Overdrive gear — removal and installation (Transit 2)

Warning: The following procedures require the rear of the vehicle to be raised and supported on jack stands with the wheels off the ground. Because this action is potentially dangerous, use extreme caution when performing it and ensure the vehicle is securely supported and the front wheels are securely blocked. Please also refer to the information contained in the "Safety First!" section at the beginning of this manual.

Removal

1. If the overdrive is working, block the front wheels, raise the rear of the vehicle and support it on stands so that the rear wheels are clear of the ground. Apply the parking brake.

2. After taking the necessary safety precautions, start the engine, engage high gear and run the car to a speed of approximately 60 km/h with the overdrive gear engaged. After disengaging the overdrive gear, allow the rear wheels to turn by inertia, then press the clutch and turn off the engine. This is necessary to wedge the splined shaft between the planetary gear retainer and the one-way clutch, making it easier to remove the overdrive gear.

3. If the overdrive gear does not work, it can be removed, but additional procedures described in paragraph 14 will be required.

4. Disconnect the negative battery cable.

5. Place a suitable container under the transmission drain plug, unscrew the plug and drain the transmission oil. Install the drain plug when finished.

6. Remove the propeller shaft as described in Chapter 8.

7. Support the gearbox with a jack and remove the overdrive set lock bolt with the large washer from the cross member.

8. Remove the bolt securing the transmission cross member to the support bracket on the left side.

9. Unscrew the two bolts securing the transmission cross member bracket to the body and remove the cross member.

10. After unscrewing the bolts, separate the mounting bracket from the overdrive unit.

11. After unscrewing the bolt, remove the retaining plate and pull out the speedometer cable.

12. Disconnect the solenoid valve wiring and release the cable mount.

13. Unscrew the eight nuts securing the overdrive unit to the intermediate flange of the gearbox (see figure 13.13).



14. Using a soft-faced hammer, tap the inside of the overdrive assembly to release it from the intermediate flange, then remove the assembly from the gearbox. If the procedures in paragraphs 1 and 2 have not been performed due to failure of the overdrive unit, or if the unit cannot be removed for any other reason, loosen the six overdrive rear case nuts until they are flush with their studs. This will wedge the splined shaft between the planetary gear retainer and the one-way clutch, making it easier to remove the overdrive assembly.

15. After removing the unit, clean off all traces of the old gasket from the contact surfaces of the overdrive transmission and the intermediate flange of the gearbox. Tighten the rear case nuts if you loosened them to make removal easier.

Installation

16. Install the mounting bracket onto the overdrive assembly.

17. Using a new gasket, attach the assembly to the intermediate flange of the gearbox and secure it with eight nuts, tightening them to the specified tightening torque. If the overdrive unit does not fully engage the intermediate flange, leaving a gap of approximately 16 mm, there is a misalignment between the overrunning clutch slots and the planetary gear mounting element. To fix this, remove the assembly and slightly turn the freewheel clutch counterclockwise with a screwdriver. After this, installing the overdrive unit should not be a problem.

18. Connect the solenoid valve wiring and the speedometer cable. Make sure you route the wiring correctly and secure it tightly.

19. Once the cross beam is in place, tighten the bolts to the specified tightening torque.

20. Install the driveshaft as described in Chapter 8.

21. Fill the transmission oil according to Chapter 1, then lower the car to the ground and connect the battery.

(The original can be found on the specified resource: FordBook.ru)