Ford COUGAR 1968 Shop Manual page 170

PART 6-2
-
Model 3.03 'three-Speed Transmission
6-13
INSTALLATION
1.
Make certain that the machined
surfaces of the transmission case and
the flywheel housing are free of dirt,
paint and burrs.
2. Install a guide pin in each
lower mounting bolt hole.
3. Start the input shaft through
the release bearing. Align the splines
on the input shaft with the splines
in the clutch disc. Move the trans-
mission forward on the guide pins
until the input shaft pilot enters the
bearing or bushing in the crankshaft.
If the transmission front bearing re-
tainer binds up on the clutch release
bearing hub, work the release bear-
ing lever until the hub slides onto the
retainer. Install the two transmission-
to-flywheel housing upper mounting
bolts and lock washers. Remove the
two guide pins and install the lower
mounting bolts and lock washers.
Torque the four mounting bolts to
specifications.
4. Raise the rear of the engine
high enough to provide clearance
for installing the crossmember. Install
the two crossmember-to-frame sup-
port attaching bolts, washers, and
nuts. Do not tighten a t this time.
5.
Align the bolts in the trans-
mission rear support with the bolt
holes in the crossmember, then lower
the engine and remove the jack. In-
stall the two transmission rear sup-
port-to-crossmember washers and nuts
and torque to specifications. Tight-
en the crossmember-to-frame support
nuts.
6. On a vehicle equipped with a
floor mounted gear shift selector lever,
position the shift selector assembly to
the extension housing and install the
attaching bolts.
7. Connect each shift rod to its
respective lever on the transmission
with a spring washer, flat washer,
and cotter pin.
8. Insert the speedometer cable
and driven gear in the extension
housing and secure with a cap screw
and lock washer.
9. Remove the tool shown in Fig.
2, Part 6-1, from the extension hous-
ing. Slide the front universal joint
yoke onto the output shaft and into
the extension housing. Connect the
rear universal joint to the axle pin-
ion flange and torque the nuts to
specifications.
10. Fill the transmission to the
proper level with the approved lubti-
cant and lower the vehicle.
11. Adjust the clutch pedal free
travel and the shift linkage as re-
quired.
4 M A J O R REPAIR OPERATIONS
DISASSEMBLY
1. Mount the transmission in a
holding fixture and drain the lubri-
cant.
2. Remove the nine cap screws
that attach the cover to the case. Re-
move the cover and the gasket (Fig.
5)
from the case.
3. Remove the five cap screws
and lock washers that attach the
extension housing to the case. Re-
move the extension and gasket from
the case.
4. Remove the four cap screws
and lock washers that attach the
front bearing retainer to the case.
Remove the retainer and gasket from
the case. Remove either a long spring FIG. 5-Transmission Case and Related Parts
-
Typical
(new design) or set screw and short
spring, (old design) that retains the
detent plug in the case (Fig. 9). Re-
move the detent plug with a small
magnet.
5. Remove the lubricant filler
plug from the right side of the case.
Working through the plug opening,
drive the roll pin out of the case
and countershaft with a 114-inch
COUNTERSHAFT
punch (Fig. 6).
6. On 6-cylinder vehicles with
model RAN transmissions, tap the
countershaft from the rear of the case
with the tool (dummy shaft) shown in c
1584- A
Fig. 7 to remove the expansion plug
from the countershaft bore at the
C 1561 - A
front of the case.
7. Hold
the countershaft gear
FIG. 6-Removing Countershaft
FIG. 7-Removing Countershaft
with a hook and with the tool (durn- Roll Pin