Raise the vehicle.

2.  Remove the cover bolts and remove the assembly

with the spring and rod.

2.  Remove oil pan, filter and valve body as

previously described.

3.  Remove the gasket.

3.  Remove the servo cover retaining circlip.
4.  Remove the servo piston by pushing carefully on

front servo pushrod.

G73112 en

307-01-62 Automatic 

Transmission 307-01-62

REMOVAL AND INSTALLATION (Continued)

Installation

6.  Remove the cover plate from the front of the

converter housing and remove the converter to

1.  Lubricate the piston ‘O’ rings with A.T.F. and fit to

flywheel bolts. Detach the inhibitor switch shield

the piston. Assemble the piston to the cover.

(93LE only).

Position the spring over the piston spigot and the

servo rod in the piston spigot.

7.  Disconnect the inhibitor switch, speedometer

transducer (where fitted) and solenoid wiring

2.  Assemble gasket to cover and assemble in case.

connectors from the side of the transmission.

NOTE: Do not use petroleum jelly on gasket.

Transmission - 93LE

3.  Apply ‘Loctite 567’ sealant to the bolt threads.

Install the bolts and tighten.

4.  Check that the band struts are correctly located.

Check band adjustment.

5.  Install valve body, filter and oil pan as previously

described.

6.  Lower the vehicle.
7.  Check the fluid level and top up as necessary.
8.  Run the engine and check for leaks at the cover

in Reverse and Manual 1.

Transmission

Removal
1. Disconnect 

the 

battery.

Item

Description

2.  Raise the vehicle. If work is to be carried out on

1

Transmission wiring loom connector

the transmission or torque converter when

2

Inhibitor switch connector

removed from the vehicle, drain the transmission

fluid.

Transmission Wiring and Shield - 97LE

3.  Mark the driveshaft and pinion flange alignment

and remove the driveshaft. Install the extension

housing seal tool in the extension housing.
NOTE: When disconnecting or removing the

driveshaft it is essential that the position of the

slip yoke relative to the output shaft and position

of the companion flange hardware be identified as

illustrated. Failure to return all parts to their

original position may induce driveline vibration.

For more information, refer to Section 205-01

4.  Remove the catalytic converter assembly by

disconnecting it from thre axhaust manifold,

muffler inlet pipe and bracket.

5.  Loosen the engine brace to cylinder block bolts.

Remove the brace to converter housing bolts

Item

Description

(97LE only).

1

Transmission wiring loom connector

2

Inhibitor switch connector

8.  Remove the starter motor mounting bolts and

position the starter motor to one side.

9.  Disconnect the fluid cooler lines. Plug the lines.
10. Separate the park brake cable joiner.
11. Support the transmission with a transmission jack.

Install the safety chain.

12. Remove the transmission crossmember.
13. Remove the mass damper and insulator from the

extension housing.

14. Lower the transmission jack until it is just

supporting the transmission.

G73112 en

 

 

 

 

 

 

 

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