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Fitzy, I'm still working on this . I will finish it later today.
THROW OUT BEARING REPAIR AND TRANS FLUID CHANGE
Ok, the following is just so you know whats involved in fixing the bearing . It looks like a big ordeal because the list is long but it is actually pretty easy and even you can do it alone in less than 8 hours.
THINGS TO GET
Order bearing seal kit p/n 62-905.
Get four jack stands from Super cheap . Cheap ones are fine . Keep the receipt and return them afterwards.
Get trans adapter for your floor jack.
Get second floor jack . The stock Mustang screw type will work or a basic post jack.
Get a bolt the same od and thread as the one holding the line to the master cylinder and get a fiber or plastic washer for it.
Two bottles of 75w-90 or 80w-90 GL4 trans fluid . If you are racing it, use 80w-140 . It will be slightly stiff to shift until the oil gets warm . You can use this on the street also . Do NOT use a bottle that says GL4/GL5 on it . It must only say GL4.
A slab of FOSTERS LAGER, Australians favorite weed killer!
HERE'S THE FUN PART
Disconnect positive battery cable.
Apply your crappy parking brake.
Put several layers of news paper on the floor under the master cylinder and trans or use a drip pan.
Put trans in first gear.
Remove screws from shifter boot then pull the boot all the way up to the T handle.
Remove the two bolts at the base of the shifter and remove shifter.
Open hood/bonnet then remove the two top bell housing bolts . Don't scratch the car with the buttons on your pants.
Grab the bolt and washer you bought for the clutch master cylinder.
Remove the bolt securing the line to the clutch master cylinder and move line and install the blot and washer you bought . This sort of takes three hands almost.
Put the end of the line in a shallow pan under the car so the fluid can drain out of it.
Loosen rear wheel nuts around 1/16 th of a turn.
Jack the rear up by the center of the diff.
Put a jack on each side of the axle near the wheels and use lowest jack position.
Jack the front of car up by the cross member under the engine.
Put a jack on each side of the front frame rail and use lowest jack position.
If the car is not high enough, raise it up until it is.
Set the car up so the rear is around 30 to 40 mm higher than the front.
Remove the rear wheels.
Put the car in neutral and remove the parking brake so the rear wheels can turn.
Drain the trans.
Remove the bolt holding the speedo cable in.
Pull on the cable to remove it . You may have to wiggle it slightly because it has an O ring on it.
Remove the nuts and U bolts on the U joints . You can rotate the driveshaft by hand to get access to them.
Rotate the driveshaft until the U joints in the differential yoke are horizontal to the ground.
Pinch the U joint caps together then push the driveshaft forward 25 mm then lower the shaft onto the ground.
If the shaft will not move forward, pinch the U joint caps then pry them out of the yoke with a long screwdriver.
Once the end of the shaft is on the ground, wrap tape around he U joint and caps so they do not fall off and spill all their tiny needle bearings on the ground.
Raise the end of the shaft up around 12 inches then pull it out of the trans . You may have to yank on it fairly hard.
Hopefully your exhaust is not in the way of removing the trans.
Loosen the 4 bolts that hold the trans to the bell housing by 1/16 of a turn only . They should still be slightly snug when you are through.
Remove the nuts that hold the trans to the cross mount.
Remove the nuts from the long bolts that hold the mount to the body.
Place a 6" long 2 x 4 on a jack so it runs from side to side of the car.
Raise the jack until the 2 x 4 contacts the rear of the oil pan right next to the bell housing.
Once the 2 x 4 hits the oil pan, raise the pan around 5 mm.
Remove long bolts that hold trans mount to body then remove mount.
Lower jack under oil pan until the end of the trans drops exactly 3 inches.
Remove positive cable from new Chinese starter motor.
Remove new Chinese starter motor.
Stick a screw driver in the access hole in the side of the bell housing and try to move the bearing forward and rearward . You are looking for around 2 to 4 mm of movement . If there is no movement, you need to adjust the free play . See notes below.
Put the trans jack under the trans long ways so it can roll from the front to the rear of the car and point the handle towards the differential.
Raise jack until it is almost touching the trans then adjust the brackets accordingly so they all contact the trans.
Raise jack just a tiny bit so the brackets apply very slight pressure on the trans.
Remove the 4 bolts that hold the trans to the bell housing.
Pull the trans rearward until it clears the bell housing then lower it and leave it on the jack and just pull it rearward so you have more room.
Remove remaining bell housing bolts.
Pry bell housing off.
Disassemble bearing per video below and install new seals . If the bearing needs to be removed to adjust the free play, you can disassemble it after you remove it from the housing.
ADJUSTING BEARING FREE PLAY
The Tilton has a threaded sleeve . There may be a set screw pushing against the sleeve that you need to loosen first . Place the bearing so the sleeve is facing you . If the bearing had zero free play, turn the sleeve clockwise one full turn.
INSTALLING TRANS FLUID
Put some newspaper or paper towels under the trans . Make sure drain plug is tight . Remove the fill plug . Put the oil in . Fill it until it runs out of the ole and all over the trans and onto the floor . Reinstall plug and make it pretty tight.
The oil is thick so it pours slowly . You can put some hot water in a pan then put the bottles in it for 5 minutes to thin the oil some.
REMOVING THOSE POS WEIGHTS FROM THE FLYWHEEL
Put tape over the opening in the center of the clutch.
Cut the wire after every three weights with big wire cutters.
Remove the wire from a set of weights with small vice grips or needle nose pliers.
Remove the three weights.
Continue this process until all these pos are off.
Remove the tape.
EFFECTS OF AIR IN A HYDRAULIC CLUTCH SYSTEM
https://www.youtube.com/watch?v=bngJkM_vkUEHOW TO INSTALL NEW SEALS IN BEARING
Yours will be most similar to the second one shown.
https://www.youtube.com/watch?v=EXfYMz7Vm30REASSEMBLY
By more beer.
Put it back together.
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