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Ford Falcon. Manual - part 261

308-03a-6

Manual Transmission — I6

308-03a-6

DESCRIPTION AND OPERATION (Continued)

Item

Description

Item

Description

Harness, Plastic

Fork, Shift, 5th

Bolt

Insert

Gear – Driving

Rail Assy., Shift

Bushing – Extension Housing

Gear, 5th Speed Drive

Connector Lead

Ring, Snap

Transducer Assembly (for non ABS

Gear, Speedo (Non ABS vehicles only)

vehicles only)

Clip, Speedo Gear (Non ABS vehicles

O-Ring

only)

Retaining Clip

Bolt

Flywheel Housing (contains input shaft

bearing retainer)

Extension, Bushing & Plate Assy.

Seal, Oil

Plate, Detent Guide

Shim

Plug, Cup

Bearing Assy., Input Shaft

Lever, Bonded Offset

Shaft, Input

Isolator cup

Cup

Ball

Taper Roller Bearing

Spring

Circlip

Seal, Oil

Gear, 5th Driving

Funnel, Oiling

Bearing Assy., Main Shaft Rear

Bolt

Gear, 1st Speed

Bolt, Alignment

Sleeve Assy., Bearing

Pin, Selector Arm

Bearing

Shaft, Shifter

Sleeve

Fork, Shift, 3-4

Ring Assy., Blocking

Fork, Shift, 1-2

Synchronizer Assy., 3rd-4th

Insert

Spring, Synchronizer

Arm Assy., Selector

Sleeve, Synchronizer

Plate, Interlock

Insert

Plate, Selector

Hub, Synchronizer

O-Ring

Gear, 3rd Speed

Plug

Bearing

Cover, Case

Spacer

Ring, Retaining

Ring, Snap

Pin, Pivot

Washer, Thrust

Switch, Back-Up

Gear, 2nd Speed

Bolt, Spring Anchor

Bearing, 2nd Speed

Lever, Shift, 5-R

Spacer

Ring, Snap

Shaft Assy., Output

Spacer, Rev. Cone

Ring, Spiral Retaining

Cone, Reverse

Washer, Thrust

Ring, Blocking

Cone, Inner

Synchronizer Assy., 5th

Race, Outer Cone

Spring, Synchronizer

Ring, 1-2 Blocking

Sleeve, Synchronizer

Spring

Insert

100

Gear, Reverse Sliding

Hub, Synchronize

101

Insert

Pin, Roll

G34501 en

308-03a-7

Manual Transmission — I6

308-03a-7

DESCRIPTION AND OPERATION (Continued)

Item

Description

102

Ball

103

Shaft and Hub Assy.

104

Spring

105

Fork, Pin & Roller Assy., Reverse

106

Bolt

107

Retainer, Rear

108

Shim

109

Pin, Roll

110

Shaft, Reverse Idler

111

Gear, Reverse Idler

112

O-Ring

113

Bearing Assy., Countershaft Rear

114

Bearing Assy., Countershaft Front

115

Gear, Countershaft

116

Case Assy., Transmission

117

Bush

118

Concentric Slave Cylinder & lines

119

Screw

120

Hose Clip

Reverse Brake

The reverse brake is applied through the 5th synchro

sleeve. This stops the rotation of the cluster gear

before the reverse idler is engaged eliminating gear

clash when the vehicle is stationary and reverse gear

is selected.
The spacer slides onto the cluster spline and rotates

with it. A snap ring holds the reverse brake

components in position. The tab on the reverse cone

locates into a recess in extension housing adjacent to

the lubrication funnel.
A shift interlock system, located in the cover prevents

engagement of more than one gear. The shift detent

is located in the extension housing turret and consists

of a detent plate, offset lever and spring loaded ball.

All gears except reverse are synchronized and helical

cut for smooth, crisp shifts and quiet operation.

Reverse is provided through a reverse idler gear

which slides along a shaft to engage spur gears on

the countershaft and output shaft. The case is

aluminium and all fasteners are metric.

G34501 en

308-03a-8

Manual Transmission — I6

308-03a-8

DIAGNOSIS AND TESTING

Gear rollover noise will disappear when the clutch is

Manual Transmission

disengaged or when the transmission is engaged in

gear. In the event that a transmission bearing is

Inspection and Verification

damaged, the noise is more pronounced while

engaged in gear under load or coast conditions than

NOTE: Gear rollover noise, inherent in manual

in NEUTRAL. When concerns of this nature are

transmissions, (caused by the constant mesh gears

encountered, it will be necessary to road test the

turning at engine idle speed while the clutch is

vehicle to determine if bearing noise exists. Under no

engaged and the transmission is in NEUTRAL), and

circumstances should any transmission rework be

clutch release bearing noise are sometimes mistaken

attempted to eliminate gear rollover noise, or clutch

for mainshaft bearing noise. Noise caused by a worn

release bearing noise.

or damaged clutch release bearing will be loudest

when the clutch is held disengaged.

Symptom Chart

Condition

Source

Action

Remove transmission. If noise is

Transmission Noisy in Gear

Lubricant level low or wrong type.

howling during start-up, check pilot
bushing. Check for loose flywheel and
housing alignment. Service or replace
as required. Refer to Section 308-01.

Transmission to flywheel housing and

Fill to bottom of filler plug hold with

flywheel housing to engine block bolts

proper lubricant.

loose.

Tighten bolts to 61-88 N-m (45-65

Pilot bushing worn or damaged.

lb-ft).

Improper transmission pilot

Replace housing or input shaft bearing

retainer as required. Refer to Section

engagement into flywheel housing.

308-01.

Worn or damaged internal

Disassemble transmission. Inspect

Input, output and countershaft

components.

bearings, gear and gear teeth for wear
and damage. Service or replace as
required.

Excessive amount of lubricant in

Check level and type. Fill to bottom of

Transmission

Leaks

transmission–wrong type.

filler plug hole.

Identify leaking fluid at engine, power

Other component(s) leaking.

steering and/or transmission.

Remove all traces of lubricant on

False report.

exposed transmission surfaces. Check
vent for free breathing. Operate
transmission and Inspect for new
leakage. Service as required.

Worn or damaged Internal

Remove transmission. Inspect for

leaks at the input shaft bearing retainer

components.

seal and gasket, shift rail expansion
plug top cover gasket. Inspect case for
sand holes. Service or replace as
required.

Inadequate thread sealant on threads.

Apply sealant to bolt threads.

Refer to Section 308-01 for clutch

Transmission difficult to shift

Improper clutch release.

servicing procedures.

Remove transmission and free up shift

Internal shift mechanism binding.

mechanism.

Synchronizer sleeve to hub fit.

Remove and check for burrs or fit.

G34502 en

308-03a-9

Manual Transmission — I6

308-03a-9

DIAGNOSIS AND TESTING (Continued)

Condition

Source

Action

Binding condition between input shaft

Check alignment and service as

and crankshaft pilot bearing.

required. Refer to Section 308-01.

Drain and refill with specified fluid

Improper fluid.

(refer Specifications section).

Gears Clash When Shifting from One

Engine idle speed too high.

Adjust engine idle speed.

Forward Gear to Another

Ensure complete clutch release. Refer

Improper clutch release.

to Section 308-01 for clutch servicing
procedures.

Binding condition between

Remove transmission and replace pilot

transmission input shaft and crankshaft

bushing. Refer to Section 308-01.

pilot bushing.

Worn or damaged shifter forks,

Service or replace as required.

synchronizer assembly, or gear clutch
teeth.

Verify Jump-out with boot removed.

Transmission Jumps Out of Gear

Stiff or improperly installed boot.

Replace boot if necessary.

Interference between shift handle and

Adjust console to eliminate

console.

interference.

Transmission to engine mounting

Tighten bolts to specification.

loose.

Flywheel housing to engine crankshaft

Replace parts as required. Refer to

out of alignment.

Section 308-01.

Improper engagement between

Replace parts as required. Refer to

transmission pilot and flywheel

Section 308-01.

housing.

Replace pilot bearing. Refer to Section

Input shaft pilot bearing worn.

308-01.

Worn or damaged internal

Check input and output shafts for

excessive end play, shift forks for

components.

loose mounting on shift rails, worn
pads, shift rail detent system for wear
or damage, synchronizer sliding sleeve
and gear clutch teeth for wear or
damage. Service or replace as
required.

Transmission Will Not Shift Into One

Floor shift, interference between shift

Adjust console or cut out floorpan to

Gear – All Other Gears OK

handle and console or floor cut out.

eliminate interference.

Restricted travel of internal shifter

Remove transmission. Inspect shift rail

and fork system, synchronizer system

components.

and gear clutch teeth for restricted
travel. Service and replace as
required.

Transmission is Locked in One Gear. It

Internal shifter components worn or

Remove transmission. Inspect the

problem gear or gearshift rails and fork

Cannot be Shifted Out of that Gear

damaged.

and synchronizer for wear or damage.
Service or replace as required.

Remove transmission. Replace

Selector arm finger broken.

selector arm assembly.

Bent shifter forks at pads and selector

Service or replace as required.

slot.

Transmission Will Not Shift Into

Worn or damaged internal

Remove transmission. Check for

damaged reverse geartrain, misaligned

Reverse (All Others OK)

components.

reverse relay lever, shift rail and fork
system

G34502 en

Content .. 259 260 261 262 ..