How Fast Can You Remove a Transmission?

Today we learned that we can remove the transmission in under 15 minutes. Unfortunately, our goal today was to install the transmission.

Starting with the Mustang's introduction in 1964, through the 1966 model year, the base 6 cylinder mustang was coupled with a 3 speed manual transmission with a non-synchronized first gear. It was originally used in the Ford Falcon (where the shifter was on the column) but then moved to the Mustang in a floor shifter format.

To put it politely, the design of the transmission is junk. Whenever we run into someone who had a car just like ours, the conversation usually includes how many times they rebuilt the transmission. I guess Ford agreed, because in 1967 they went to a more robust 3 speed transmission in the Mustang.

The transmission in our car has been rebuilt numerous times. After the engine was rebuilt in the 1980's, the transmission kept getting torn up and it was the failure of the transmission that ultimately resulted in the car being garaged and not driven. Last year, one of our first projects was to rebuild the transmission, which we accomplished successfully. Unfortunately, after only minimal driving, it seemed to be having issues again. Thus, a couple of weeks ago we once again removed the transmission with the plan that we would at the same time replace the clutch.

In replacing the clutch we learned something very important. There's a thing called a pilot bushing that keeps the input shaft of the transmission lined up properly. It appears that after the engine was rebuilt, that bushing was not installed. Thus it explains why a piece of junk transmission was even worse. So, we bought a pilot bushing along with clutch plate, pressure plate, and rebuilt the transmission. That brings us to today.

After careful measurement, we successfully installed the pilot bushing. We then installed the new clutch using an old input shaft to insure we had everything lined up right. After getting the transmission bolted into place we started installing the drive shaft. This is where we realized the error of our ways. We went to turn the drive shaft to get a better angle on one of the U-bolts. It didn't turn freely. We checked to make sure we had it in neutral. We did. Thus we had no choice but to remove the transmission once more (in less than 15 minutes). After inspection we realized that the fork holding the first gear in place was put in backwards, causing first gear to always be at least partially engaged.

So, next weekend we get to put the transmission back in, after taking it apart and putting it together properly.