Ford FTE III Series Repair Manual Supplement
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Ford FTE III Series Repair Manual Supplement

Ford FTE III Series Repair Manual Supplement

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Series3 T-Series & XR8 Pursuit 250 Ute (Supplement)
Series 3 T-Series & XR8 Pursuit 250 Ute
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http://fordworkshop.net/workshopnet/Workshop/T3/T3.htm [13/05/02 9:52:21 AM]
(Supplement)
* Updated 4/02
Brakes
* Updated 4/02
* Updated 5/02
+
308-00
+
308-03B
Manual Transaxle/Transmission - TR3650
Engine
* Updated 4/02
Ignition System
* Updated 4/02
Electronic Engine Management & Fuel System
Exhaust System
* Updated 4/02
Lighting
* Updated 4/02
Body
* Updated 4/02
Schematics
* Updated 4/02
* Updated 4/02
* Updated 4/02
* Updated 4/02

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  • Page 1: Table Of Contents

    Series3 T-Series & XR8 Pursuit 250 Ute (Supplement) Series 3 T-Series & XR8 Pursuit 250 Ute (Supplement) BACK Table of Contents Introduction * Updated 4/02 Brakes * Updated 4/02 Suspension, Steering Wheels & Tyres * Updated 4/02 Driveline * Updated 5/02 Automatic Transmission * Updated 4/02 Manual Transmission...
  • Page 2 PART No. WM 50FTE FORD MOTOR COMPANY OF AUSTRALIA LIMITED A.B.N. 30 004 116 223 Registered Office: 1735 Sydney Road, CAMPBELLFIELD, VICTORIA 3061 Copyright - Ford Motor Company of Australia Limited Reproduction in whole or in part is prohibited without written approval. M.N.

  • Page 3: Introduction

    Reproduction in any manner, in whole or in part, is IMPORTANT SAFETY NOTICE prohibited without the express permission in writing of Ford Appropriate service methods and proper repair Motor Company of Australia Ltd., Special Vehicle procedures are essential for the safe, reliable operation of Operations, Sydney Road, Campbellfield, Victoria, 3061.
  • Page 4 T SERIES & XR8 PURSUIT 250 UTE REPAIR MANUAL GROUP BRAKES PART 2-1A General Brake Service (Premium Brakes) PART 2-1B General Brake Service (Brembo Brakes)
  • Page 5 General Brake Service (Premium Brakes) 2-1A-1 GENERAL BRAKE SERVICE PART 2-1A (PREMIUM BRAKES) Introduction Brake master cylinder The following brake system components are unique to T- Master cylinder and booster design is the same as Series Series and XR8 Pursuit 250 Ute Premium Brakes: III, but the master cylinder crack point and boost ratio are •...
  • Page 6 2-1A-2 General Brake Service (Premium Brakes)
  • Page 7 General Brake Service (Premium Brakes) 2-1A-3...
  • Page 8 2-1A-4 General Brake Service (Premium Brakes)

  • Page 9: Brake Specifications

    General Brake Service (Premium Brakes) 2-1A-5 BRAKE SPECIFICATIONS Component 1” master cylinder with 1.25” fast-fill, 2.5 MPa crack point Master cylinder Booster 8”/9” dual diaphragm vacuum booster. Boost ratio 6.6:1 Brake Pedal AUII XR Pedal ratio 3.19:1 Brake Fluid DOT 4, bp 280°C Front caliper Twin piston, pad-guided Sliding Caliper Piston diameter: 40.5 mm Brake Pads: Bendix BM709...
  • Page 10 2-1A-6 General Brake Service (Premium Brakes)
  • Page 11 General Brake Service (Brembo Brakes) 2-1B-1 GENERAL BRAKE SERVICE PART 2-1B (BREMBO BRAKES) Introduction Brake master cylinder The following brake system components are unique to T- Master cylinder and booster design is the same as Series Series and XR8 Pursuit 250 Ute Brembo Brakes: III Falcon, but the master cylinder crack point and boost •...
  • Page 12 2-1B-2 General Brake Service (Brembo Brakes)
  • Page 13 General Brake Service (Brembo Brakes) 2-1B-3...
  • Page 14 2-1B-4 General Brake Service (Brembo Brakes) BRAKE SPECIFICATIONS Component 1” master cylinder with 1.25” fast-fill, 2.5 MPa crack point Master cylinder Booster 8”/9” dual diaphragm vacuum booster. Boost ratio 6.6:1 Brake Pedal AUII XR Pedal ratio 3.19:1 Brake Fluid DOT 4, bp 280°C Front caliper Brembo four piston fixed Caliper Piston diameters: 40.0/44.0 mm...

  • Page 15: Suspension, Steering Wheels & Tyres

    T SERIES & XR8 PURSUIT 250 UTE REPAIR MANUAL SUSPENSION, GROUP STEERING, WHEELS AND TYRES PART 3-2 Front Suspension PART 3-2B Independent Rear Suspension PART 3-7 Wheels, Tyres and Front Hubs...

  • Page 16: Front Suspension

    Front Suspension 3-2-1 PART FRONT SUSPENSION INTRODUCTION Wheel Alignment All T-Series and XR8 Pursuit 250 Ute vehicles are fitted All T-Series models feature a sports handling suspension with a front camber/caster kit. Front camber/caster and toe package based on the multi link independent rear are adjustable.
  • Page 17 3-2-2 Front Suspension...
  • Page 18 Front Suspension 3-2-3...
  • Page 19 3-2-4 Front Suspension SUSPENSION COMPONENT SUMMARY Component TE50 TS50/TE50 OPTION TL50 XR8 PURSUIT 250 UTE Suspension Koni hydraulic dampers Koni hydraulic dampers Dampers: 23.5 mm front stabiliser 23.5 mm front stabiliser Monroe - standard XR8 sports bar (ILO 24 mm) bar (ILO 24 mm) suspension Standard rear bar...

  • Page 20: Independent Rear Suspension

    Independent Rear Suspension 3-2B-1 INDEPENDENT PART REAR SUSPENSION 3-2B (T-Series Vehicles only) INTRODUCTION Wheel Alignment All T-Series vehicles are fitted with a front camber/caster All T-Series models feature a sports handling suspension kit. Front camber/caster and toe are adjustable. The IRS package based on the multi link independent rear features adjustable camber and toe.
  • Page 21 3-2B-2 Independent Rear Suspension...
  • Page 22 Independent Rear Suspension 3-2B-3...

  • Page 23: Front Wheel Alignment

    3-2B-4 Independent Rear Suspension SUSPENSION COMPONENT SUMMARY Component TE50 TS50/TE50 OPTION TL50 Suspension Koni hydraulic dampers Koni hydraulic dampers 23.5 mm front stabiliser 23.5 mm front stabiliser XR8 sports bar (ILO 24 mm) bar (ILO 24 mm) suspension Standard rear bar Standard rear bar Springs Linear front springs-...

  • Page 24: Wheels And Tyres

    Wheels, Tyres and Front Hubs 3-7-1 WHEELS, TYRES AND PART FRONT HUBS WHEELS AND TYRES TS50 & TL50 The rear wheels fitted to TS50 and TL50 vehicles have a different offset to the front wheels and MUST NOT be fitted TE50 to the front axle.

  • Page 25: Drive Shaft

    Driveline 5-1-1 DRIVELINE - XR8 PURSUIT PART 250 UTE SUBJECT PAGE DESCRIPTION AND OPERATION ...5-1-1 DESCRIPTION AND OPERATION DRIVESHAFT The driveshaft is the means of transferring power from 4. Use the level and zero level off the chassis rail. the engine to the differential in the rear axle and then on to 5.
  • Page 26 T SERIES & XR8 PURSUIT 250 UTE REPAIR MANUAL AUTOMATIC GROUP TRANSMISSION PART 7-1 BTR Model 97LE Automatic Transmission...

  • Page 27: Automatic Transmission

    BTR Model 97LE Automatic Transmission 7-1-1 BTR MODEL 97LE PART AUTOMATIC TRANSMISSION General description Mode Switch The T Series and XR8 Pursuit 250 Ute 97LE transmission With the engine running and selector in Drive, press the is similar in most aspects to the AU Falcon 97LE unit with switch to toggle the automatic transmission shift mode the exception of various internal upgrades including: between Adaptive Shift Strategy and Electronic Sport Shift.
  • Page 28 7-1-2 BTR Model 97LE Automatic Transmission Selecting ADP sub-modes (TS50 & TL50) In ESS mode, the transmission state is displayed in the cluster to indicate the following conditions: 1. Stop the vehicle, apply Park Brake and turn Ignition Off 2. Apply Foot Brake and move gear selector to: •...
  • Page 29 BTR Model 97LE Automatic Transmission 7-1-3 SPECIFIC ENGINE INPUTS B1 RELEASE AIR CONDITIONING REQUEST C1 CLUTCH C2 CLUTCH THROTTLE POSITION SENSOR (On Throttle Shaft) C3 CLUTCH ENGINE SPEED SHIFT (Tachometer) SCHEDULE EEC-V MODULE ROAD SPEED INDICATOR SHIFT VALVE BODY C4 CLUTCH (Speedo Transducer) FEEL LINE...
  • Page 30 7-1-4 BTR Model 97LE Automatic Transmission ESS wiring circuit Circuit operation Changes to the wiring to accommodate ESS is in two V Ref (5v) is applied internally within the PCM to pin 11, parts. These are: through a current limiting resistor. A signal voltage will be created by the external circuit depending on the status of 1.

  • Page 31: Hydraulic Valves

    BTR Model 97LE Automatic Transmission 7-1-5 HYDRAULIC VALVES - Manual Valve The T Series and XR8 Pursuit 250 Ute valve body tracking has been modified so that drive oil is fed to the LO track when the T Bar is in D, M3, M2 and M1. This enables engine braking in ESS 1st gear. Primary Regulator Valve Line pressure is not boosted in reverse in the T Series and XR8 Pursuit 250 Ute transmission...
  • Page 32 7-1-6 BTR Model 97LE Automatic Transmission HYDRAULIC VALVES - Converter Clutch Regulator Valve This valve regulates the pressure of the oil supplied to the converter clutch. The input oil to this valve is from the line pressure circuit and the output is variable according to the 1.65x signal pressure from the S5 circuit.
  • Page 33 BTR Model 97LE Automatic Transmission 7-1-7 HYDRAULIC VALVES - Valve retaining pins S5 Solenoid and Damper...
  • Page 34 7-1-8 BTR Model 97LE Automatic Transmission HYDRAULIC VALVES - Lower Valve Body...
  • Page 35 BTR Model 97LE Automatic Transmission 7-1-9 DEFAULT TRANSMISSION OPERATING MODES These are additional modes to the current AU 97LE program. Throttle Fault In ESS mode, the gear state display on the cluster may stay in 5, but gears may still be changed via steering wheel shift buttons.

  • Page 36: Manual Transmission

    308-00-1 Manual Transaxle/Transmission and Clutch — General Information 308-00-1 Manual Table of Contents SECTION 308-00Manual Transaxle/Transmission — General Information CONTENTS PAGE DIAGNOSIS AND TESTING Manual Transmission ......................308-00-2 Inspection and Verification ....................308-00-2 Symptom Chart ......................... 308-00-2 Pinpoint Tests ........................308-00-7...

  • Page 37: Diagnosis And Testing

    308-00-2 Manual Transaxle/Transmission and Clutch — General Information 308-00-2 DIAGNOSIS AND TESTING Manual Transmission and Clutch Inspection and Verification It is important to get an accurate description of the concern before any diagnosis can be carried out. Ask questions as to whether it occurs when hot or cold, during shifting, driving at a particular speedor in a particular gear.
  • Page 38 308-00-3 Manual Transaxle/Transmission and Clutch — General Information 308-00-3 DIAGNOSIS AND TESTING (Continued) Symptom Chart (Continued) Condition Possible Sources Action • NOTE: While verifying the • Lubricant. • ADD or DRAIN AND FILL condition, determine whether with specified lubricant. the noise is gear rollover noise, release bearing rub or some other transmission-related noise.
  • Page 39 308-00-4 Manual Transaxle/Transmission and Clutch — General Information 308-00-4 DIAGNOSIS AND TESTING (Continued) Symptom Chart (Continued) Condition Possible Sources Action • Gears Clash When Shifting • Pilot bearing. • CHECK for a binding From One Forward Gear to condition between the input Another shaft and the engine crankshaft pilot bearing.
  • Page 40 308-00-5 Manual Transaxle/Transmission and Clutch — General Information 308-00-5 DIAGNOSIS AND TESTING (Continued) Symptom Chart (Continued) Condition Possible Sources Action • Transmission Is Locked In • Internal components. • INSPECT the problem gears, One Gear And Cannot Be shift rails, forks and the Shifted Out Of That Gear synchronizer for wear or damage.
  • Page 41 308-00-6 Manual Transaxle/Transmission and Clutch — General Information 308-00-6 DIAGNOSIS AND TESTING (Continued) Symptom Chart (Continued) Condition Possible Sources Action • Bearing Failure • Other part failure. • REMOVE, DISASSEMBLE • Racewaysor rollers. and CLEAN the transmission. • Lubricant. Inspect for damagedparts and •...
  • Page 42 308-00-7 Manual Transaxle/Transmission and Clutch — General Information 308-00-7 DIAGNOSIS AND TESTING (Continued) Pinpoint Tests PINPOINT TEST F: HARD SHIFTING CONDITIONS DETAILS/RESULTS/ACTIONS F1 CHECK TRANSMISSION SHIFTING-ENGINE OFF Depress the clutch pedal. Shift the transmission. • Does the transmission shift smoothly? VERIFY customer concern.
  • Page 43 308-00-8 Manual Transaxle/Transmission and Clutch — General Information 308-00-8 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST G: EXCESSIVE NOISE CONDITIONS DETAILS/RESULTS/ACTIONS G1 TRANSMISSION NEUTRAL GEAR ROLLOVER TEST Start the engine and let it idle with the transmission in neutral and the clutch engaged (pedal up).
  • Page 44 308-03B-1 Manual Transaxle/Transmission —TR3650 308-03B-1 Manual Table of Contents SECTION 308-03B Manual Transaxle/Transmission — TR3650 CONTENTS PAGE SPECIFICATIONS ..................308-03B-2 DESCRIPTION AND OPERATION ManualTransmission ................... 308-03B-2 DIAGNOSIS AND TESTING ManualTransmission ................... 308-03B-7 GENERAL PROCEDURES Bearings—Inspection ..................... 308-03B-8 Transmission—Oil Inspection ................308-03B-10 IN-VEHICLE REPAIR Seal ......................308-03B-11 GearshiftLeverandBoot..................

  • Page 45: Specifications

    308-03B-2 Manual Transaxle/Transmission —TR3650 308-03B-2 SPECIFICATIONS General Specification Torque Specifications Item Specification Description lb-ft lb-in Inspection Standards and Tolerances Gearshift lever to — extension housing bolt Synchronizer blocking ring 0.5 mm (0.02 in) to conical face runout Gear shift lever to gear —...
  • Page 46 308-03B-3 Manual Transaxle/Transmission —TR3650 308-03B-3 DESCRIPTION AND OPERATION (Continued) Transmission Internal Components —Disassembled View...
  • Page 47 308-03B-4 Manual Transaxle/Transmission —TR3650 308-03B-4 DESCRIPTION AND OPERATION (Continued) Item Part Number Description Item Part Number Description — First/second gear synchronizer 7052 Input shaft seal sleeve (part of 7124) 7L172 Shim 7127 First gear needle bearing 7025 Input shaft front bearing and 7100 First gear —...
  • Page 48 308-03B-5 Manual Transaxle/Transmission —TR3650 308-03B-5 DESCRIPTION AND OPERATION (Continued) Item Part Number Description Item Part Number Description — Fifth gear synchronizer spring — Retaining ring (part of 7124) — Reverse idler gear support — Fifth gear synchronizer hub Shim (part of 7124) 7140 Reverse idler gear shaft —...
  • Page 49 308-03B-6 Manual Transaxle/Transmission —TR3650 308-03B-6 DESCRIPTION AND OPERATION (Continued) Transmission Case and Shift Components — Disassembled View Item Part Number Description Item Part Number Description 7242 Fifth/reverse shift rail 7358 First/second shift rail — Reverse gear shift fork 7239 First/second shift fork —...

  • Page 50: Diagnosis And Testing

    308-03B-7 Manual Transaxle/Transmission —TR3650 308-03B-7 DESCRIPTION AND OPERATION (Continued) Item Part Number Description Item Part Number Description 7F018 Gearshift offset lever 7L027 Magnet — Spacer 7K201 Shift interlock plate — Bearing 7005 Transmission main case 7210 Gearshift lever — Interlock pins —...

  • Page 51: General Procedures

    308-03B-8 Manual Transaxle/Transmission —TR3650 308-03B-8 GENERAL PROCEDURES Bearings —Inspection NOTE: If any of the following conditions exist, install a new bearing. 1. Inspect the bearing for a bent cage. 2. Inspect bearings for galling (metal smearson roller ends). • Galling is causedby overheating, poor lubrication or an overload situation.
  • Page 52 308-03B-9 Manual Transaxle/Transmission —TR3650 308-03B-9 GENERAL PROCEDURES (Continued) 4. Inspect bearing for cracked inner race. 5. Inspect the bearing and raceway for etching. • If etching is present, inspect the seals. 6. Inspect the bearing for heat discoloration (dark blue). •...

  • Page 53: Transmission-Oil Inspection

    308-03B-10 Manual Transaxle/Transmission —TR3650 308-03B-10 GENERAL PROCEDURES (continiued) Transmission —Oil Inspection 1. Clean around the filler plug and remove the plug. 2. With the vehicle in a vertical position, insert a piece of wire in the fill hole to measure the oil level in the transmission case.

  • Page 54: In-Vehicle Repair

    308-03B-11 Manual Transaxle/Transmission —TR3650 308-03B-11 IN-VEHICLE REPAIR Seal Special Tool(s) Installer, Transmission Extension Housing Oil Seal 308-227 (T94P-7657-A) Slide Hammer 100-001 (T50T-100-A) Remover, Bushing 307-001 (TOOL-1175-AC) or Equivalent Removal 1. With the vehicle in NEUTRAL, raise and support the vehicle. CAUTION: Index-mark the driveshaft flange and pinion flange, and the driveshaft slip yoke and transmission output shaft.

  • Page 55: Gearshiftleverandboot

    308-03B-12 Manual Transaxle/Transmission —TR3650 308-03B-12 IN-VEHICLE REPAIR (Continued) Installation 1. Using the special tool, install the extension housing fluid seal. CAUTION: Align the index marks. Install the driveshaft. 3. Check the transmission fluid level, add fluid if necessary. 4. Lower the vehicle. Gearshift Lever and Boot Removal FRONT OF...

  • Page 56: Outputshaft Speed (Oss) Sensor

    308-03B-13 Manual Transaxle/Transmission —TR3650 308-03B-13 Output Shaft Speed (OSS) Sensor Removal and Installation 1. With the vehicle in NEUTRAL, raise and support the vehicle. 2. Disconnect the electrical connector. 3. Remove the output shaft speed (OSS) sensor. 4. To install, reverse the removal procedure.

  • Page 57: Removal Transmission

    308-03B-14 Manual Transaxle/Transmission —TR3650 308-03B-14 REMOVAL Transmission 1. Disconnect the battery ground cable. FRONT OF VEHICLE 2. Unscrew the gearshift knob (1) from the gear lever. 3. Removethe boot (2) from the lever. 1. Knob Trans Gearshift Lever 2. Cover 3.
  • Page 58 308-03B-15 Manual Transaxle/Transmission —TR3650 308-03B-15 REMOVAL (Continued) 6. Disconnect the OSS sensor electrical connector. Disconnect the wiring harnessfrom the transmission. 7. If transmission disassembly is necessary, drain the transmission fluid. 8. Position a transmission jack and support the transmission. 9. Remove the bolts and the transmission 45Nm - 55Nm crossmember.
  • Page 59 308-03B-16 Manual Transaxle/Transmission —TR3650 308-03B-16 REMOVAL (Continued) 10. Remove the 4 bolts from the spacer block .

  • Page 60: Disassembly Transmission

    308-03B-17 Manual Transaxle/Transmission —TR3650 308-03B-17 DISASSEMBLY Transmission Special Tool(s) Special Tool(s) Holding Fixture, Transmission Remover, Mainshaft Bearing 307-003 (T57L-500-B) 308-058 (T77J-7025-H) Screw, Bearing Removal tube 308-092 (T84T-7025-B) Remover, Bushing 307-001 (TOOL-1175-AC) Remover/Installer, Bearing Tube 308-024 (T75L-7025-B) Disassembly NOTE: During disassembly,if any roll pins, retaining rings or bearings are removed, install new components.
  • Page 61 308-03B-18 Manual Transaxle/Transmission —TR3650 308-03B-18 DISASSEMBLY (Continued) 3. Attach the transmission to the special tool. 4. NOTE: Position a drain pan under the transmission. Remove the case plug, then rotate the transmission to a horizontal position. 5. Using the special tools, remove the extension housing fluid seal.
  • Page 62 308-03B-19 Manual Transaxle/Transmission —TR3650 308-03B-19 DISASSEMBLY (Continued) 6. NOTE: Rotate the transmission to a vertical position. NOTE: Position the gearshift lever in NEUTRAL. Remove the bolts and the gearshift lever. 7. Inspect the gearshift offset lever insert and O-ring for wear or damage.Install a new insert as necessary.
  • Page 63 308-03B-20 Manual Transaxle/Transmission —TR3650 308-03B-20 DISASSEMBLY (Continued) 10. Remove the 12 bolts. 11. Using a flat-blade screwdriver, separatethe extension housing, then remove the gearshift offset lever from the transmission case. • Remove and discard the split pin from the gearshift offset lever during removal. 12.
  • Page 64 308-03B-21 Manual Transaxle/Transmission —TR3650 308-03B-21 DISASSEMBLY (Continued) 14. Remove the shipping seal. 15. Remove the OSS sensor tone wheel retaining ring. 16. Using the special tools, remove the OSS sensor tone wheel.
  • Page 65 308-03B-22 Manual Transaxle/Transmission —TR3650 308-03B-22 DISASSEMBLY (Continued) 17. Remove the OSS sensor tone wheel check ball. 18. Remove and discard the fifth gear synchronizer retaining ring. 19. Using a 5/32-inch drift and a hammer, remove and discard the pin from the fifth gear shift fork.
  • Page 66 308-03B-23 Manual Transaxle/Transmission —TR3650 308-03B-23 DISASSEMBLY (Continued) 21. Remove the fifth gear clutch cone. 22. Remove the fifth gear synchronizer blocking ring. • Inspect the blocking ring for wear or damage.Install new blocking rings as necessary. 23. Remove the fifth gear synchronizer sleeve from the synchronizer hub.
  • Page 67 308-03B-24 Manual Transaxle/Transmission —TR3650 308-03B-24 DISASSEMBLY (Continued) 25. Remove the needle bearings and the thrust washer. • The fifth gear needle bearing is three separate pieces: bearing, spacer, bearing • Inspect the needle bearing for wear or damage. Install new bearings as necessary. 26.
  • Page 68 308-03B-25 Manual Transaxle/Transmission —TR3650 308-03B-25 DISASSEMBLY (Continued) 29. Remove the main shift rail and the plastic spacer. 30. Remove the bolts and the shift interlock plate. 31. Using a magnet, remove the interlock pins. • One lock pin in the center rail, two between the rails.
  • Page 69 308-03B-26 Manual Transaxle/Transmission —TR3650 308-03B-26 DISASSEMBLY (Continued) CAUTION: Do not remove all the bolts while in the horizontal position. Remove the bolts. • Rotate the transmission to a horizontal position. Remove 12 bolts, leaving two opposing bolts in. Rotate the transmission to a vertical position, then remove the remaining two bolts.
  • Page 70 308-03B-27 Manual Transaxle/Transmission —TR3650 308-03B-27 DISASSEMBLY (Continued) 35. Remove the transmission main case from the spacer block. 36. Lift the mainshaft 13 mm (0.50 in) upward, tilt the countershaft outward and remove the countershaft.
  • Page 71 308-03B-28 Manual Transaxle/Transmission —TR3650 308-03B-28 DISASSEMBLY (Continued) 37. Remove the mainshaft and shift assembly. 38. Remove the input shaft. For input shaft disassembly, refer to Input Shaft and Bearing this section. 39. Remove the shift rails and shift forks from the main shaft.
  • Page 72 308-03B-29 Manual Transaxle/Transmission —TR3650 308-03B-29 DISASSEMBLY (Continued) 40. Remove the reverse idler shaft bolt. Remove and discard the seal. 41. Remove the reverse idler gear assembly. 42. Remove the reverse idler gear from the shaft. • Inspect the gear for wear or damage. Install a new gear as necessary.
  • Page 73 308-03B-30 Manual Transaxle/Transmission —TR3650 308-03B-30 DISASSEMBLY (Continued) 44. Disassemble the spacer block. 1 Remove the countershaft bearing cup and shim. 2 Remove the input shaft bearing cup and shim. 3 Remove the input shaft seal. Carefully pry out from the inside of the case.

  • Page 74: Disassembly And Assembly Of Subassemblies

    308-03B-31 Manual Transaxle/Transmission —TR3650 308-03B-31 DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES Input Shaft and Bearing Special Tool(s) Remover, Driver Pinion Bearing Cone 205-D002 (D79L-4621-A) or equivalent Installer, Drive Pinion Bearing Cone 205-011 (T57L-4621-B) Remover/Installer, Bearing Tube 308-024 (T75L-7025-B)
  • Page 75 308-03B-32 Manual Transaxle/Transmission —TR3650 308-03B-32 DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued) Disassembly and Assembly 1. Disassemble the input shaft. 1 Remove the third/fourth synchronizer blocking ring. 2 Remove the input shaft bearing race. 3 Remove the input shaft bearing. 4 Remove the input shaft washer. 4 Remove the input shaft needle bearing.

  • Page 76: Outputshaft

    308-03B-33 Manual Transaxle/Transmission —TR3650 308-03B-33 DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued) 4. Using the special tools and a press, install the new input shaft front bearing. 5. Install the input shaft needle bearing, the washer, input shaft bearing, the bearing race and the third/fourth synchronizer blocking ring.
  • Page 77 308-03B-34 Manual Transaxle/Transmission —TR3650 308-03B-34 DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued) Disassembly 1. Remove the retaining ring above fifth gear. CAUTION: Hand tighten the special tool to prevent gear damage. CAUTION: Support the output shaft while using the press to prevent damage to the shaft or gears.
  • Page 78 308-03B-35 Manual Transaxle/Transmission —TR3650 308-03B-35 DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued) 4. Remove the check ball and the blocking ring. • Inspect the blocking ring for wear or damage.Install new blocking rings as necessary. 5. NOTE: Install the special tool with the flat side facing first gear.
  • Page 79 308-03B-36 Manual Transaxle/Transmission —TR3650 308-03B-36 DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued) 7. Remove the first gear synchronizer inner cone, the first gear synchronizer outer cone and the first gear synchronizer blocking ring. • Inspect all components for wear or damage. Install new components as necessary.
  • Page 80 308-03B-37 Manual Transaxle/Transmission —TR3650 308-03B-37 DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued) 10. Remove the third/fourth blocking ring. 11. Remove the third gear. • Inspect the gear for wear or damage. Install a new gear as necessary. 12. Remove the third gear needle bearing. •...
  • Page 81 308-03B-38 Manual Transaxle/Transmission —TR3650 308-03B-38 DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued) 14. Remove the check ball and second gear needle bearing. • Inspect the needle bearing for wear or damage. Install a new needle bearing as necessary. 15. Remove the second gear synchronizer inner cone, second gear synchronizer outer cone and the second gear synchronizer blocking ring.
  • Page 82 308-03B-39 Manual Transaxle/Transmission —TR3650 308-03B-39 DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued) Assembly 1. Carry out the following before reassembling: • Inspect the gears for broken or cracked teeth. Check for unusual wear patterns. • Inspect the thrust washers for face wear, cracks, scoring and for signs of heat damage.
  • Page 83 308-03B-40 Manual Transaxle/Transmission —TR3650 308-03B-40 DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued) 4. Install the first gear synchronizer blocking ring. • Align the blocking ring tabs with the synchronizer assembly. 5. Install the outer first gear synchronizer cone. 6. Install the inner first gear synchronizer cone. Rotate the inner cone till it is seated.
  • Page 84 308-03B-41 Manual Transaxle/Transmission —TR3650 308-03B-41 DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued) 8. Install first gear. • Rotate the gear to align the gear slots with the inner cone tabs. 9. Install the reverse synchronizer cone. 10. Install the reverse gear blocking ring.
  • Page 85 308-03B-42 Manual Transaxle/Transmission —TR3650 308-03B-42 DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued) 11. Using the special tools, install the reverse gear bearing spacer. 12. Install reverse gear needle bearing. • Apply petroleum jelly to the bearing.
  • Page 86 308-03B-43 Manual Transaxle/Transmission —TR3650 308-03B-43 DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued) 13. Install reverse gear. • Rotate the gear to align the gear slots with the inner cone tabs. 14. Install the check ball. • Use petroleum jelly to hold the check ball in place.
  • Page 87 308-03B-44 Manual Transaxle/Transmission —TR3650 308-03B-44 DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued) 16. Install a new rear output shaft bearing, then fifth gear. Using the special tool, press both the bearing and gear into place. 17. Reposition the output shaft with the input end facing upward.
  • Page 88 308-03B-45 Manual Transaxle/Transmission —TR3650 308-03B-45 DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued) 20. Install the second gear bearing. • Apply petroleum jelly to the bearing. 21. Install second gear. • Rotate the gear to align the gear slots with the inner cone tabs.
  • Page 89 308-03B-46 Manual Transaxle/Transmission —TR3650 308-03B-46 DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued) 22. Install the check ball. • Use petroleum jelly to hold the check ball in place. 23. Install the thrust washer. Be sure to align the slot in the washer with the check ball.
  • Page 90 308-03B-47 Manual Transaxle/Transmission —TR3650 308-03B-47 DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued) 24. Press the bearing spacer onto the output shaft. 25. Install the third gear bearing. • Apply petroleum jelly to the bearing.
  • Page 91 308-03B-48 Manual Transaxle/Transmission —TR3650 308-03B-48 DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued) 26. Install third gear. 27. Install the third gear synchronizer blocking ring.
  • Page 92 308-03B-49 Manual Transaxle/Transmission —TR3650 308-03B-49 DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued) 28. Install the third/fourth gear synchronizer body. • Install the synchronizer body with the raised center facing downward. • Rotate the blocking ring until seated. 29. Install a new retaining ring.

  • Page 93: Countershaftbearing

    308-03B-50 Manual Transaxle/Transmission —TR3650 308-03B-50 DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued) Countershaft Bearing Special Tool(s) Remover, Drive Pinion Bearing Cone 205-D002 (D79L-4621-A) or equivalent Installer, Drive Pinion Bearing Cone 205-011 (T57L-4621-B) Disassembly and Assembly 1. Cut the outer cage, then remove the outer cage and rollers.

  • Page 94: Synchronizers

    308-03B-51 Manual Transaxle/Transmission —TR3650 308-03B-51 DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued) 3. Using the special tools, install the new countershaft bearing. Synchronizers Disassembly and Assembly NOTE: This procedure applies to all synchronizer assemblies. 1. Scribe an alignment mark on the sliding sleeve and the hub for assembly reference.

  • Page 95: Gearshiftrailbushing

    308-03B-52 Manual Transaxle/Transmission —TR3650 308-03B-52 DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued) Gearshift Rail Bushing Special Tool(s) Universal Puller Set 303-DS005 (D80L-100-A) or equivalent Installer, Shift Rail Bushing 308-244 (T96P-7025-F) Slide Hammer 100-001 (T50T-100-A) Disassembly and Assembly 1. Using the special tools, remove the gearshift rail bearing from the transmission case.

  • Page 96: Gearshiftrailandfork

    308-03B-53 Manual Transaxle/Transmission —TR3650 308-03B-53 DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued) 2. Using the special tool, install the main shift rail bearing. Gearshift Rail and Fork Disassembly and Assembly 1. Using a 5/32-inch drift and a hammer, remove and discard the split pin. Slide the shift fork from the shift rail.

  • Page 97: Assembly

    308-03B-54 Manual Transaxle/Transmission —TR3650 308-03B-54 DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued) CAUTION: Support the shift rail to prevent damage to the parts. Position the gearshift fork on the shift rail. Align the split pin hole and install a new split pin.
  • Page 98 308-03B-55 Manual Transaxle/Transmission —TR3650 308-03B-55 ASSEMBLY (Continued) Special Tool(s) Materials Replacer/Adapter Item Specification 308-239 (T96P-7025-A) MERCON Multi-Purpose MERCON (ATF) TransmissionFluid XT-2-QDX or equivalent Premium Long Life ESA-M1C75-B Grease XG-1-C, K or T Installer, Transmission Extension Housing Oil Seal 308-227 (T94P-7657-A) 1.
  • Page 99 308-03B-56 Manual Transaxle/Transmission —TR3650 308-03B-56 ASSEMBLY (Continued) 4. Install the rear countershaft bearing. 5. Install the reverse idler gear bearings and spacer on the shaft. 6. Install the reverse idler gear on the shaft. 7. Install the reverse idler gear into the case.
  • Page 100 308-03B-57 Manual Transaxle/Transmission —TR3650 308-03B-57 ASSEMBLY (Continued) 8. Install a new seal on the reverse idler bolt, then install the bolt in the transmission case. 9. NOTE: If a new front input shaft bearing or front countershaft bearing was installed, install new bearing cups.
  • Page 101 308-03B-58 Manual Transaxle/Transmission —TR3650 308-03B-58 ASSEMBLY (Continued) 12. Install the mainshaft onto the spacer block. • The notches on the shift rail should be pointing upward. • Align the shift rails in the bores. 13. Install the countershaft. • Lift the mainshaft upward, tilt the countershaft and install.
  • Page 102 308-03B-59 Manual Transaxle/Transmission —TR3650 308-03B-59 ASSEMBLY (Continued) 15. NOTE: Rotate the transmission so that the input shaft is pointing upward. NOTE: Rotate the input shaft to seat the bearings. Using the special tools, measurethe input shaft 0.0254 - 0.1270 mm end play by applying an upward load on the output shaft.
  • Page 103 308-03B-60 Manual Transaxle/Transmission —TR3650 308-03B-60 ASSEMBLY (Continued) 18. Remove the two bolts and lift the transmission main caseoff. 19. Remove the countershaft.
  • Page 104 308-03B-61 Manual Transaxle/Transmission —TR3650 308-03B-61 ASSEMBLY (Continued) 20. Remove the mainshaft. 21. Remove the input shaft. 22. Remove the front input shaft bearing cup and the front countershaft bearing cup.
  • Page 105 308-03B-62 Manual Transaxle/Transmission —TR3650 308-03B-62 ASSEMBLY (Continued) 23. Using the special tools, install the new input shaft seal. 24. Using the recorded end play measurements, select and install the appropriate shims to achieve the proper end play. 25. Install the front input shaft bearing cup and the front countershaft bearing cup.
  • Page 106 308-03B-63 Manual Transaxle/Transmission —TR3650 308-03B-63 ASSEMBLY (Continued) 27. Install the mainshaft. 28. Install the countershaft.
  • Page 107 308-03B-64 Manual Transaxle/Transmission —TR3650 308-03B-64 ASSEMBLY (Continued) 29. Clean the mating surfaces of the transmission main case and the spacer block. Apply a bead of silicone rubber to the sealing surface on the spacer block then install the transmission main case. Tighten the bolts in a star pattern. 30.
  • Page 108 308-03B-65 Manual Transaxle/Transmission —TR3650 308-03B-65 ASSEMBLY (Continued) 32. Install the detents and the detent springs. 33. Install the detent plugs. 34. Install the check ball. • Use petroleum jelly to hold the check ball in place.
  • Page 109 308-03B-66 Manual Transaxle/Transmission —TR3650 308-03B-66 ASSEMBLY (Continued) 35. Install the thrust washer and the three-piece fifth gear needle bearing. 36. Install the synchronizer springs and inserts. 37. Install the sliding sleeve on the synchronizer hub. • Align the pocketsin the blocking ring with the struts in the synchronizer.
  • Page 110 308-03B-67 Manual Transaxle/Transmission —TR3650 308-03B-67 ASSEMBLY (Continued) 39. Install the fifth gear synchronizer cone. 40. Install the fifth gear shift fork, the synchronizer assembly, the synchronizer cone and fifth gear as an assembly. 41. Install a new split pin. • Install the pin until it is flush with the fork. 42.
  • Page 111 308-03B-68 Manual Transaxle/Transmission —TR3650 308-03B-68 ASSEMBLY (Continued) 43. Install the third/fourth shift finger, then install a new split pin. • Install the split pin until it is flush with the shift finger. 44. Install the control rail and the plastic spacer, then install the first/second shift finger.
  • Page 112 308-03B-69 Manual Transaxle/Transmission —TR3650 308-03B-69 ASSEMBLY (Continued) 47. Install a new OSS sensor tone wheel retaining ring. 48. Install the fifth/reverse gear lockout. 49. Install the bolt. 50. Clean the mating surfaces of the transmission main case and the extension housing. Apply a bead of silicone rubber to the sealing surface of the transmission case.
  • Page 113 308-03B-70 Manual Transaxle/Transmission —TR3650 308-03B-70 ASSEMBLY (Continued) 51. Install the extension housing and at the same time install the gear shift off-set lever. 52. Install the shift spring and bracket. 53. Install a new split pin in the gear shift off-set lever.
  • Page 114 308-03B-71 Manual Transaxle/Transmission —TR3650 308-03B-71 ASSEMBLY (Continued) 55. Using the special tool, install a new extension housing seal. • Lubricate the seal with transmission fluid. 56. Install the shipping seal. 57. Rotate the transmission to a horizontal position. 58. Clean the mating surfaces of the shift cover opening surface and the shift cover.

  • Page 115: Installation

    308-03B-72 Manual Transaxle/Transmission —TR3650 308-03B-72 ASSEMBLY (Continued) 59. Install the gear shift lever. 60. NOTE: Before installing the transmission, the ball stud, the and the input shaft guide tube must be cleaned and lubricated. 61. Fill the transmissionwith transmission fluid to the specified level.
  • Page 116 1. NOTE: Before installing the transmission, the ball stud, and the input shaft must be cleaned and lubricated. Use a grease which meets the Ford specification ESA-M1C75-B or equivalent. To install, reverse the removal procedure. For additional information, refer to Transmission this section.
  • Page 117 T SERIES & XR8 PURSUIT 250 UTE REPAIR MANUAL GROUP ENGINE PART 8-7 Engine 250kW 5.6L V8...
  • Page 118 250kW 5.6L V8 Engine 8-7-1 ENGINE PART 250kW 5.6L V8 NEW PARTS IN 250kW 5.6L V8 ENGINE REWORKED CYLINDER BLOCK Unique parts in the 250kW 5.6L V8 engine include: A notch has been ground out of each barrel. • Reworked block •...
  • Page 119 8-7-2 250kW 5.6L V8 Engine CRANKSHAFT NOTE: Where necessary, crankshaft must be balanced with the original balancer and flywheel fitted. INSTALLATION – additional instructions 1. Before installing the rear main bearing cap, apply loctite as shown below. 2. Fit the cleaned bearings to the cylinder block, apply engine oil to the bearing faces then fit the crankshaft. 3.

  • Page 120: Pistons And Connecting Rods

    250kW 5.6L V8 Engine 8-7-3 CRANKSHAFT REAR MAIN OIL SEAL INSTALLATION – additional instructions NOTE: When installing the seal using the seal installation tool, ensure that the rear face of the seal is within 0.13 – 0.25mm of the rear face of the block. 1.
  • Page 121 8-7-4 250kW 5.6L V8 Engine Piston rings to pistons NOTE: Piston must first be assembled to conrod before installing the piston rings. 1. Fit the expander to the piston making sure that the closed section of the expander ring is pointing downwards, as shown below in View 'A'.
  • Page 122 250kW 5.6L V8 Engine 8-7-5 After fitting the conrod big end onto the crankshaft journal and prior to fitting the conrod caps and nuts, apply ARP MOLYLUBE to the faces of the nuts and the bolt threads then tighten and torque the nuts. Refer to Specifications. WARNING: Failure to apply ARP MOLYLUBE to the nuts prior to tightening will result in the installation of the pistons and connecting rods being out of specification.

  • Page 123: Cylinder Heads

    8-7-6 250kW 5.6L V8 Engine CRANKSHAFT VIBRATION DAMPER INSTALLATION – additional instructions 1. Apply engine oil to the oil seal rubbing surface of the vibration damper inner hub to prevent damage to the seal. 2. Apply loctite to the key way groove in the damper before installing onto the crankshaft. 3.
  • Page 124 250kW 5.6L V8 Engine 8-7-7 ROCKER COVERS INSTALLATION 1. Clean the mounting surface of the rocker covers and cylinder heads with a solvent and rag. 2. Fit new gaskets to the cylinder heads. 3. Fit the bolts, as shown below in View 'A'. 4.
  • Page 125 8-7-8 250kW 5.6L V8 Engine INSTALLATION – Lower Intake Manifold 1. Clean the lower intake manifold mounting surface and make sure that the lower manifold intake ports are free from any swarf or gasket waste. 2. Position the lower intake manifold onto the engine locating pins. 3.
  • Page 126 250kW 5.6L V8 Engine 8-7-9 INSTALLATION – Upper Intake Manifold 1. Fit the upper intake manifold. 2. Secure it with bolts, noting the bolt locations as shown below. Refer to Specifications. 3. Fit the gasket to the upper intake manifold. INSTALLATION –...
  • Page 127 8-7-10 250kW 5.6L V8 Engine INSTALLATION - Left Side Injectors, Fuel Rail, Harness, Fuel Regulator Hose and HVAC Line 1. Fit the injectors (left side only) to the lower intake manifold, as shown below. 2. Fit the fuel rail (left side only) and secure with bolts. Refer to Specifications. 3.
  • Page 128 250kW 5.6L V8 Engine 8-7-11 UNIQUE 250kW 5.6L V8 ENGINE SPECIFICATIONS Plenum cover to upper intake manifold bolts – 8 – 12 Nm Note: For other specifications, refer to part 8-6 Fuel pressure regulator – bolts to fuel rail 5 – 7Nm Specifications and Special Tools (8Cylinder) of the AUII –...
  • Page 129 8-7-12 250kW 5.6L V8 Engine...
  • Page 130 T SERIES & XR8 PURSUIT 250 UTE REPAIR MANUAL GROUP IGNITION SYSTEM PART 9-1 Ignition System...

  • Page 131: Ignition System

    Ignition System 9-1-1 PART IGNITION SYSTEM Spark plugs Type 250 kW Motorcraft AGSF-22 PP OR AGSF-22 PPM Size M14 X 1.25 20.6 AF Reach 17 mm 1.3-1.4 mm Torque 20 Nm Gasket Taper seat...
  • Page 132 T SERIES & XR8 PURSUIT 250 UTE REPAIR MANUAL ELECTRONIC ENGINE GROUP MANAGEMENT AND FUEL SYSTEM PART 10-1 EEC-V Electronic Engine Management...
  • Page 133 EEC-V Electronic Engine Management 10-1-1 EEC-V ELECTRONIC ENGINE PART 10-1 MANAGEMENT INTRODUCTION BASE IDLE SPEED Apart from the Electronic Sport Shift control, PCM CAUTION: With the engine running, there are rotating operation and strategy is standard EEC-V. Calibration is and HOT components within the engine compartment. modified to suit the unique needs of each engine running on Use extreme care to avoid entanglement and personal Premium Unleaded Petrol.

  • Page 134: Exhaust System

    T SERIES & XR8 PURSUIT 250 UTE REPAIR MANUAL GROUP EXHAUST SYSTEM PART 12-3 Exhaust Pipes and Mufflers 8 Cylinder...

  • Page 135: Torque Requirements

    Exhaust Pipes and Mufflers 8 Cylinder 12-3-1 EXHAUST PIPES AND MUFFLERS PART 12-3 8 CYLINDER DESCRIPTION Exhaust outlets TL50 Downward pointing twin exhaust outlets are discretely 250 kW engine positioned behind the rear bumper panel. Ceramic coated tubular exhaust manifolds are combined with 1.8 litre high flow catalysts.
  • Page 136 12-3-2 Exhaust Pipes and Mufflers 8 Cylinder...
  • Page 137 Exhaust Pipes and Mufflers 8 Cylinder 12-3-3...
  • Page 138 12-3-4 Exhaust Pipes and Mufflers 8 Cylinder...
  • Page 139 T SERIES & XR8 PURSUIT 250 UTE REPAIR MANUAL GROUP LIGHTING PART 15-1 Lighting System...

  • Page 140: Lighting System

    Lighting System 15-1-1 PART LIGHTING SYSTEM 15-1 DRIVING LAMPS TS50 is fitted with driving lamps mounted in the lower bumper cover. Replacing the driving lamp bulb • Switch off lights and allow to cool. • Remove the windage tray from under the front bumper bar.
  • Page 141 15-1-2 Lighting System Fuse and Relay Box (Engine Compartment)
  • Page 142 Lighting System 15-1-3...
  • Page 143 T SERIES & XR8 PURSUIT 250 UTE REPAIR MANUAL GROUP BODY PART 17-1 Sunroof PART 17-5 Front and Rear Bumpers...
  • Page 144 Front and Rear Bumper 17-5-1 FRONT & REAR PART 17-5 BUMPER SUBJECT PAGE SUBJECT PAGE FRONT BUMPER REAR BUMPER TE50 ......17-5-2 TE50 .
  • Page 145 17-5-2 Front and Rear Bumper...
  • Page 146 Front and Rear Bumper 17-5-3...
  • Page 147 17-5-4 Front and Rear Bumper...
  • Page 148 Front and Rear Bumper 17-5-5...
  • Page 149 17-5-6 Front and Rear Bumper...
  • Page 150 Front and Rear Bumper 17-5-7...

  • Page 151: Installation

    17-5-8 Front and Rear Bumper REAR BUMPER BAR - XR8 PURSUIT 250 UTE INSTALLATION Tool required: • Rivet gun. 1. Connect wiring loom to reverse lamp and numberplate lamps at rear bumper assembly as shown in view A. 2. Secure wiring to bumper skin using gaffer tape (view A). 3.
  • Page 152 Front and Rear Bumper 17-5-9...
  • Page 153 17-5-10 Front and Rear Bumper REAR BUMPER BRACKET - XR8 PURSUIT 250 UTE INSTALLATION 1. Remove plastic dust shield as shown in view A. 2. Place rear bumper bracket onto rear of vehicle making sure all 4 studs protrude through the body holes (view 3.
  • Page 154 Front and Rear Bumper 17-5-11...
  • Page 155 Grille and Exterior Mouldings 17-6-1 EXTERIOR MOULDINGS - PART 17-6 XR8 PURSUIT 250 UTE SUBJECT PAGE SUBJECT PAGE REAR STYLE BODY KIT ....17-6-1 BODY ROCKER PANEL SIDE STYLE KIT .
  • Page 156 17-6-2 Grille and Exterior Mouldings...
  • Page 157 Grille and Exterior Mouldings 17-6-3 SIDE STYLE BODY KIT COMPONENTS: INSTALLATION Tools required: • Air screwdriver • Sika gun • Drill • Brush 1. Place drill jig over the style side area. Drill 5.00mm hole using the drilling boss as the location. Enlarge drilled hole to 9.00mm.
  • Page 158 17-6-4 Grille and Exterior Mouldings...
  • Page 159 Grille and Exterior Mouldings 17-6-5 Z-BRACKET: REWORK Tools required: • Air hacksaw • 6mm drill piece 1. Place rear Z-bracket from Right and Left hand end rocker panels onto cutting fixture. Place marking jig onto centre section of Z-bracket and mark centre cut line and extra 6mm hole location as shown in View A.
  • Page 160 17-6-6 Grille and Exterior Mouldings...
  • Page 161 Grille and Exterior Mouldings 17-6-7 Z-BRACKET TO ROCKER PANEL ASSEMBLY Tools required: • Sika gun • Rivet gun • 1” brush 1. Clean all sika trails on all rocker panels (Right hand front, Left hand front, Right hand end, Left hand end, Intermediate right and Intermediate left) using sika cleaner and all mating surfaces on hand rocker (Left and right) and hand rocker extension (Left and right).
  • Page 162 17-6-8 Grille and Exterior Mouldings...
  • Page 163 Grille and Exterior Mouldings 17-6-9 BODY ROCKER PANEL MOULDINGS: INSTALLATION: Tools required: • sika gun • circlip pliers 1. Thoroughly clean glue tracks off rocker mouldings with sika cleaner and clean cloth. Allow 5 minutes to dry before applying sika primer. 2.
  • Page 164 17-6-10 Grille and Exterior Mouldings...
  • Page 165 T SERIES & XR8 PURSUIT 250 UTE REPAIR MANUAL GROUP SCHEMATICS PART 22-1 Schematics...
  • Page 166 Schematics 22-1-1...
  • Page 167 22-1-2 Schematics...
  • Page 168 Diagrams 24-4-17 SECTION E–2 EXTERIORLIGHTING– HIGH SERIES – SWB L/H DRIVING LAMP 57 BR C-1006 188 BR 12 BL 188 BR DRIVING LAMP RELAY DRV LP 188 BR C- 1005 R/H DRIVING LAMP 57 BK...
  • Page 169 Diagrams 24-4-31 SECTION G–2 INSTRUMENTCLUSTER– HIGH SERIES – SWB...

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