PD Courier 1997 4x4 Transmission tear down advice needed.

patanga · #1 02-07-2018, 07:25 PM

Hi. I'm new to the forum and am hoping to find a bit of advice on the 4x4 transmissions. My vehicle is a 1997 PD Ford Courier or Ranger in the U.S.. The problem I have is that the box is making wierd noises in the lower gears (at this stage) which I've been advised is likely to be due to case hardening failure on the main shaft and possibly the spigot input shaft as well. I've got the gearbox out and am looking for more info on how to tear the box down and carry out the neccessary repairs. I've attached a photo of the gearbox below.

My questions are as follows:

Are there any 'how to' links to articles on this page?

Does anyone know the production years that Mazda/Ford used this particular gearbox design in the 4x4 utes.? I have a PDF repair manual from a 1992 model but I don't know if they were the same.

Any further tips would be greatly appreciated.

Thanks in advance

12 Deg North Industries · #2 02-07-2018, 11:22 PM

Got yourself quite the project waiting for you there mate..

Some starter information here. I thought you may have an auto transmission but then it looked like the side of the bell housing had an old style square hole for a mechanical slave cylinder type lever mechanism. So obviously the two internally will be quite different. Are you working with an auto or manual?

Are you in the Perth area by chance?

patanga · #3 02-08-2018, 05:59 AM

Thanks for your reply James. It's a 5spd manual. I'm located is Brisvegas on the east coast so nowhere near W.A.

12 Deg North Industries · #4 02-08-2018, 08:45 PM

Quote:

Originally Posted by patanga

Thanks for your reply James. It's a 5spd manual. I'm located is Brisvegas on the east coast so nowhere near W.A.

PM me an email address.

I'll put you in touch with the lead tech from Liberty Gears here in the States, amazing crew and guys in the professional world of transmissions is concerned; They do all of the NASCAR truck series stuff too. If anyone could or would offer a walk though consultation on the inner workings of a trannie it would be my contact there. Worked with those guys in a business capacity for over a decade and a half if not two.

tomw0 · #5 02-09-2018, 04:11 AM

Most times the lower gears will cause noise if the countershaft bearings have failed, allowing the shaft to move relative to the gears, so the mesh gets wrong. Once the mesh gets bad, the faces of the teeth get funny wear patterns, causing noise.

There are images here that may help identify your transmission:

http://therangerstation.com/tech_lib...smission.shtml

Looking, it appears your case matches the first images, FM145, but don't depend on my eyes.
tom

Added: I think what we in USA call the 'countershaft' may be called the 'layshaft' in British influenced countries. It rotates 100% of the time the engine is running, clutch engaged, and feeds power from the input shaft to the non-direct gears. Most run on roller bearings, and from experience with an old MG transmission, are very subject to low fluid llevels, or improper fluid used.

patanga · #6 02-19-2018, 10:43 PM

Quote:

Originally Posted by 12 Deg North Industries

PM me an email address.

I'll put you in touch with the lead tech from Liberty Gears here in the States, amazing crew and guys in the professional world of transmissions is concerned; They do all of the NASCAR truck series stuff too. If anyone could or would offer a walk though consultation on the inner workings of a trannie it would be my contact there. Worked with those guys in a business capacity for over a decade and a half if not two.

Thanks 12 Deg North Industries. I've since discovered a PDF workshop manual that might do the trick but it is dated for the 1992 model so I'm not sure if it is the same gearbox. Rather than have your associate spend time with a blow by blow 'how to' description could I impose upon you to ask him if the 1992 type & manual is the same as those used in the later models?.. The relevant section of the workshop manual (see below) can be found under chapter J3. Assuming they are the same I should be able to manage things from there. Thanks in advance.

Darn it.. Dropbox won't allow me to post an active link here without opening the account with a password. Can anyone suggest a PDF friendly cloud site where forum links can be posted and accessed?

12 Deg North Industries · #7 02-20-2018, 07:07 PM

Quote:

Originally Posted by patanga

Thanks 12 Deg North Industries. I've since discovered a PDF workshop manual that might do the trick but it is dated for the 1992 model so I'm not sure if it is the same gearbox. Rather than have your associate spend time with a blow by blow 'how to' description could I impose upon you to ask him if the 1992 type & manual is the same as those used in the later models?.. The relevant section of the workshop manual (see below) can be found under chapter J3. Assuming they are the same I should be able to manage things from there. Thanks in advance.

Darn it.. Dropbox won't allow me to post an active link here without opening the account with a password. Can anyone suggest a PDF friendly cloud site where forum links can be posted and accessed?

Good to hear and can do... I will contact my guy tomorrow (21st) and verify that for you.

12 Deg North Industries · #8 02-22-2018, 12:42 AM

Was unavailable to reach when I called him today for whatever reason, will be attempting again tomorrow for you.

12 Deg North Industries · #9 02-23-2018, 09:53 PM

By chance does your transmission have the tin "like" pan or the Aluminum one?