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Ford Falcon. Manual - part 263

308-03a-14

Manual Transmission — I6

308-03a-14

REMOVAL AND INSTALLATION (Continued)

4. Apply loctite to thr

eads. Screw the knob onto the 2. Detach the fluid hose from the mounting clips and

shift lever until it starts to tighten, continue

extricate it from the flywheel housing.

tightening until the graphics on the knob are

correctly aligned.

Speedometer Transducer and Drive

Gear

Removal
NOTE: Only vehicles not fitted with ABS utilise a

transmission driven speedometer transducer, hence

the following removal/installation procedures are

pertinent only to such vehicles.

1. Raise

the

vehicle.

2. Disconnect the wiring plug.
3. Remove the transducer.

3. Using a T30 Torx® driver remove the two CSC

4. Pry off the retaining clip and remove the gear.

mounting bolts that attach the CSC to the flywheel

5. Remove the ’O’ ring seal.

housing.

Installation

1. Install the ’O’ ring.

1. Place the CSC in the position shown and install

the two CSC mounting bolts. Torque to

2. Install the gear and the retaining clip.

specification.

3. Lubricate the seal and gear with transmission oil.

2. Route the CSC hydraulic hose in the orientation

4. Install the transducer into the housing and

shown and tighten the CSC-to-hydraulic hose

connect the wiring.

fitting. Torque to specification.

5. Lower the vehicle.

NOTE: Ensure the hydraulic hose is mounted in

the clips located on and in the flywheel housing.

Concentric Slave Cylinder (CSC)

Transmission Damper

Removal
NOTE: Before the CSC can be removed the

Removal

transmission must be removed from the vehicle and

1. Undo the nuts on the three transmission damper

the clutch bled according to the procedure setout in

mounting bolts.

Section 308-01.

2. Remove the transmission damper mounting bolts.

1. Undo and disconnect the CSC fluid hose from the

3. Detach the damper and mounting bracket from

CSC using a suitable 10-mm spanner.

the transmission extension housing.

Installation
1. Position the transmission damper and bracket

such that the holes in the bracket line up with the

holes in the extension housing.

2. Insert the three transmission damper mounting

bolts through the aligned holes in the damper

bracket and extension housing.

3. Thread the damper mounting nuts onto the bolts.

Torque to specification.
NOTE: The damper mounting nuts are of the

Nyloc® variety and should be replaced each time

the transmission damper is removed.

Item

Description

Hose Clip

CSC-to-Hose fitting

Bleed Screw

G34512 en

308-03a-15

Manual Transmission — I6

308-03a-15

REMOVAL AND INSTALLATION (Continued)

5. Detach the transmission-to-isolator mounting plate

Reversing Light Switch

from the transmission, remove the nuts from the

two mounting bolts numbered (3).

Removal
1. Disconnect the wiring plug and remove the switch

from the left hand side of the case with a 22 mm

socket.

Installation
1. Clean the threads of the switch and apply pipe

sealant with Teflon to the threads.

2. Install the switch and torque to specification.

Transmission Cross - Member

Removal
1. Raise the vehicle on a hoist and support the

transmission on a trolley jack.

2. Remove the four cross-member to chassis

mounting bolts.

3. Unscrew the isolator-to-cross member mounting

Item

Description

nut (numbered (6)) from the bolt numbered (2) in

Isolator-to-Cross Member Bracket

the figure below, together with the two bolts

Bolt - (M10x89) Wafer HD

numbered (5).

Bolt - (M8x46)x2 Wafer HD

4. Remove and disassemble the cross

Insulator Element

member-to-isolator assembly.

Nut - (M10x1.25)

Bolt - (M10x1.5x25)x2

Screw - (M10x50)x4 (Trilobial)

Transmission Cross Member

Transmission-to-Isolator Mounting Plate

Nut - (M8x1.25)

Installation
1. Position the transmission-to-isolator mounting

plate in the orientation shown and attach it to the

transmission by installing the two mounting bolts

numbered (3) and mating nuts (numbered (10)).

Torque nuts to specification.
NOTE: Ensure that the isolator to cross-member

bolt (numbered (2)) is installed in the mounting

plate before affixing it to the transmission.

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308-03a-16

Manual Transmission — I6

308-03a-16

REMOVAL AND INSTALLATION (Continued)

2. Assemble the cross member isolator assembly

and attach it to the transmission isolator mounting

plate.

3. Install the two screws numbered (5) and attach

the nut numbered (6). Torque all screws and nuts

to specification.

4. Using a transmission jack, ensure that the

transmission cross member is aligned with the

mounting points on the underside of the chassis.

5. Install the two cross-member-to-chassis mounting

screws (numbered (7)). Torque screws to

specification.

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308-03a-17

Manual Transmission — I6

308-03a-17

REMOVAL

Special Service Tools

WARNING: Failure to match marks when

re assembling the driveshaft may induce

Tool Number

Description

driveline vibration.

T40

Torx Bit (Countershaft)

NOTE: Before disassembly, mark the matching

E1673U15A

Puller Adaptor (Use with

points on the slip yoke and transmission output

E1673P or E1673MT)

shaft. Mark the mating points on the CV flange,

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

T50

Torx Bit (Pivot Pin)

Re-assemble with matching points matched

± 1

E9319

Snap Ring

spline, and all mating hardware in original hole.

Expander/Installer

8. Bleed the concentric slave cylinder (CSC)

E9320

Input Shaft Seal Installer

according to the procedure set out in section

Kit

308-01. Disconnect the CSC hydraulic clutch line

E9318

Countershaft Bearing

from the firewall.

Cup

Remover/Installer

WARNING: Failure to support CSC

connector during tightening or loosening of

E7518B

Bearing Installation Tool

bleed screw may result in damage to CSC.

(Countershaft)

Attachment for E7511-A

9. Remove the starter motor bolts and remove the

Handle

motor.

E9322

Dial Indicator Mounting

10. Support the engine and transmission assembly

Rod

with a transmission jack.

E1673P or E1673MT

Puller (Use with

11. Remove the bolts securing the transmission

E1673U15A)

cross-member to the body.

E7511A

Countershaft Bearing

12. Lower the transmission jack until the rear of the

Installer (Handle)

engine rests against the bulkhead.

E9321

Extension Housing

13. Disconnect the reversing light switch and, where

necessary, the speedometer transducer.

T30

Torx Bit (CSC)

14. The engine must be tilted down at the

Transmission

transmission and before removing the flywheel

housing-to-engine bolts. Raise the vehicle’s

Removal

bonnet before tilting the engine or else the bonnet

1. Unclip the console cover to access the gear

may be damaged. The engine can be tilted by

shifter prior to removing the gearshift boot,

either:

insulating foam and lever.

1. jacking up the front end or

2. From inside the vehicle, remove the gearshift

2. using a harness to pull down the rear of the

boot, insulating foam and lever.

motor.

3. Raise the vehicle on a hoist.

15. Remove the flywheel housing-to-engine bolts.

4. The exhaust should be removed from the outlet

WARNING: Do not seperate transmission

manifold and unbolted from the vehicle.

from vehicle engine by removing the 4

5. Detach the exhaust from the hanger bracket on

transmission case bolts.

the transmission damper.

6. After removing the exhaust, drain the clutch

reservoir of all fluid into a container. This is to

stop any change of the fluid dripping on to the

exhaust when it is re-installed into the vehicle.

7. Mark the driveshaft so that it may be installed in

the same relative position.

Disconnect the shaft at the centre bearing mount,

by detaching the centre bearing bracket from the

centre bearing carrier (cross member) and detach

the rear CV joint from the diff pinion companion

flange, by undoing the bolts. Slide the driveshaft

backwards, until the slip yoke slides off the output

shaft. Install a dust cover or extension housing

seal replacer into the extension housing to

prevent lubricant leakage.

G34518 en

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