Ford Falcon. Manual - part 262

308-03a-10 

Manual Transmission/Transaxle — I6 

308-03a-10

GENERAL PROCEDURES

12. Inspect the synchronizer blocking rings for

Transmission Cleaning

widened index slots, rounded clutch teeth, and

1.  Wash all parts except ball bearings, O-rings and

smooth internal surfaces (must have machined

seals in a suitable cleaning solvent. Brush or

grooves). With the synchronizer blocking ring on

scrape all foreign matter from the parts. Be careful

the cone, the distance between the face of the

not to damage any parts with the scraper.

synchronizer blocking ring and the clutch teeth on

the gear must not be less than 0.5mm (0.020

 CAUTION: Do not clean, wash or soak

inch).

transmission seals in cleaning solvents. Dry

13. Replace speedometer drive gear (where fitted) if

all parts with compressed air.

teeth are stripped or damaged. Make certain to

2.  Rotate ball bearings in a cleaning solvent until all

install correct size replacement gear.

lubricant is removed. Hold bearing assembly to

14. Replace the output shaft if there is any evidence

prevent it from rotating and dry it with compressed

of wear or if any of the splines are damaged.

air.

15. Inspect bushing and seal in the extension

3.  Lubricate bearings with Multi-Purpose Grease and

housing, and replace if worn or damaged. The

wrap them in a clean, lint-free cloth or paper until

bushing and/or seal should be replaced after the

ready for use.

extension housing has been installed on the

4.  Clean the magnet in the bottom of the case with

transmission.

kerosene or mineral spirits.

16. Replace the seal in the input shaft bearing

retainer.

Transmission Inspection

17. Replace seals on the cam and shafts.

1.  Inspect transmission case for cracks, worn or

damaged bearing bores, damaged threads, or any

other damage that could affect operation of the

transmission.

2.  Inspect the front face of the case for small nicks

or burrs that could cause misalignment of the

transmission with the flywheel housing. Remove

all small nicks or burrs with a fine file.

3.  Replace any 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.  Inspect the bearings. Refer to Bearing Inspection.
6.  Replace roller bearings that are broken, worn or

rough, and check their respective races.

Aluminium Transmission Case Service

7.  Replace the countershaft (cluster) gear if the teeth

NOTE: If an aluminum transmission case thread is

are chipped, broken or worn. Replace the

damaged, service kits may be purchased from local

countershaft if it is bent, scored or worn.

jobbers. To service a damaged thread, the following

8.  Replace the reverse idler gear or sliding gear if

procedures should be carefully followed.

the teeth are chipped, worn or broken. Replace

the idler gear shaft if bent, worn or scored.

1.  Drill out the damaged threads, using the same

drill size as the thread OD. For example, use a

9.  Replace the input shaft and gear if the splines are

16mm drill for a M16x1.5 thread.

damaged or if the teeth are chipped, worn or

broken. If the roller bearing surface in the bore of

2.  Select the proper special tap and tap the drilled

the gear is worn or rough, or if the cone surface is

hole. The tap is marked for the size of the thread

damaged, replace the gear and the gear rollers.

being serviced. Thus, the special tap marked

M16x1.5 will not cut the same thread as a

10. Replace all other gears that are chipped, broken

standard M16x1.5 tap. It does cut a thread large

or worn.

enough to accommodate the insert, and after the

11. Check the synchronizer sleeves for free

insert is installed the original thread size

movement on their hubs. Make sure that the

(M16x1.5) is restored.

alignment marks (if present) are properly indexed.

G34503 en

308-03a-11 

Manual Transmission/Transaxle — I6 

308-03a-11

GENERAL PROCEDURES (Continued)

3.  Select the proper coil inserting tool. These tools

3.  Clean the plug, inspect the gasket condition and

are marked with the thread size being serviced.

replace where necessary.

Place the insert on the tool and adjust the sleeve

4.  Install the plug.

to the length of the insert being used. Press the

insert against the face of the tapped hole. Turn

Drain and Refill Transmission

the tool clockwise and wind the insert into the

1.  Clean the area around the drain and filler plugs.

hole until the insert is one-half turn below the

2.  Remove the drain and filler plugs.

face.

3.  Clean the drain and filler plugs. (Apply pipe

4.  Working through the insert, bend the insert tang

sealant with Teflon to the plug threads.)

straight up and down until it breaks off at the

notch.

4.  Install the drain plug.

5.  Improperly installed inserts can be removed with

5.  With the vehicle on a level surface fill the

the extractor tool. Place the extractor tool in the

transmission to the bottom of the filler plug hole

insert so that the blade rests against the top coil

with the specified transmission oil.

one-fourth to one-half turn away from the end of

6.  Install the filler plug.

the coil. Tap the tool sharply with a hammer so

that the blade cuts into the insert. Exert downward

pressure on the tool and turn it counterclockwise

until the insert is removed.

These tools are marked with the thread size being

serviced. Place the insert on the tool and adjust

the sleeve to the length of the insert being used.

Press the insert against the face of the tapped

hole. Turn the tool clockwise and wind the insert

into the hole until the insert is onehalf turn below

the face.

Taper Roller Bearings Inspection

NOTE: It is recommended to replace all bearings

during a major overhaul of the gearbox. The cost of

removing and disassembling transmissions is too high

to run the risk of bearing damage after they have

been put back together.

1.  If it is desired to reuse bearings, the cone

assembly must not be removed from the

component. The bearings should be inspected for

the following damage:

Discolouration of surfaces by heat.
Excessive pitting and bruising caused by

foreign material.
Etching or corrosion.
Spalls from fatigue of metal.
Scoring of roller ends due to inadequate

lubrication.
Damaged bearing cage.
Gauges or nicks on bearing surfaces.

NOTE: The bearing should be replaced as a unit. Do

not replace cup or cone assembly only.

Fluid Level Check

1.  Clean around the filler plug and remove the plug.
2.  If lubricant does not flow from the filler hole, fill the

case with the specified lubricant until it is level

with the bottom of the filler hole with vehicle in a

level position.

G34510 en

308-03a-12 

Manual Transmission — I6 

308-03a-12

REMOVAL AND INSTALLATION

Removal

Rear Extension Housing Oil Seal

1.  Remove driveshaft. Refer to Section 205-01.

Special Tool(s)

 WARNING: Failure to match marks when

re-assembling the driveshaft may induce

Impact slide hammer

driveline vibration.

100-001

NOTE: Before dis-assembly, mark the matching

points on slip yoke and transmission output shaft.

Mark the mating points on bolt, yoke flange,

companion flange, nut and balance nut (if fitted).

Re-assemble with matching points matched 

± 1

spline, and all mating hardware in original hole.

Seal remover

NOTE: Do not hang the driveshaft from the

307-365

transmission extension housing as this may

damage the extension housing oil seal and/or

bush.

2.  Remove oil seal from extension housing with

impact slide hammer and seal remover.

Extension housing seal replacer

308-260 (E9321)

Installation

4.  Remove any contaminants from the driveshaft slip

yoke’s working surface before re-installingit into

1.  Lubricate extension housing oil seal bore by

the transmission extension housing.

wiping with approved lubricant.

NOTE: During installation of the driveshaft into

2.  Using seal replacer, push oil seal into extension

transmission, plunge the slip yoke the minimum

housing flush of housing rear face.

distance into the extension housing to avoid slip

3.  Lubricate oil seal lips with approved fluid.

yoke radius damaging oil seal.

G34511 en

308-03a-13 

Manual Transmission — I6 

308-03a-13

REMOVAL AND INSTALLATION (Continued)

3.  Working through the console aperture remove the

one bolt and one nut securing the shift lever to the

transmission and remove the lever.

 WARNING: Failure to match marks when

re-assembling the driveshaft may induce driveline

vibration.
NOTE: Before dis-assembly, mark the matching

points on slip yoke and transmission output shaft.

Mark the mating points on bolt, yoke flange,

companion flange, nut and balance nut (if fitted).

Re-assemble with matching points matched 

± 1

spline, and all mating hardware in original hole.

Shift Lever and Boot Assembly

Removal
1.  Unscrew the gearshift knob from the gear lever.
2.  Gently prise the boot retaining panel from the

console and lift the boot and retainer from the

lever. For more information refer to Manual

Transmission Ecternal Control 308-06.

Item

Description

1

Lever Knob

2

Lever Locator

3

Bolt

4

Nut

5

Transmission Stalk Sleeve

6

Plate

7

Bolt Locator (with bolt stud)

8

Nut

9

Shift Lever

10

Boot Assembly

Installation
1.  Position the shift lever on the left hand side of the

transmission lever, install and torque the bolts to

specification.

2. Push yellow 

foam block down firmly over lever join 

to its home position. Make sure the "L" printed on 

foam block faces passenger side.

3.  Locate the boot and retainer over the shift lever

and press the retainer lugs into the console.

G34512 en