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Home >> Ford >> 2009 >> Flex Limited, FWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 1490 (Manual Transmission - Tr6060) >> Disassembly And Assembly Of Subassemblies >> Gearshift Rail and Fork >> Disassembly And Assembly

Disassembly And Assembly

WARNING: This page is about a different car, the 2009 Ford Mustang. However, it is still accessible from the selected car via links, so may be relevant.
  1. Disassemble the 1st/2nd and 3rd/4th shift rail as follows:
    • Rotate the interlock plate until it is opposite of the shift links.
    • Slide off the 3rd/4th shift fork and shift link.
    • Slide off the 1st/2nd shift fork and shift link.
    • Using a 5/32-inch drift and a hammer, remove and discard the roll pin. Remove the interlock plate.
  2. Disassemble the 5th/6th and reverse shift rail as follows:
    • Using a 5/32-inch drift and a hammer, remove and discard the roll pins. Slide the collar and the reverse shift lever from the shift rail.
    • Remove the snap ring.
    • Slide off the 5th/6th shift lever and shift link.
    • Using a press, separate the 5th/6th outer shift rail lever from the inner shift rail lever.
  3. Inspect the shift rail components.
    • Check the rails, shift forks, shift levers and shift links for wear or damage. Install new components as necessary.
    • Check the shift fork pads for wear. Install new pads as necessary.
  4. To assemble, reverse the disassembly procedure.
    • Install new roll pins.
  5. Fig 1: Identifying 5th/6th Outer Shift Rail Lever
    GF0001198Courtesy of FORD MOTOR CO.
    Fig 2: Identifying Inner Shift Rail Lever
    GF0001199Courtesy of FORD MOTOR CO.