Remove rear wheels.
Insert spring spreader.
Remove right hand brake plate assembly from axle.
Place a block under torque tube to keep weight of axle off of universal joint.
Disconnect Brake rods, Shock absorber arms, Spring shackles and radius rods from axle.
Remove right and left hand axle housings.
Remove ring gear and differential assembly from axle.
NOTE: Do not remove torque tube from differential housing.
Disassemble Ford ring gear and differential assembly ass shown in illustration No.1. Do not remove bearing from ring gear. (This is used in this manner in the dual unit)
NOTE: The following Ford parts are not used in the Two Speed Axle assembly
1 R.H. Axle housing.
2 Differential case R.H. half with bearing.
3 Differential case L.H. half.
4 Differential spider.
5 Ring gear bolts and nuts.
OPERATION No. 2.
(USE TWO SPEED AXLE ASSEMBLY AS RECEIVED IN SHIPPING BOX.)
Assemble Two-Speed Axle Assembly to right side of Ford center member as shown in illustration No. 2, using nine original Ford cap screws, and one long cap screw with copper washer provided for front top side of housing. (This cap screw will be found wired into the hole in which it is to be used.)
It is not necessary to disassemble Two Speed Axle unit.
IMPORTANT: KEEP ALL PARTS CLEAN.
File or grind scale and all high spots from the unground diameter of right hand drive shaft for a space of 8" from back of side gear. Clean thoroughly and then dip side gear ends of axle shaftys in rear axle lubricant. (DO NOT USE CUP GREASE) approximately 5 inches before re-assembly. Insert Ford axle shaft through Two-Speed Axle Unit.
OPERATION No.3. (USE SUB-ASSEMBLY No.1)
Assembler original Ford differential pinions to the special differential spider provided in Sub-Assembly No.1, and be certain that the 4 bronze thrust washers indicated by letter "A" in illustration No.3, are installed on spider back of pinions.
NOTE: Washers should be lubricated with oil before assembling. (DO NOT USE CUP GREASE)
Assemble spider and differential pinions with washers in place in the Two-Speed differential case, as shown in illustration No. 3. Make sure pinions mesh properly into side gear.
OPERATION No. 4 (USE SUB-ASSEMBLY No. 2)
Insert Ford axle shaft with bronze washer in place, as indicated by letter (B) in illustration No. 4, through the original Ford ring gear and bearing assembly. NOTE: Assemble washer so that both tongues enter slots in Two-Speed differential case. Be sure that tongues do not drop out of slots during assembly, of Ford drive gear.
Bolt original Ford Ring Gear and bearing assembly to the Two-Speed differential case using special cap screws provided as shown in illustration No. 4.
IMPORTANT: Ring gear and differential case surfaces must be absolutely clean and free from nicks to assure true-ness of ring gear. Ring gear bolts must be drawn up tight and wired with lock wire provided.
OPERATION No. 5
Assemble original Ford left hand
axle housing to center member as shown in completed Two-Speed
axle assembly in illustration No. 5.
Connect Radius rods, brake rods, shock absorber arms and spring shackles to axle.
Attach hose clip to radius rod with longer screw provided.
Assemble right hand brake plate assembly to the Two-Speed axle housing.
Mount rear wheels.
NOTE: Make sure that hub fits taper on axle shaft and does not ride on axle shaft key, and axle shaft nuts are drawn up tight as possible.
OPERATION No. 6
Install selector valve in the
dash from the motor side. See illustration 6. Drill 27/32"
or 7/8" hole in dash, marking correct location of hole through
template furnished. NOTE: Do not drill larger hole or spacer will
not clamp valve to dash.
With knife or sharp instrument cut hole through felt pad on dash large enough to insert selector valve and spacer.
Remove nut, washer and spacer from valve, insert valve through hole from motor side. NOTE: The two small lugs on bottom side of valve are to keep it from turning and should fit agianst the angular part of dash.
Insert spacer through hole from drivers side and bolt together with nut and washer. See illustration No. 6, also letter "D" on general diagram.
OPERATION No. 7 (USE SUB-ASSEMBLY No. 4)
Straighten coiled end of
copper tubing only, the other end is formed to fit dash. These
tubes are used to connect the selector valve on the dash to the
vacuum cylinder on the rear axle.
NOTE: General diagram and illustrations Nos 6 and 7 for proper routing of tubes and location of brackets for clamping tubes.
NOTE: It is necessary to drill two 11/32" diameter holes in bottom flange of X member for the front and rear tube clamp brackets. (For location of holes see letter "E" on General diagram.
Lift right side of hood, feed both copper tubes under floor board, between brake rod and X member. Before clamping tubes to rear bracket, slide tubes through rubber grommets in center tube bracket, which is to be attached to the rear side of center cross member as indicated by letter "F" in general diagram.
Connect tubes to selector valve with rubber couplings provided.
NOTE: To prevent tearing or ruffling inside of rubber coupling when assembling to valve or tubing, moisten the end of couplings with water.) This note applies to all rubber couplings.
Attach bracket to dash as shown in illustration No. 6 , also letter "C" on general Diagram. Connect Left Hand rubber tube from vacuum cylinder to Right Hand copper tube.
Connect right hand rubber tube to left hand copper tube allowing slack in rubber tubing between the rubber tube clamps and the copper tube to allow for spring action.
Tape rubber tubes together and
to radius rod as indicated by letter "H" in General
Diagram, also in illustration No. 7.
NOTE: Copper tubes MUST BE PARALELL as shown and rubber tubes MUST BE CROSSED as described above.
IMPORTANT: Make sure that all joints are tight and that there are no sharp kinks in any part of the vacuum lines; also that the tubes are not pinched. (This would cut off vacuum and prevent proper operation of the vacuum shift.)
OPERATION No. 8 (USE SUB-ASSEMBLY No. 5 )
Install clutch pedal valve on
bell housing See illustration No. 8. Remove center cap
screw on left side of bell housing and attach valve at this point
using longer cap screw provided with valve.
IMPORTANT: Dowel on bracket of valve must fit dowel hole in bell housing which locates valve in correct position.
Disconnect clutch pedal spring from clevis pin.
Remove clutch pedal clevis pin.
Assemble pressed steel lever extension over clutch pedal as shown in illustration No. 8 and letter "J" on General Diagram. This lever extension must be a snug fit over clutch shaft so that there is no lost motion.
Insert new clevis pin furnished.
Replace clutch pedal spring.
Assemble pedal valve link, as shown in illustration No. 8.
CLUTCH PEDAL VALVE ADJUSTMENT.
With clutch pedal down against floor board, adjust the adjustable clevis on link of clutch pedal valve so the line of the valve piston is flush with the face of the valve as indicated by letter "K" in General Diagram. Tighten lock nut against clevis.
THIS ADJUSTMENT IS IMPORTANT.
To obtain a proper shift in the
Two-Speed axle, depends largely on the timing of the clutch pedal
valve opening with the engine clutch disengagement.
THE VALVE MUST NOT OPEN
UNTIL THE ENGINE CLUTCH IS COMPLETELY DISENGAGEMENT. To check
the correct valve timing, set selector lever on dash in neutral
position. Move transmission shift toward first gear until the
gears just start rubbing, declutch slowly till gears stop turning.
The clutch is now disengaged. Continue declutching slowly until
air is heard passing through selector valve, indicating opening
of pedal valve.
There should be ½"
minimum clutch pedal travel from disengagement of clutch to the
opening of the valve. If necessary readjust engine clutch.
OPERATION No. 9 (USE SUB-ASSEMBLY NO. 6 )
Install intake manifold spacer
shown in illustration No.9, also indicated by letter "L"
in General Diagram.
Remove carburettor from intake manifold and discard studs. Insert manifold spacer with gasket on each side of spacer and replace carburettor with longer studs furnished. The copper tube connection on the spacer should be on the left hand side of the carburettor as indicated by letter "M" in illustration No. 9.
Connect copper tube from manifold spacer to clutch pedal valve.
Connect rubber tube from clutch pedal valve to selector valve on dash as illustrated. Attach clip to dash as shown by letter "S".
After installation of manifold spacer, the throttle or choke controls in drivers compartment will be out of position. The original position of these controls can be retained by bending, (See illustration No. 9) the choke and throttle rods under the hood. CAUTION: Care should be used in this operation to avoid leaving motor permanently choked or with open throttle.
OPERATION No. 10 (USE SUB-ASSEMBLY No. 7 )
Install control lever bracket
to the instrument panel as per illustration No. 10, also indicated
by letter "N" in general Diagram.
Insert hook end of control lever rod into slot of selector valve as indicated by letter "O" in General Diagram.
Hold control lever bracket to the flanged edge of instrument panel four inches from center line of instrument panel as indicated by letter "P", in General Diagram. In this position drill two 7/32" or ¼" holes in the flange of the instrument panel and bolt bracket in place.
Disconnect speedometer shaft from speedometer head.
Insert square key furnished, into speedometer adaptor, connect adaptor to speedometer head with shifting lever shaft up in vertical position, as indicated by letter "R" in General Diagram.
Attach speedometer shaft to adaptor. MAKE SURE THAT SHAFT IS FREE FROM SHARP BENDS. This may cause noise. The minimum radius in shaft must not be less than three inches See view in General Diagram. If desired, drill holes in dash directly in line with adaptor and insert speedometer shaft from motor side.
Connect speedometer shifting rod from control rod, to adaptor. Place rubber bushing on each side of spring lever on adaptor as shown in general Diagram, and clamp with two lock nuts, and cotter at control rod end.
With wheels off of floor and car in operation, set selector lever in vertical or neutral position, move adaptor so speedometer needle is at zero, and tighten adaptor clamp screw.
NOTE: If speedometer fails to register correctly on road test, loosen clamp screw and move adaptor to right or left as necessary and re-tighten clamp screw.
If car is equipped with Waltham speedometer, be sure to use bushing furnished with adpaptor to maintain alignment of adaptor with speedometer head, make sure that the revolving shafts in adaptor and speedometer head are not clamped tight end wise. This may cause noise.
LUBRICATION INSTRUCTIONS IMPORTANT
With rear wheels off of floor fill rear axle through filler hole in Two-Speed Axle housing with 4½ Pints of standard Ford rear axle lubricant. (DO NOT USE CUP GREASE ) Start motor, shift transmission into high, and Two-Speed Axle control valve in high, depress clutch pedal to floor board, which completes shift in rear axle. Allow clutch pedal to return and run five minutes in this position. This is for the purpose of circulating oil through the entire Two-Speed Axle Unit. Next remove jack and with wheels on floor, BE SURE to refill axle to new oil level plug.