Auto >> AutoSPT >  >> Engine

How do you install a gearbox on EF Ford Falcon?

Installing a gearbox on an EF Ford Falcon is a major mechanical undertaking, requiring significant mechanical skills, specialized tools, and a safe working environment. This is not a job for a beginner. Improper installation can lead to serious damage to the vehicle and potentially injury. If you lack extensive experience with automotive transmissions, seek professional help from a qualified mechanic.

However, if you're determined to attempt this yourself, here's a highly generalized overview. This is NOT a comprehensive guide, and omits many crucial details:

1. Preparation:

* Safety First: Disconnect the battery negative terminal. Use jack stands and safety ramps appropriately. Wear safety glasses and gloves.

* Gather Tools and Parts: You'll need a complete set of metric sockets, wrenches, torque wrenches, transmission jack, engine hoist (possibly), alignment tool, new gaskets and seals, transmission fluid, and a workshop manual specifically for an EF Falcon.

* Drain Fluids: Drain the engine oil and the transmission fluid.

* Remove Components: This will likely involve removing the driveshaft, exhaust system components, possibly parts of the steering system, and potentially the engine mounts (depending on the approach). Consult your workshop manual for the exact steps and order.

2. Transmission Removal:

* Support the Transmission: Use a transmission jack to support the weight of the transmission.

* Disconnect the Transmission: Disconnect the linkage, clutch cable (if applicable), and all electrical connectors.

* Remove the Transmission: Carefully lower the transmission using the transmission jack.

3. Installation:

* Clean Mounting Surfaces: Thoroughly clean all mating surfaces on the engine and transmission.

* Install New Seals and Gaskets: Replace all worn or damaged seals and gaskets.

* Align the Transmission: Use the alignment tool to ensure the transmission is correctly aligned with the engine.

* Install the Transmission: Carefully lift the transmission into place using the transmission jack.

* Reconnect Components: Connect the driveshaft, exhaust, linkage, clutch cable, and electrical connectors.

* Tighten Bolts: Tighten all bolts to the specifications in your workshop manual. Using a torque wrench is critical.

4. Final Steps:

* Refill Fluids: Refill the transmission with the correct type and amount of fluid.

* Check Fluid Levels: Check and adjust fluid levels as needed.

* Test Drive: Carefully test drive the vehicle, checking for leaks, proper shifting, and unusual noises.

Crucial Considerations:

* Workshop Manual: You absolutely *must* have a workshop manual specific to your EF Falcon model and year. It will provide detailed instructions, torque specifications, and diagrams.

* Clutch (if applicable): If you're replacing the clutch as well (highly recommended if you're this far), this is an additional complex procedure requiring specialized tools and knowledge.

* Torque Specifications: Incorrect torque can damage components. Always use a torque wrench and follow the specifications in your workshop manual.

* Alignment: Proper alignment is essential to prevent damage to the transmission and the engine.

Again, this is a simplified overview. Attempting this without the proper knowledge, tools, and a workshop manual is strongly discouraged. The consequences of an improperly installed transmission can be severe. Hire a qualified mechanic to avoid potential problems.