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Shift Fork: Service and Repair


Gear Shift Housing
Disassembly
1. Remove the floor mat or carpet, rubber boot cover and floor pan cover. Remove front seat assembly if necessary.
2. Remove the foam weather pad from the gear shift housing.
3. Shift the unit into second gear and remove the gear shift lever from the transmission. Then, disconnect the back-up lamp switch from the connector and remove the back-up lamp switch from the rear of the gear shift housing.






4. Remove the shift housing tower from the transmission (Fig. 18).

NOTE: After the shift housing tower is removed, inspect all internal transmission components for damage, chips and/or foreign material within the transmission case assembly.

5. Remove the three expansion plugs from the forward end of the shift housing (Fig. 18). Using a pin punch, remove the three lock pins from the shift forks and the three lock (roll) pins from the gear shifter shaft gates.

Disassembled View Of Shift Control Housing:






Part 1 Fig. 19






Part 2 Fig. 19

6. Tap the shifter shaft(s) out of the housing (forward) while holding a shop towel over the poppet ball(s), (Fig. 19), and spring hole(s) in the housing to prevent loss of spring(s) and/or poppet ball(s).

7. Remove the interlock pin from the middle shift rail (Fig. 19).
8. Remove the shift forks and shift gates.
9. Remove the poppet balls and springs from the housing. Then, remove the interlock plungers from the housing.

Assembly
1. Install the spring and plunger in the reverse gate, press the plunger through the gate and fasten it in place with the clip, if the reverse gate assembly has been disassembled.
2. Place the poppet spring and ball in the reverse shifter shaft hole in the gear shift housing. Insert the shaft part way into the housing. Install the reverse shift fork on the shaft (reverse shifter) then, press down on the poppet ball and spring with a long thin drift and position the reverse shifter ball notch so that it does not slide over the ball.
3. Slide the reverse gate onto the shaft (long end forward), and drive the shaft into the housing until the ball snaps into the groove of the shaft. Install the lock pin that fastens the gate to the shaft.
4. Insert the two interlocking plungers in the pockets between the shifter shaft holes. Place the poppet spring and ball in the low-and-second shifter shaft hole. Press down on the poppet ball and spring with a long thin drift and insert the shifter shaft part way into the housing.
5. Slide the low-and-second shifter shaft gate onto the shaft, and install the low-and-second shifter fork on the shaft so that the off-set of the fork is toward the rear of the housing. Push the shaft all the way into the housing until the poppet ball snaps into the shaft groove. Then, install the lock pins that fastens the fork and gate to the shaft.

6. Insert the three-four shifter shaft through the center rear hole of the housing. Then, insert the interlock pin into the interlock pin hole in the shifter shaft.

NOTE: Apply a daub of petroleum jelly to hold the pin in position.

7. Apply a coating of petroleum jelly to the interlock plungers and insert them into their respective holes in the housing.
8. Place the poppet spring and ball in the center shifter shaft hole in the housing. Press down on the poppet ball with a long thin drift, and carefully push the shifter shaft into the housing over poppet ball and spring.
9. Position the third-fourth shift gate onto the shifter shaft. The spring loaded-ball tang should be installed facing rear of transmission.

NOTE: It is extremely important that the shift gate be installed on the shifter shaft with the long flat "tang" end of the gate area facing forward of the gear shift housing. To insure proper installation, measure the two flat "tangs" of the shift gate, note the longer dimension 8.25mm (23/32 inch) and apply a daub of bright paint. This tang should be installed facing forward on the shifter shaft.

10. Position the three-four shifter fork on the shifter shaft so that the lockpin hole in the shifter fork is toward the rear of the housing. Push the shifter shaft into the housing until the poppet ball seats into the second detent (neutral). Install the lock pins attaching the shifter fork and shifter gate to the shifter rail

NOTE:. Install the shifter gate lock pin so that the pin is flush with the bottom of the notch in the shifter gate.

11. Install new expansion plugs in front and rear of transmission housing.
12. Shift the gear shift housing into the "second gear" position. Shift the transmission gears into the "second gear" position. Install the back-up lamp switch and connect the wiring. Then, place the transmission gear shift housing onto the transmission.
13. Apply Pipe Sealant with Teflon D8AZ-1 9554-A (ESG-M4G1 94-A and ESR-M18P7-A) or equivalent to the six shift gear housing-to-transmission case attaching bolts. Tighten the bolts to 24-27 N-m (17-20 ft-lb).
14. Position the foam weather pad on the gear shift housing. lnstall the gear shift lever. Install cab floor pan cover, rubber boot and floor mat or carpet. Install front seat.
15. Fill transmission with Standard Transmission Lubricant (SAE 80W), D8AZ-1 9C547-A (ESPM2C83-C) or equivalent, ADD 1/4 liter (1/2 pint) of lubricant through the speedometer cable hole in the rear transmission retainer.
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