ball bearing – One Man And His Mustang

A short week after the Easter break meant that my weekend trip to Mustang Maniac arrived in no time. I was sure to take my ball bearing down with me to fit into the fully exposed C4 gearbox. The weather started of bad but was promising to be a nice day. I arrived at the office to see Adam in the office with a room full of people, a couple of faces I recognised and a number I didn’t. Is this the male equivalent of the ladies coffee mornings, a load of blokes all standing around talking cars? Eventually I tore myself away to get down to the task in hand, finishing the gearbox. Last week the missing ball bearing stopped play unfortunately so hopefully we could make some time back up.

I pulled out the box of bits I had taken down and carefully removed the bearing and spring to check for size.

In order to wedge the bearing in place I dropped the bearing onto a slim screwdriver and lowered it into place and made sure there was clearance with no binding at all as this needed to release pressure. Once I was happy I let the bearing go and rest in place. Now I was well chuffed.

Next up was the gasket for the filter and fitting the spring into the pressure release, The filter was fitted to the correct position ensuring the spring was in place and not ping out.

spring in place

filter ready

filter clamped down

The next part was the gearbox sump pan. The old pan was a little dented but could of been cleaned up and reused with a new gasket. Adam suggested a newer design drained sump, no it was not concourse, and as I was a slight resto-mod anyway I was swayed with the super shiny chrome. The gasket was laid on the gearbox and pan fitted in place ready to tighten the bolts up.

The last part that had to go onto the gearbox was the new engine mount. This wasn’t able to be done up tight to start with as the gearbox needed to be in position first. That meant due to where the bolt heads are the mounting bracket would have to be fitted then removed to tighten the bolts fully.

At this point Adam joined me to help with the gearbox fitting, we decided to dry a fit to make sure everything was in place and where it should be. It was going to take longer with bits going on and coming off again, but as we have seen some of the previous handy work we wanted to make sure. I fitted the flex plate and the retaining plate first, not doing things up to tight, just to make sure it was held in place. Then we jacked the gearbox to the engine to check alignment.

Adam was happy with the fit and gave me the next set of instructions. Remove the flex plate again, clean up the torque converter, spray the engine back plate and then give him a shout. As the sun was out and a gorgeous day the spraying was dry by the time I had cleaned up the converter. The torque converter was cleaned up on the outside being careful not to get any cleaner into the converter itself.

With the converter now cleaned I took that and the plate back to the workshop. Fitting the newly sprayed engine plate to the back of the engine was simple as it was more like a huge gasket. The flex plate was remounted and bolts done up tight.

The torque converter was fitted into the bell housing and checked all was aligned correctly.

The gearbox was lifted to the engine and the gearbox was held in place while, the torque converter was aligned up to the flex plate with a single bolt to hold it in place from slipping out of position. The bell housing bolts were fitted to the engine and tightened up with Adam’s new fancy Snap On tool. Note to self – future Christmas prezzie!

Next up was the gearbox support bracket that we dry fitted earlier. The gearbox mounting bracket was now in place and tight so we just had to tighten the nuts to the bolt threads. Now the gearbox was supported under her own weight and the lift was released.

A huge step forward and we were on a roll. We decided to fit the prop shaft in place while we were at it. Adam carefully inspected the UJ bearings to make sure that there were no needle bearings missing. Once he was happy with that they were fitted to the end of the prop shaft universal joint and clamped into place.

The drive train was now in place. Technically ready to move under her own power and drive.

To finish the day we day we quickly fitted up the hand brake counter lever to keep the cables of the floor.

Next week it shall be back to putting things back in the engine bay. I hope to fit my new engine headers and the radiator. I am so looking forward to that.

Adam showed me a quick peak at the interior I wanted and it looks pretty darn good, but I would say that as it’s mine. I will have to start working on striping the seats down ready for the fitters sooner rather than later.

A great day, thanks Adam.

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Easter weekend and I have lots of days on the car, well that’s what I was hoping anyway. I had promised to help to wife around the garden over Easter and the day we were hoping to have away in London didn’t happen for various reasons. But, I was still allowed a day pass to go work on my car so I was happy. I arrived at Mustang Maniac tools and food at the ready to last me the day. I managed to grab some time with Terry who kindly showed me how to change the main seals in the C4 transmission with me.

The first part was to remove the kick-down and gear lever on the side of the gearbox. This was a case of undoing the gear selector pressure plate on top of the valve body and removing the brains of the gearbox. The brains of the gearbox is a series of pipes and valves that operate in certain pressure conditions and should not be played with unless you know exactly what you are doing. A single thread from a cloth will be enough to damage the valves inside.

The bolts being removed from the valve body or brain.

Lifting the brain out and exposing the intricate pathways of the transmission fluid.

With the valve body lifted carefully out-of-the-way, it allowed access to the gear lever and kick-down mechanism. Remove the bolt from the outside and the two halves of the lever will separate the smaller part inside the outer sleeve.

The two rubber seals need to be replaced at this point, one on the main gearbox housing where the larger outer sleeve fits through on the outside casing, the other is on the end of the lever bar itself and will need to be pressed in with help of a vice as it’s a tight fit.

A rare glimpse at the inner workings of a C4 transmission.

connection to gear lever at the top

To fit the lever back into place was simple enough, but locating the position of the gear selection lever to the valve body kick-down mechanism is tricky. The lever has to sit inside a cam and the kick-down connection sits just behind that. The horizontal bar at the top of the picture below shows where the lever cam must be located.

With the valve body in place it’s time to tighten the valve body back down in place, make sure the body does not lift of or move from the gear arm.

The next part would be to fit the filter back on, then the transmission sump. This is where my problem started. When the filter was first removed we also removed the spring but there was no steel ball bearing or valve plate sitting in the pressure relief channel. We were going to check if this model need it. It does.

The spring locates just where you can see two half-moon parts of casing just below the end of the spring. This is in fact a pressure regulator for the two half’s of the gearbox. So not only was it put back together with a pressure valve part missing, but there was also a bolt missing from the gear selector arm sprung plate as well. John hunted high and low all over the place for a ball bearing that size, he even opened up some scrap parts that may of had a bearing in them. Do you think we found one? No. We even split open a couple of old used spray cans to get the ball bearing(s) out. In today’s world that bearing has been replaced with a glass marble so it seems. Now it’s at this point I need to apologise again to John who punctured a can I gave him to get the (potential) bearing out. The tin of black spray paint gushed out, (even though no gas was coming out of the nozzle after I emptied it), and proceeded to spray satin black paint over his overalls and neck. Sorry John. John to his credit managed to remain calm, but the air did go a little blue if you get me. So I was going to have to try and buy one as the search was not proving to be successful at all. I was not a happy Easter Bunny at this point because some herbert didn’t put the gearbox back together properly, and it makes me wonder even more now about the health of the gearbox in general. The only good thing is that the fluid is clean, which can be a good sign of health for an auto transmission gearbox. But, these setbacks do happen in restoring old classic cars and I dare say there will be more. The guys at MM see it all the time where things are put back together with bits missing or not even secured where they should be, such as brake pipe valves, fuel lines, engine parts etc. Anyway in the mean time I cleaned up the back of the gearbox, fitted the seal gasket and re-attached the rear of gearbox and tightened the bolts up.

gasket in place

With the two halves back together again I fitted the new rear seal that protects the prop shaft from leaking when located in the gearbox. This particular seal is an upgraded version as these new seals have a collar rather than just the ring on the inside. I found a very large socket to fit over the end of the collar and tap it back into place.

The governor valve was next up to be fitted to the side of the gearbox, this is held in place by a sprung loaded clip and a bolt. Make sure the thin rod that fits into the end of the governor is in place or the gearbox will not change gear!

governor in place

sprung slip

vacuum pipe

With the parts in place it was time to prep the sump and gasket ready to be fitted to the gearbox.

chrome cleaned up

gasket in place

Now there wasn’t a great deal I could do so I just tinkered around. I said my farewells to the chaps at the end of the day and thought all the way home where I could get a single ball bearing from. Once I arrived home I went to my man cave and looked through my odds and ends tin. As a creature of habit when I finish a can of spray I cut it open to get the ball bearing out.

Note: Please be very careful if you are mad enough to attempt this at home as it could explode if any air pressure remains in the tin, if in doubt don’t do it.

In previous posts I have used the bearings to seal up fittings when spraying or to stop the area being contaminated. They do come in handy. So I opened the lid and tipped it out onto my bench, I found the perfect size!

I have now packed the spring and bearing away very carefully ready for next week. Not only did a find a bearing, but I found two balls, now I was a happy bunny again. It’s amazing how a single tiny part can stop an entire days plans. I was hoping to get the box fitted back on the car last week, but it will have to be next week now. Something to look forward to now.