Ford COUGAR 1968 Shop Manual page 180

PART
6-3
-
Ford Design Four-Speed Transmission
6-23
PARTS REPAIR OR
REPLACEMENT
GEAR SHIFI'
CONTROL ASSEMBLY
1. After removing the six screws
from the gear shift lever boot retainer,
slide the retainer and boot up on the
lever. Remove the plungers and springs
from the lever (Fig. 12).
2. Remove the two bolts retaining
the shift lever to the trunion and re-
move the shift lever.
3. Raise the vehicle on a hoist.
4. Disconnect the three shift rods
at the transmission by removing the
hair pin type retainer (Fig. 3).
5. Remove the three bolts retaining
the shift assembly to the transmission
extension housing and remove the shift
assembly.
6. Remove the back up-light switch
from the shift assembly.
7.
Remove the snap ring from the
end of the selector shaft with pointed
snap ring pliers (Fig. 12).
8. Remove the flat washer and
spring.
9. After removing two bolts, pull
the retainer, selector levers and bracket
from the shaft.
1U.
Drive the short selector lever
pin from the shaft with a large pin
punch.
I I. Drive the long trunion pin from
the shaft and remove the trunion and
shaft.
12. Clean and inspect all parts.
13. Lubricate all mating friction
surfaces with Rotunda Lube C I A Z -
19586-B.
14. Install the shaft in the brack-
et. Position the trunion and drive the
long straight pin through the trunion
and into the shaft until an equal len-
gth of the pin is exposed on both sides
of the shaft.
15. Drive the short pin into the shaft
until the pin is centered in the shaft.
16. Install the selector levers and
neutral index on the shaft as shown in
Fig. 12.
17. Position the retainer and start
the bolts.. Before tightening the bolts,
be sure that the retainer is not inter-
fering with free movement of the shaft.
Tighten the bolts.
18. Install the spring, flat washer
and snap ring.
19. Position the shift assembly to
the transmission extension housing and
install the three retaining bolts.
20. lnstall the back up light switch.
21. Connect the shift rods at the
transmission by installing a wave wash-
er, flat washer and hair pin-type re-
~ D E T E N T P L U G
-
7C316
FIRST A N D S E C O N D SPEED SHIFT RAlL
7240
THIRD A N D FOURTH
SPEED SHIFT F O R K 7230
SCREW. 377886
-
S
DETEl
~ L J I O
NTERLOCK P I N
FIRST A N D S E C O N D
SPEED SHIFT FORK
-
7230
SCREW-
377886
-
S
I
THIRD A N D FOURTH
6 D B E N T P L U G - 7'3'6
SPEED SHIFT RAlL
7241
- - -
I
DETENT
REVERSE SHIFT RAlL
REVERSE SHIF'T FORK
7240
7231
7C316
3
EXPANSION
PLUG
-
741 12.5
' b -
378206
-
S
& M A G N E T I C DRAIN P L U G -373719-S
FIG.
5-Shift Rails a n d Forks Disassembled
tainer at each connection.
22.
Adjust the back up light switch.
23. Adjust the shift linkage cross-
over pattern.
24. Lower the vehicle on the hoist.
25. lnstall the two bolts retain-
ing the shift lever to the trunion.
lnstall the springs and plungers in
the shaft.
26. Slide the shift lever boot and
retainer down on the shift lever and
install the retainer with six screws.
27. Check the operation of the shift
assembly.
C A M AND S H A H ' SEALS
each shift lever and remove the three
levers.
2. Remove the three cam and
shafts from inside the case.
3. Remove the O-ring from each
cam and shaft (Fig. 13) and discard
the O-rings.
4.
Dip the new O-rings in gear lu-
bricant and install them on the cam
and shafts.
5. Slide each cam and shaft into
its respective bore in the transmission
case.
6. Position a shift. lever on each
cam and shaft and secure with a flat
washer, lock washer and nut.
I. Remove the attaching nut, lock
I N P U T SHAFT BEARlhG
washer and the flat washer from
I. Remove the snap ring that se-