Chapter 6 Manual gearbox For modifications, and information applicable to later models, see Supplement at end of manual Contents Fault agnosis - manual gearbox . Gearbox - removal and reiting leaving engine in vehicle) Gearbox (A, B and C types) dismantiig into major assemblies... 4 Gearbox (A, B and C types) - reassembly. 8 Gearbox (N type) - dismantlaing into major assemblies. 9 Gearbox (N type) - reassembi 3 Gearbox components (A, B and C types) ~ inspection. 5 Gearbox components (N type) - inspection... 10 Gearbox input shaft (A, B and C types) - dismantling and reassembly... ' 6 Gearbox input shaft (N type) ~ dismantiing and reassembly. u Gearbox mainshaft (A, Band C types) ~ dismantling and, reassembly. oe Gearbox mainshaft(N type) — dismanting and pdreassomby. 2 General descr 1 Maintenance and inspection “ 2 typelspecifcation: 4speed gearbox Speed g@ItDOX ener Four forward speeds (A,B and C type gearboxes) or five forward speeds (N type gearbox) and reverse. Synchromesh on all forward speeds At and C types ‘A2,B, Cand N types: 5 Cand N types Band N types Band N types a a2 B c 3.66: 3381 3.65:1 35841 2ags 199: i781 2011 Yass va2a 43741 1.4031 00st 1.90:1 1.0081 1.00:1 4261 a7 2166:1 a32H1 All models except P100 100 models 3.65:1 391-1 19741 2291 1371 138: 1001 100-1 oa 02:1 3661 3.66:1 Gear oll, viscosity SAE 80EP, to Ford spec SQM-2C 9008-A, (Duckhams Hypoid 80) Gear ol, viscosity SAE 80EP, to Ford spec ESD-M2C 175-A (Duckhams Hypoid 7590S) 0.98 tre (1.72 pints) 1.46 litres (2.57 pints) 1.25 lites (2.20 pints) 1.80 litres (3.34 pints) 1.25 litres (2.20 pints)168 Chapter6 Manual gearbox Torque wrench settings Nm wre Clutch housing-1o-gearbx eosin bots 707090 521066 Clutch Rousing-o-enaine bots. 491080 300037 Clutch release bearing quide sloave bolts: Allexcept type - ato 7108 Ciype 21%025 15t018 Extension housing io-gearbox casing bots a5t049 331036 ‘Top cover batt ‘A encept C type 101013 71010 Ctype So 211025 iSro10 Gearbox crossmemer o-underbady belt 201025 1ato18 Gearbox crossmember-o-gearbox bol 0057 37042 Reversing ight witch ; 1102 dstois Oiiflertevel pha. Btoat 24%030 Sth driving gear retaining nit (type 12010 150 fatoitt ‘th gear locking plate bolts (N type) 211026 151019 Gear everto-extension housing screws 211026 wi01s Gearbox Oittovel 1 Genera desertion Antive-speed gearboxes rom 20.010 26.0 mm (07910099 May 1984 buccade EC) ta end in) below lower edge of “The manual gearbox may be of four or five-speed type, depending of April 1985 fbiidcade FP}and _ilerieve! hole ‘onmodal. Thre different ypes of four speed geurbox havebeen fited af vehicles but up to Apri 1984 {oSiera models these being the AB and C types. The A and B type ‘(bud code 6) subsequortly tarboxes are similar, but alVA type gearboxes have an integral clutch —_ittad wth a modited gearbox: frousing, whereas B type gearboxes may have elther an integral or extonsion housing bot-on clutch housing, The type gearbox is substantially diffrent ro tho Nand Dtypet ard procedures offer deta Aive-speed N ype —-Allfvespeed gearboxes from 010.5 0mm (010 0.2in) {eorbox fs also available, with the fifth oar instalad in the talshaft May 7985, betow ower edge of filereve/ hole housing ofthe gearbox on an extended gear cluster. ‘ll gearboxes follow conventional rear-wheel-drive practice. Drive from the clutch is picked up by the input sheft, which runs inline with the mainshaft. The input shaft gear and mainshaft geers are in constant ‘mesh withthe cauntershaft gear cluster. Selection of gears is by sliding synchomesh hubs, which lock the appropriate mainshaft goar to the mainshatt Gear selection is by means of a floor-mounted lever which fits directly into the gearbox extension housing and operates the selector shaft, The selector shaft operates the selector forks which act on the ssynchroniser units ‘When contemplating overhaul of a gearbox, due consideration should be given 10 the casts involved, ince itis often more economical to-obtain a serviee exchange or good sacendhand grarbox rather than fit new parts to the existing unit 2. Maintenance and inspection 1. Maintenance ig ited to checking the oil lovel periodically, and checking fo leaks i the levels low. Proceed as follows, 2 For improved access, jack up the vehicle and support on axle Stands, Note that the vehicle must be level in order to carry out an accurate check. 3 If the transmission is hot due to the vehicle having been driven Facently, allow itto cool fora few minutes. Thisisnecessary because the bilan foam when hot, leading toa false level reading. 4 Wipe clean around the fillorlovel plug, which ts located on the left-hand side of the gearbox. Unscrew the plug and remove it iphoto). 5 Using a suitably marked piece of bent wire as a dipstick, check that the oil levels as follows, according to gearbox type: Gearbox type Oil evel All four-speed geerboxes 00 50mm 0 t00.2in) below lower edge of filleriovel hole Alltive-speed gearboxes upto Level with bottom edge of ‘April 19864 build code E6) tiertevel hole except those subsequenty {ied with a modified extension housing Note that the vebicle build cade appears as the twelfth and thirteenth ‘charactors of the VIN number on the plate in the angine compartment {6 Top up the level if nacessary, using clean oil of the specified type. Do not overfil a this can lead to leakage and difficult gear changing Allow excess cil to drip out ofthe fillerevel hole if necessary. Refit and tighten the fillertovel plug on completion, 7. The frequent need for topping up can only be due to leaks, which should be rectified. The most likely sources of leaks are the reer ‘extension housing and input shat ol seals Oil seal renewal is described in Section § forall gearbox types. is specified, and no drain plug is fitted. 1 Removal of the engine and manus! gearbox us an assombiy & described in Chapter 1, Section 12. 2. Disconnect the battery negative lead 3. Working in the engine compartment, unscrew and remove the fou lupper engine-to-gearbox bolts, noting the location of the earth lead, 4." Working inside the vehicle, unscrew the gear lever knob and 1e- move the centre console as described in Chaptor 12. Where fulllength ‘consoles fitted, itis only necessary to remove the front tray. 5 Detach the outer gaiter from the retaining frame and withdraw it ‘over the gear lever (photo). 8 Undo the securing screws on early models, or release the clips on later models, and remove the gaiter retaining frame and inner gate (photos) 7 Using a suitable Torx key, remove the screws securing the gor lover to the gearbox axtension housing, and withdraw the gear level Note how the base of the gear lever locates over the selector shat (photos). 8 Jack up the vehicle and support on axle stands. Ensure that theres sufficiant working room beneath the vehicle. 9 To improve access, disconnect the exhaust downpipe trom the ‘manifold and remove the exhaust system as described in Chapter 3, 10 Remove the propeller shaft as described in Chapter 8. 11 Where applicable, bend back the locktabs, then unscrew the two bolts securing each of the two anti-roll bar U.clamps to the vehi Underbody. Lower the anti-roll bar as far as possible. 12. Disconnect the wiring from the starter motor and remove the startar motor with eferance to Chapter 13 f necessary.Chapter 6 Manual gearbox 169 24Gearbox filerievel plug location [erowed) ~N type gearbox the retaining frame 35 Detach the goar lever outer gaiter from 36A Remove the gaiter retaining frame 4813Disconnect the wiring from the Fevering lamp switch gearbox 42 Disconnect the wiring from the reversing lamp switch (photo). Mt Remove the retaining circip, and withdraw the speedometer cable fon the gearbox extension housing (photo), 15 Disconnect the clutch cable from the release arm with reference to Drier 5, Section 3. 18 Suppor the gearbox witha trolley jack, and an interposed block of Wood to spread the load. 1. Unserew the four bolts securing the gearbox crossmember to the Inhice underbody. Unscrew the central bat securing the crossmember {athe gearbox and remove the cross member. Note the position of the tarh strap, where applicable, Recover the mounting cup and where ipoicble the exhaust mounting bracket and heat shield (photos. 8 Unscrew and remove the remaining engine-to-gearbox bolts, Joing the location ofthe engine/gearbox brace on the right-hand side of, tepearbox on OHC mode's iphoto) With the help of an assistant, lft the gearbox from the engine, 3.14 Remove the circlp (arrowed) and ‘withdraw the speedometer cable - N type 3.17 Unscrew the gearbox crossmember Securing bolts arrowed) Using the toley jack to take the weight. Do not allow the weight of the {gearbox to hang on the input shaft. It may be necessery to rock the transmission a litle to release it from the engine. 20. With the gearbox removed, temporarily reconnect the antill bar to the underbody ifthe vehicle isto be moved. 21. ‘Refitting is a reversal of removal, taking note of the following points. 22 Before attempting to refit the gearbox, check that the clutch friction dise is contralised as described in Chapter 5, Section 7. This is necessary to ensure that the gearbox input shaft splines will pass through the splines in the centre ofthe friction dsc. 23. Check that the clutch release arm and bearing are correctly fitted, and lightly graase the input shaft splines. 24 Check that the engine adapter plate is correctly positioned on its locating dowels, 25 Refit the propeller shaft as described in Chapter 8,