PART 6-5 FORD DESIGN FOUR-SPEED TRANSMISSION
Section Page Section Page 1 Description and Operation................ 6-30 3 Removal and Installation... 6-32 2 In-Car Adjustment and Repairs... 6-32 4 Major Repair Operations.... 6-33
1 DESCRIPTION AND OPERATION
The Ford designed 4-speed transmission (Fig. 1, 140K) is of the fully synchronized type with all gears except the reverse sliding gear being in constant mesh. All forward-speed changes are accomplished with synchronizer sleeves instead of sliding gears. The synchronizers will enable quicker shifts, greatly reduce gear clash, and permit down-shifting into any forward-speed gear while the car is moving.
FIG. 1 -Four-Speed Transmission, 140K
The shift linkage is mounted directly on the transmission extension housing (Fig. 1, 140K) and enters the driver's compartment through an opening in the floor pan. A flexible rubber dust boot is provided to seal the driver's compartment from the exterior.
The shift pattern is shown on the top of the gear shift lever knob. A finger-operated release lever is provided on the shift lever to prevent the transmission from being accidentally shifted into reverse gear. All forward-speed gears in the transmission are helical-type, however, the reverse sliding gear and the exterior of the first- and second-speed synchronizer sleeve are spur-type gears. The specifications of this section Part 6-6 lists the transmission model numbers and vehicles in which they are used.
A transmission service identification tag is located on the right side of the case at the front. The first line on the tag will show the transmission model and service identification code when required. The second line will show the transmission serial number.
Trans. Model HEH-A 1 Service identifcation code (when required 012345 to reflect service parts changes affect- ing interchangeability) Serial Number
The four-speed transmission will be designated by the numeral 5 on the vehicle warranty plate.
In first-speed (Figure 2, 170K), the firstCl 535-5 and second-speed synchronizer sleeve is moved rearward by the shift fork.
PART 6-5- FORD DESIGN FOUR-SPEED TRANSMISSION 6-31
Figure 2 Power Flow, 170K
The sleeve engages the first-speed blocking ring, which acts as a cone clutch applied to the free-wheeling first-speed gear. This action speeds up or slows down the first-speed gear to match the speed of the output shaft. Further movement of the sleeve locks the first-and-second-speed synchronizer hub to the first-speed gear by means of internal splines. On engagement of the clutch, power flows through the input shaft and gear to the meshed countershaft gear and thence to the first-speed gear. This gear transmits the power through the locked synchronizer hub to the transmission output shaft. All the other forward-speed gears are in idler motion, as they are all driven by the countershaft (cluster) gear, but they do not transmit power because they are not locked to the output shaft. All the forward-speed shifts are made in the same manner as the first-speed shift, due to the constant-mesh features.
Reverse gear is engaged by moving the reverse sliding gear forward on the reverse idler gear until it meshes with the external teeth (spur-type) of the first-and second-speed synchronizer sleeve. Movement of the sliding gear is accomplished by the center shaft lever. With all forward-speed synchronizer sleeves in neutral, power flow in reverse is through the input shaft to the constant-mesh countershaft (cluster) gear, thence to the constant mesh reverse idler. Splines then carry the power through the reverse sliding gear to the first-and-second speed synchronizer sleeve which is locked to the output shaft. As the reverse sliding gear is meshed with the synchronizer sleeve, power is transmitted to the output shaft, rotating it in a reverse direction.
6-32 GROUP 6-MANUAL SHIFT TRANSMISSIONS
2 IN-CAR ADJUSTMENTS AND REPAIRS
FIG. 3-Adjusting Shift Linkage, 236K
SHIFT LINKAGE ADJUSTMENT
1. Loosen the three shift linkage adjustment nuts. Install a 1/4 inch diameter alignment tool through the control bracket and levers as shown in Fig. 3, 236K.
An alignment tool can be made from 1/4" diameter drill rod bent to an "L" shape. The extensions should be 1 1/2" and 3 3/4" from the elbow. Short end of alignment pin should be inserted into control bracket and linkage holes until it bottoms.
2. Tighten the three linkage adjustment nuts and then remove the alignment pin.
3. Check the gear shift lever for a smooth crossover.
3 REMOVAL AND INSTALLATION
1. Before raising the car, remove the transmission gear shift selector lever boot retainer and slide the boot upward on the selector lever. Remove the selector lever retaining bolts and remove the selector lever from the control assembly being careful not to lose the two trunnions and springs. The remaining shift linkage may be left on the transmission during removal.
2. Disconnect the drive shaft from the rear U-joint flange. Slide the drive shaft off the transmission output shaft and install the extension housing seal installation tool into extension housing to prevent lubricant leakage.
3. Disconnect the speedometer cable from the extension housing.
4. Disconnect the parking brake at the equalizer bar and support the engine with a transmission jack.
5. Remove the extension housing-to-engine rear support attaching bolts.
6. Raise the rear of the engine with the transmission jack. Disconnect the frame crossmember at the frame and remove the crossmember and engine rear support as a unit.
7. Support the transmission on a jack and remove the bolts that attach the transmission to the flywheel housing.
8. Move the transmission and jack rearward until the transmission input shaft clears the flywheel housing. If necessary, lower the engine enough to obtain clearance for transmission removal.
Do not depress the clutch pedal while the transmission is removed.
1. Make sure that the mounting surfaces of the transmission and the flywheel housing are free of dirt, paint, and burrs. Install two guide pins in the flywheel housing lower mounting bolt holes. Move the transmission forward on the guide pins until the input shaft splines enter the clutch hub splines and the case is positioned against the flywheel housing.
2. Install the two upper transmission to flywheel housing mounting bolts snug and then remove the two guide pins. Install the two lower mounting bolts. Torque all mounting bolts to specifications.
3. Raise the rear of the engine, and install the crossmember and the engine rear support as a unit. Torque the crossmember attaching bolts to specifications, then lower the engine.
PART 6-5 -FORD DESIGN FOUR-SPEED TRANSMISSION 6-33
4. With the transmission extension housing resting on the engine rear support, install the transmission extension housing attaching bolts. Torque the bolts to specifications.
5. Connect the speedometer cable to the extension housing, and connect the parking brake cable to the equalizer.
6. Remove the extension housing installation tool and slide the forward end of the drive shaft over the transmission output shaft. Connect the drive shaft to the rear U-joint flange.
7. Place both forward gear shift levers and the reverse shift lever in the neutral position and insert a 1/4 inch diameter alignment tool in the shift linkage alignment hole (Fig. 3, 235K.) It may be necessary to loosen the adjustment nuts to install the alignment tool. Adjust the linkage as necessary and tighten the adjustment nuts to specifications. Remove the alignment tool.
8. Fill the transmission to the proper level with the specified lubricant.
9. Lower the car and install the shift selector lever and the dust boot.
10. Check the shift and crossover motion for full shift engagement and smooth crossover operation.
4 MAJOR REPAIR OPERATIONS
1. Remove the retaining clip, flat washer and spring washer that secures the shift rods to the shift levers.
2. Remove the shift linkage control bracket attaching screws and remove the shift linkage and the control bracket.
3. Remove the cover attaching screws from the case. Lift the cover and gasket from the case.
4. Remove the extension housing attaching screws and lock washers. Remove the housing and the gasket.
5. Remove the input shaft bearing retainer attaching screws. Slide the retainer off the input shaft.
6. Support the countershaft gear with a wire hook. Working from the front of the case, push the countershaft out the rear of the case as shown in Fig. 4, 95K. Lower the countershaft to the bottom of the case with the wire hook. Remove the hook.
FIG. 4-Removing Countershaft from Case, 95K
FIG. 5-Shift Rails and Forks Disassembled, 134K
6-34 GROUP 6-MANUAL SHIFT TRANSMISSIONS
7. Place the first-and-second-speed gear shift lever and the reverse shift lever in the neutral position. Place the third- and fourth-speed gear shift lever in the third-speed position.
8. Remove the bolt that retains the third- and fourth-speed shift rail detent spring and the plug in the left side of the case as shown in Fig. 5, 134K. Remove the spring and the plug with a magnet.
9. Remove the detent mechanism set screw from the top of the case. Remove the detent spring and plug with a small magnet.
10. Remove the attaching screw from the third- and fourth-speed shift fork. Tap on the inner end of the shift rail to unseal the expansion plug from the front of the case. Then withdraw the third- and fourth-speed shift rail from the front of the case. Do not lose the interlock pin from the shift rail.
11. Remove the set screw from the first- and second-speed shift fork. Slide the first- and second-speed shift rail out the rear of the case.
FIG. 6-Removing Output Shaft Bearing, 177K
FIG. 7-Removing Shift Forks from Case, 121K
FIG. 8-Removing Output Shaft Assembly, 121K
12. Remove the interlock plug and the detent plug from the top of the case (Fig. 5, 134K) with a magnet.
13. Remove the snap ring that secures the speedometer drive gear to the output shaft. Slide the gear off the shaft, then remove the speedometer gear drive ball.
14. Remove the snap ring that secures the output shaft bearing to the shaft.
15. Remove the output shaft bearing as shown in Fig. 6, 177K.
16. Remove the input shaft and bearing and the blocking ring from the front of the case.
17. Move the output shaft to the right side of the case to provide clearance for the shift forks. Rotate the forks as shown in Fig. 7, (121K) then lift them from the case.
18. Support the first-speed gear to prevent it from sliding off the shaft, then lift the output shaft assembly from the case as shown in Fig. 8, (121K).
19. Remove the reverse gear shift fork set screw. Rotate the reverse shift rail 90 deg as shown in Fig. 9, 124K. Slide the shift rail out the rear of the case. Lift the reverse shift fork from the case.
FIG. 9-Rotating Reverse Shift Rail, 124K
20. Remove the reverse detent plug and spring from the case with a magnet.
PART 6-5 -FORD DESIGN FOUR-SPEED TRANSMISSION 6-35
FIG. 10-Removing Reverse Idler, 139K.
21. Remove the reverse idler gear shaft from the case as shown in Fig. 10, 139K.
22. Lift the reverse idler gear and the thrust washers from the case. Be careful not to drop the bearings and the dummy shaft from the gear.
23. Lift the countershaft gear and the thrust washers from the case. Be careful not to drop the bearings or the dummy shaft from the countershaft gear.
24. Remove the snap ring from the front of the output shaft. Slide the third- and fourth-speed synchronizer (Fig. 11. 174K) blocking ring and the third-speed gear off the shaft.
25. Remove the next snap ring and the second-speed gear thrust washer from the shaft. Slide the second-speed gear and the blocking ring off the shaft.
26. Remove the next snap ring, then slide the first- and second-speed synchronizer, blocking ring and the first-speed gear off the shaft.
27. Remove the thrust washer from the rear of the shaft.
FIG. 11, 174K -Output Shaft Disassembled
6-36 GROUP 6-MANUAL SHIFT TRANSMISSIONS
PARTS REPAIR OR REPLACEMENT
CAM AND SHAFT SEALS
1. Remove the attaching nut, lock washer and the flat washer from each shift lever and remove the three levers.
2. Remove the three cam and shafts from inside the case.
3. Remove the 0-ring from each cam and shaft (Fig. 12, 104K).
4. Dip the new 0-rings in gear lubricant and install them on the cam and shafts.
5. Slide each cam and shaft into its respective bore in the transmission case.
6. Secure each shift lever with a flat washer, lock washer and nut.
FIG. 12, 104K -Cam and Shafts and Shift Levers Disassembled
INPUT SHAFT BEARING
1. Remove the snap ring that secures the bearing to the shaft (Fig. 13, 70K).
2. Press the input shaft gear out of the bearing as shown in Fig. 14, 64K.
3. Press a new bearing onto the input shaft with the tool shown in Fig. 14, 64K.
4. Secure the bearing with a snap ring.
1. Push the synchronizer hub from each synchronizer sleeve (Fig. 15, 101K).
2. Separate the inserts and insert springs from the hubs. Do not mix the parts of the first- and second-speed synchronizer with the third- and fourth-speed synchronizer.
3. Position the hub in the sleeve, making sure that the alignment marks are properly indexed.
FIG. 13, 70K-input Shaft Gear Disassembled
4. Place the three inserts into place on the hub. Install the insert
PART 6-5- FORD DESIGN FOUR-SPEED TRANSMISSION 6-37
springs making sure that the irregular surface (hump) is seated in one of the inserts. Do not stagger the springs.
COUNTERSHAFT GEAR BEARINGS
1. Remove the dummy shaft, two bearing retainer washers, and the 21 roller bearings (Fig. 16, 60K) from each end of the countershaft gear.
2. Coat the bore in each end of the countershaft gear with grease.
3. Hold the dummy shaft in the gear and install the 21 roller bearings and the retainer washer in each end of the gear.
FIG. 14, 64K -Replacing Input Shaft Bearing
FIG. 15, 101K -Synchronizers Disassembled
REVERSE IDLER GEAR BEARINGS
1. Slip the reverse idler sliding gear off of the reverse idler gear (Fig. 17, 64K).
2. Remove the dummy shaft, two bearing retainer washers and the 44 roller bearings from the reverse idler gear.
3. Coat the bore in each end of the reverse idler gear with grease.
4. Hold the dummy shaft in the gear and install the 22 roller bearings and the retainer washer in each end of the gear.
5. Install the reverse idler sliding gear on the reverse idler gear making sure that the shift fork groove is toward the front (Fig. 17, 64K).
INPUT SHAFT SEAL
1. Remove the seal from the input shaft bearing retainer as shown in Fig. 18, 51K.
2. Coat the sealing surface with lubricant.
3. Install the seal as shown in Fig. 19, 57K.
1. Coat the countershaft gear thrust surfaces in the case with a thin film of lubricant and position a thrust washer (Fig. 16, 60K) at each end of the case.
2. Position the countershaft gear, dummy shaft, and roller bearings in the case.
3. Place the case in a vertical position. Align the gear bore and the thrust washers with the bores in the case and install the countershaft.
4. Place the case in a horizontal position and check the countershaft gear end play with a feeler gauge. The end play should be 0.004-0.018 inch. If not within these limits, replace the thrust washers.
6-38 GROUP 6-MANUAL SHIFT TRANSMISSIONS
5. After establishing the correct end play, install the dummy shaft in the countershaft gear and allow the gear to remain at the bottom of the case.
6. Coat the reverse idler gear thrust surfaces in the case with a thin film of lubricant and position the two thrust washers (Fig. 17, 64K) in place.
7. Position the reverse idler gear, sliding gear, dummy shaft and the roller bearings in place making sure that the shift fork groove in the sliding gear is toward the front of the case.
8. Align the gear bore and thrust washers with the case bores and install the reverse idler shaft.
9. Measure the reverse idler gear end play with a feeler gauge. End play should be 0.004-0.018 inch. If the end play is not within limits, replace the thrust washers. If the end play is within limits, leave the reverse idler gear installed.
10. Position the reverse gear shift rail detent spring and detect plug in the case. Hold the reverse shift fork in place on the reverse idler sliding gear and install the shift rail from the rear of the case. Secure the fork to the rail with the Allen head set screw.
11. Install the first-and second speed synchronizer onto the front of the output shaft (Fig. 11, 174K) making sure that the shift fork groove is toward the rear of the shaft.
12. Position the blocking ring on the second-speed gear.
13. Slide the second-speed gear onto the front of the shaft, make sure that the inserts in the synchronizer engage the notches in the blocker ring.
14. Install the second-speed gear thrust washer and snap ring.
15. Slide the third-speed gear onto the shaft with the synchronizer coned surface toward the front.
16. Place a blocking ring on the third-speed gear.
17. Slide the third-and fourth-speed gear synchronizer onto the shaft making sure that the inserts in the synchronizer engage the notches in the blocking ring.
18. Install the snap ring on the front of the output shaft.
19. Position the blocking ring on the first-speed gear.
20. Slide the first-speed gear onto the rear of the output shaft making sure that the notches in the blocking ring engage the synchronizer inserts.
FIG. 16, 60K -Countershaft Gear Disassembled
FIG. 17, 64K -Reverse Idler Gear Disassembled
21. Install the heavy thrust washer on the rear of the output shaft.
22. Carefully lower the output shaft assembly into the case as shown in Fig. 8.
23. Position the first-and second-speed shift fork and the third-and fourth-speed shift fork in place on their respective gears and rotate them into place.
PART 6-5- FORD DESIGN FOUR-SPEED TRANSMISSION 6-39
FIG. 18, 51K -Removing Input Shaft Seal
FIG. 19, 57K -installing Input Shaft
FIG. 20, 60K -installing Output Shaft Bearing
24. Place a detent plug (Fig. 5, 134K) in the detent bore. Place the reverse shift rail into neutral position.
25. Coat the third-and fourth-speed shift rail interlock pin with grease and position it in the shift rail.
26. Align the third-and fourth-speed shift fork with the shift rail bores and slide the shift rail into place making sure that the three detents are facing toward the outside of the case. Place the front synchronizer into third-speed position and install the set-screw in the third-and fourth-speed shift fork. Move the synchronizer to the neutral position. Install the third-and fourth-speed shift rail detent plug, spring and bolt in the left side of the transmission case (Fig. 5, 134K). Place the interlock plug (tapered ends) in the detent bore.
27. Align the first-and second-speed shift fork with the case bores and slide the shift rail into place. Secure the fork with the set screw. Install a detent plug and spring in the detent bore. Thread the set screw into the case until the head is flush with the case.
28. Coat the input gear bore with a thin film of grease, then install the 15 roller bearings in the bore. A thick film of grease could plug the lubricant holes and restrict lubrication to the bearings.
29. Position the front blocking ring in the third and fourth-speed synchronizer. Place the input shaft gear in the transmission case making sure that the output shaft pilot enters the roller bearings in the input gear.
30. Place a new gasket on the input shaft bearing retainer. Dip the attaching bolts in sealer and install and tighten them to specifications.
31. Install the output shaft bearing as shown in Fig. 20, 60K. Install the snap ring to retain the bearing.
32. Position the speedometer gear drive ball in the output shaft and slide the gear into place. Secure the gear with the snap ring.
33. Place the transmission in a vertical position as shown in Fig. 21, 52K. Align the countershaft gear bore and thrust washers with the bore in the case. Install the countershaft.
34. Use a new gasket and secure the extension housing to the case with the attaching screws. Use a sealer on the extension housing attaching screws. Torque the screws to specifications.
35. Install the filler and drain plugs in the case if they were removed. Make sure that the mag-
6-40 GROUP 6-MANUAL SHIFT TRANSMISSIONS
netic plug is installed in the bottom of the case.
FIG. 21, 52K -Installing Countershaft
36. Pour the specified lubricant over the entire gear train while rotating the input shaft.
37. Place each shift fork in all positions to make sure that they operate properly.
38. Use a new cover gasket and install the cover. Coat the cover attaching screws with sealer and install and tighten them to specifications.
39. Coat the third-and fourth-speed shift rail plug bore with a sealer and install a new plug.
40. If the extension housing bushing and seal are to br replaced, refer to Section 4.
41. Secure each shift rod to its respective lever with a spring washer, flat washer and a retaining pin.
42. Position the shift linkage control bracket to the extension housing and install and torque the attaching screws to specifications.
43. Adjust the shift linkage as detailed in Section 4.