Repairing the gearbox housing on a Ford Town Car, Crown Victoria, or Grand Marquis can be a complex task that requires a solid understanding of automotive mechanics. more details on the download manual click here…..
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Below is a detailed guide on how to approach the repair, including descriptions of every component involved.
### Tools and materials Needed
1. **Tools:**
– Socket set (metric and standard)
– Wrench set
– Screwdrivers (flathead and Phillips)
– Torque wrench
– Pliers
– Pry bars
– Hammer
– Seal puller
– Gasket scraper
– Transmission Jack or floor jack
– Jack stands
– Safety glasses
– Gloves
2. **Materials:**
– Replacement gearbox housing (if cracked or damaged)
– New seals and gaskets (for the gearbox and other components)
– Transmission fluid (specific to your vehicle)
– Cleaner/degreaser
– Loctite (if necessary for bolts)
### Steps for Gearbox Housing Repair
#### 1. Preparation
– **Safety First:** Ensure the vehicle is parked on a flat surface. Disconnect the battery to prevent any electrical issues.
– **Raise the Vehicle:** Use a floor Jack to lift the vehicle and secure it on Jack stands. Ensure the vehicle is stable before working underneath.
#### 2. Remove the Driveshaft
– **Locate the Driveshaft:** The driveshaft connects the transmission to the rear axle.
– **Disconnect:** Remove the bolts securing the driveshaft to the rear differential using the socket set. Support the driveshaft with your hands or a prop to prevent it from falling.
– **Slip Joint:** If applicable, slide the driveshaft out of the transmission.
#### 3. Drain Transmission Fluid
– **Drain Plug:** Locate the transmission pan’s drain plug and use a pan to catch the fluid. If no drain plug is available, remove the transmission pan bolts (which will also be removed later) and allow the fluid to drain.
#### 4. Remove the Transmission Pan
– **Unscrew Bolts:** Use the socket set to unscrew the bolts holding the transmission pan in place. Carefully pry the pan off using a pry bar or screwdriver.
– **Clean the Pan:** After removal, clean the pan and inspect for metal shavings or debris, which could indicate internal damage.
#### 5. Remove the Gearbox Housing
– **Locate and Remove Bolts:** Identify the bolts securing the gearbox housing to the transmission. Use the socket set to remove these bolts. Keep track of the bolts and their locations.
– **Disconnect Linkages and Sensors:** If applicable, disconnect any linkages (shift linkage, throttle valve cable) and electrical connectors (speed sensor, neutral safety switch) attached to the gearbox housing.
– **Remove Housing:** Once all connections are free, carefully pull the gearbox housing off the transmission. You may need to wiggle it gently to free it from any tight spots.
#### 6. Inspect Components
– **Check for Damage:** Inspect the gearbox housing for cracks or warping. Check internal components like gears, bearings, and seals for wear or damage.
– **Assess the Need for Replacement:** If the housing is cracked or severely damaged, you may need to replace it with a new or remanufactured part.
#### 7. Clean and Prepare Surfaces
– **Gasket Removal:** Use a gasket scraper to remove old gasket material from the gearbox housing and transmission. Ensure the surfaces are clean and free from debris.
– **Degrease:** Use a cleaner/degreaser to clean the areas around the gearbox housing.
#### 8. Install New Parts
– **New Gaskets
and Seals:** Install new gaskets and seals as necessary. Apply a small amount of gasket maker (if required) to ensure a good seal.
– **Align and Attach Housing:** Carefully align the new or repaired gearbox housing with the transmission and press it into place. Make sure no wires or linkages are pinched.
– **Secure Bolts:** Tighten the bolts to the manufacturer’s specified torque using a torque wrench.
#### 9. Reassemble the Transmission Pan
– **Gasket Installation:** Place a new gasket on the transmission pan.
– **Reattach the Pan:** Position the pan back on the transmission and secure it with the bolts. Tighten to the specified torque.
#### 10. Reinstall the Driveshaft
– **Reconnect Driveshaft:** Slide the driveshaft back into the transmission and secure it to the rear differential with the bolts.
– **Ensure Proper Alignment:** Ensure everything is properly aligned and secured.
#### 11. Fill Transmission Fluid
– **Fluid Check:** Using the dipstick tube, fill the transmission with the appropriate type of transmission fluid as specified in the owner’s manual.
#### 12. Reconnect Battery
– Reconnect the battery terminals.
#### 13. Test Drive
– start the vehicle and allow it to warm up. Check for leaks and ensure that the transmission functions properly. Perform a test drive to verify operation.
### Final Notes
– **Documentation:** Always refer to the specific service manual for your model for torque specifications, fluid types, and detailed schematics.
– **Professional Help:** If you’re unsure about any step in this process, it may be prudent to consult with a professional mechanic.
This guide provides a comprehensive overview of how to repair the gearbox housing on a Ford Town Car, Crown Victoria, or Grand Marquis. Each step should be performed with care and attention to detail to ensure a successful repair.
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