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HOMESERVICE MANUALSFORD1985BRONCO 5.8 G, STANDARD, TODREPAIR AND DIAGNOSIS (SINGLE PAGE)TRANSMISSIONMANUAL TRANSOVERHAUL - TOD 4-SPEED OVERDRIVECOMPONENT DISASSEMBLY & REASSEMBLYGEARSHIFT HOUSING ASSEMBLY OVERHAULREASSEMBLY
1985 Ford Bronco 5.8 G, Standard, TOD

Gearshift Housing Assembly Overhaul: Reassembly

1985 Ford Bronco 5.8 G, Standard, TODSECTION Reassembly
  1. Coat all shift rails with transmission lubricant. Install back-up light switch in gearshift housing, if it was removed. Lubricate "O" ring and shaft on reverse rocker arm assembly with multi-purpose lubricant.
  2. Force shift bias spring outward only enough to install reverse rocker arm assembly in housing. Install clip that retains reverse rocker arm assembly.
  3. Drop an interlock spring and meshlock plunger in each bore in front of housing. Position reverse shift rail in housing.
  4. Detent slots in rail must be inserted into housing first with slots facing meshlock plunger. See Fig 1 . Install reverse shift fork so it engages reverse rocker arm assembly and fork pad faces inside. Slide rail through fork bore and up to meshlock plunger.
    Fig 1: Shift Rails Showing Detent Slots
    G95D56104Courtesy of FORD MOTOR CO.
  5. Use a small punch to force meshlock plunger down into bore. Push rail forward until it blocks plunger. Withdraw punch and push rail through bore. Align roll pin holes in fork and rail. Install roll pin.
  6. Position 1st-2nd shift rail in housing. Detent slots in rail must be inserted into housing first with slots facing meshlock plunger. See Fig 1 . Install 1st-2nd shift fork so gate on fork faces inside of housing. Slide rail through fork and up to meshlock plunger. Repeat step 5).
  7. Ensure that 1st-2nd and reverse shift forks are in neutral position and 1st-2nd fork should be in alignment. 1st-2nd fork should be in center detent position. Reverse fork should be shifted fully rearward.
  8. Install interlock plungers through 3rd-overdrive bore in rear of housing. One plunger will be positioned against reverse shift rail. The other plunger will be positioned against 1st-2nd shift rail.
  9. Position 3rd-overdrive shift rail in housing. Detent slots in rail must be inserted into housing first with slots facing meshlock plunger. Place 3rd-overdrive shift gate in housing so slot in gate faces down and small tab is rearward in housing. Slide rail forward until it is just through gate.
  10. Install interlock pin to rear of 3rd-overdrive shift rail. Place 3rd-overdrive shift pawl in housing. Position pawl so that slot is on reverse rail side of housing. Slide rail through pawl up to plunger.
  11. Repeat step 5. Align roll pin holes in pawl, gate and rail. Install roll pin. Apply stud and bearing mount sealer to outside diameter of shift rail cup plugs. Drive cups into bores located in rear of housing. Place gearshift housing assembly in 2nd gear for installation.
RENDER: 1.0x

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