Serv

ice

Man

ual

Service Manual

THIS IS A MANUAL PRODUCED BY JENSALES INC. WITHOUT THE AUTHORIZATION OF FORD OR IT’S SUCCESSORS. FORD AND IT’S SUCCESSORS

ARE NOT RESPONSIBLE FOR THE QUALITY OR ACCURACY OF THIS MANUAL.

TRADE MARKS AND TRADE NAMES CONTAINED AND USED HEREIN ARE THOSE OF OTHERS, AND ARE USED HERE IN A DESCRIPTIVE SENSE TO REFER TO THE PRODUCTS OF OTHERS.

LGT, YT, LT RE and Attachments

Volume 1 of 2

FO-S-LGT,YT,LT

Manual Tool Key

102

103

104

105

106

108

201

301

,. 302

304

402

Ford Tool No.

*Bushing Driver 808

*Step Plate 630-2

*Step Plate 630-3

***Step Plate 630-9

**step Plate 630-1

**7/16" Socket 1/2" Drive

Adjustable Reamer 0.8765"

Use Shim Stock over Key Way

1" Pipe or bushing driver T809 if unit disassembled

Use Shim$,tost,~.lVer ,Key Way

3/ 4"~p\pe or st~: Plate 630-7 if unit disassembled

Bushing Driver 807

.;rRANSAXLE MECHANIC'S HANDBOOK Special Service Too!s~

SECTION 2

SPECIAL SERVICE TOOLS

Page Reference

3-6, 3-7, 7-1

3-7, 7-1

3-7, 7-1

3-7, 7-1

3-7, 7-1

3-7, 5-1, ~7-1

3-9, 6-1, 7-2

3-1, 3-3, 3-8, 3-9, 7-2

3-1, 3-3, 3-9, 7-2

3-9, 7-2

3-1, 3-6, 3-9, 7-1

3::4; 3-5, 6 .. 1, 6~, 7-2"

Operation

Transaxle output shaft 15/16" x 1-3/16" needle beariJ;:ig removal and installation; ,ft

Transaxle brake shaft 7/8" x 1-1/8" needle bearing removal and installation.

Transaxle brake shaft 1" x 1-1/4" needle bear­ing removal and installation.

Transaxle differential carrier 1(..3/4" x 2-1/8" needle bearing removal and installation.

Transaxle input shaft and low speed 3/4" x In needle bearing removal and installation.

Transaxle shifter shaft pilot bearing 7/16'." needle bearing installation>

Transaxle differential cfl-rrier bushing;' ~'J&"3 , t~-· 6'ear cluster bushing sizip.g operation.

Transaxle brake shaft 1" seal installation.

Transaxle brake shaft and axle 1" seal in­stallation.

Transaxle input ShaLt 3/4" seal installation.

Transaxle input shaft seal, input bearing 3/4" seal and bearing installation.

7/8" bushing removal and installation.

2-1

Sp~cialService Tools

Manual Tool Key

501

Ford Tool No.

Step Plate 630-7 w/axle housing disassembled

. TRANSAXlE MECHANIC'S ~H:IliB1l11it., . . ',-~ ,;:'" ;, '; ;,.;i.,.;.:~.)

SPECIAL SERVl!=E TOOLS (Continued)

Page Reference Operation

3-8, 7-1 Transakle 1" shaft ball bearing 'outer· ra,ce installation .. '

*Needle bearings in the case cover must be positioned 0.015"~O.020" below the thrust surface .

. *"'Needle bearJngs for low speed shaft and shifter shaft pilot must be positioned 0.010'~ below the thrlist surface.'

~~'*Differential carrier bearing must be pOSitioned 0.290" below outer housing surface.

2-2

~r!!: f

.-", .. -- TRANSAXLE MECHANIC'S HANDBOOK Four-Speed T~t;l4tle

SECTION 3 -

FOUR - SPEED TRANSAXLE

r~liFOiJR-s';~~b TRANSAXLE SERVICE. . . .

a. Prior to removing a trans axle frorri a vehicle for service, look for a malfunction in the power deliveiysystem. Malfunction of the items listed be­low will 'cause a trans axle to become inoperative.

(1) Loose.drive belts.

(2) Improperly adjusted or badly worn clutch.

(3» Loose or lost set screws and or sheared keys in drive and driven pulleys.

(4) Oil saturated drive belts and clutches .

. (5) Operators bad habits, such as using a clutch • for a foot rest and allowing slippage. Im­. proper operation of the clutch.

b. Before r.emoving· the transaxle from the vehicle attempt to confiJ:!.e the service. requirement to aparti­cular opetatioI!.'lf the tranS axle is operative, run the vehicle in all speed~id hi pin pointing the problem.

...., _. I -

3-2. OlL-~~E~~:~eaks should be pinpOinted as accurately as PClspible,prior to removing the trans­axlefrom'the veh~c}e. O"n~ leakage is usually caused by, seal failure or loose gasket surfaces. This may be cor.rected without ---' the coin-plete tear down of the

;/Efansaxle. . - ...

.~~,i>il leakage aroundseallSor gaskets surfaces sijptil~; be -cor'rected by the installation of new seals aI1d gilskets. Shaft siIrf~ces should be examined be­fore installing new seals, if scratched, pitted or __ -damaged in any way the I3haft will have to be replaced. Leakage around' gasket surfaces may be caused by loose bolts or possibly damaged gasket surface.

Fig/He 3-1. tour-Speed T ronsaxle

Figure 3-2. Input Shoft Seal

Figure3~3. Brake Shaft Seal

Tightening the bolts may be sufficient to stop leakage. Seriously damageggasket surfaces will require re­placement of the part. Minor imperfections may be corrected by the use of gasket cement.

b. INPUT SHAFT SEAL. (Figures 3-1, 3-2.) To replace the input shaft seals, remove the input drive pulley -- and 3 cap screws holding the cover to the gear case. Lift out the input gear and bearing "A" (Figure 3-2.) Remove thrust washer and snap ring to allow removal of input gear "B" (Figure 3-2.) Examine the input gears and shaft for wear or damage.Re­place when wear is evident.

Examine bearings_ and replace when necessary. See Section 7, BUSHING AND BEARING SERVICE, for proper procedure.

When reassembling, use oil seal sleeve. key--302:.a,nd '.' seal driver Key 304 to prevent damage to seals.

c. BRAKE SHAFT SEAL. (Figures 3-1,3-3;)Re­move all rust and burrs from the shaft. Remove the seal. Be careful not to damage the shaft or seal bore. Use the seal sleeve Key 301 and seal driver Key 302 when installing the seal.

3-1

Four-Speed Transaxle TRANSAXLE MECHANIC'S HANDBOOK

- THIS JOINT SEALED WITH INTERNAL QUAD •

-RINGSEAL -

Figure 3-4. Shift Lever Housing

d. SHIFT LEVER HOUSING GASKET. (Figures 3-1, 3-4.) Oil leakage at the gasket surface (Figures 3-4, 3-5) between the shift lever housing and the transaxle case may be corrected by replacing the gasket. (Fig­ure 3-5.)

(1) Clean the area surrounding the shift lever housing.

(2) Move the shift lever to Neutral.

(3) Remove the three socket head cap screws (Figure 3-4) and lift off the shift lever and housing assembly.

(4) Remove the old gasket from both gasket sur­faces. Be careful that dirt or gasket residue does not fall into the transaxle. Install new gasket.

(5) Position the inner end of the shift lever in the notches in the shifting forks. (Figure 3-5.)

Figure 3-5. Shifter Forks

(6) Replace the shift lever and housing, secure with the three socket head cap screws, torque to 10 ft. Ibs. (Figure 3-4.)

(7) If the shift lever and housing were removed withbut placing the shift lever in Neutral, correct before assemblying. Place a large screwdriver on side of shifting fork opposite direction to be moved and against side of opening, press against side of :shifting fork to move.

(8) If lubricant is leaking at the point where the­shift lever enters the housing, (Figure 3-4) remove the assembly as in paragraph 3-2d, 1 thru 4 above. For additional service informa­tion refer to Section 4 Shift Lever Service. Replace as in 3-2d, 5 thru 7.

e. CASE AND COVER GASKET. (Figure 3-1.) Fol­low disassembly steps, paragraph 3-3a, 1 thru 4. Reassemble as per paragraph 3-5d, 1 thru 6.

f. AXLE SUPPORTS. (Figure 3-6.) Lubrication leakage at either the axle support to case/cover mat­ing surface or outboard end of the axle support indi­cates failure of internal seals or seals located inside the axle support.

(1) Expose and clean th~ive end of the axle. (Figure 3-6.) Bolted on axle supports are re­moved by removing the four hex head bolts. (Figure 3-6.) The seal is in the cavity in the case/cover. (Figure 3-7,3- 8.)

(2) Examine the "0" ring seal (Figure 3-7) be­tween the axle support and trans axle casel cover. Look for cuts, cracks, etc., to deter­mine reason for leaking. Always replace this "0" ring seal to assure leakproof sealing.

(3) Remove seal retainer and seal assembly (Figures 3- 7,3- 8). Pull the axle out as far as possible to move the seal retainer out of the bore in the case/cover. (Figure 3-7.) Remove

Figur.e 3-6. Axle Supports

- --,,­Ii

-.-_ .....

Four-Speed T ron saxl e TRANSAXLE MECHANIC'S HANDBOOK

3·4

Figure 3·10 Faur.Speed Disassembly

the brake shaft is the cover. (Figure 3-1.) Separate the case from the cover as follows: Lift the case upward horizontally about l-l/Z to Z inches. (Figure 3-11.) Tilt the case edge

,nearest the serviceman higher--about 45 degrees. (Figure 3-11.) Rotate the shift lever opening end clockwise, while lifting the case upward and off. (Figure 3-11.)

(5) Remove the three gear cluster (Figure 3-lZ) anC1 1/3Z" thrust washer by sliding vertically

Figure 3·11 Separate elise From Cover

Figure 3·12 Remove Three Gear Cluster

off the brake shaft. Examine the internal bush­ings and replace if necessary. See Section 7, Bushing and Bearing Service for procedure. Replace bushing, if worn in excess of .878.

(6) Examine the reverse idler gear, shaft and spacer assembly. (Figure 3-13.) Note that the rounded end of the gear teeth are toward the spacer and flange. Remove the entire assem­bly by lifting out. If the gear is loose on the 'shaft, or worn, or damaged, replace. Replace the shaft if wear is evident. (Figure 3-13, 3-14.) -

(7) Remove the shifting assembly. (Figures 3-14, 3-15.) Grasp the tops of the shifter rods, as illustrated, and squeeze tightly, -causing the assembly to bind. Lift out carefully. It may be necessary to turn the gears slightly -to re­lease.

NOTE

l1uld the assembly in the hand. and examine the parts to become familiar with the ar­rangement. This will aid during reassem­bly. See Section 5, Shifting Assembly, also see Section 7, Bushing and Bearing Service, for the procedure of removing the bearing from the end of the'shifter shaft.' -

Figure 3.13 Reverse Idler Gear, Shaft and Spacer