Article 111 - Second Gear Jumpout

TSB #10 - January 28, 1972
(1970-71 Bronco Built After January 1, 1970 - [Not to be used on 1972 Transmissions])


New second and third shifter rail, shifter interlock spring and detent plug have been released for service for the transmission of the subject vehicles. These parts will prevent the transmissions of these vehicles from disengaging from 2nd gear when the transmission is under heavy load.

REMOVAL:
Remove the transmission and disassemble using procedure specified in 1971 Shop Manual, Volume 1, Part 6-11, Section 4 and 5 until the extension housing and gasket are removed from the case. Complete disassembly as follows.
    1. Place both shift levers in the neutral (center) position.
    2. Remove the long spring which retains the detent plug in the case. Remove the detent plug with a small magnet.
    3. Remove the set screw that secures the first and reverse shift fork to the shift rail. Slide the first and reverse shifter rail out through the rear of the case.
    4. Move the second and third speed shift fork to the second speed position to gain access to the set screw. Remove the set screw from the fork. Rotate the shift rail 90° as shown in Figure 13, Section 16-11, of the Shop Manual.
    5. Lift the interlock pin from the case with a magnet.
    6. Tap on the inner end of the second and third speed shift rail to remove the expansion plug from the front of the case. Remove the shift rail.
    7. Remove the second and third speed shift rail detent plug and spring from the detent bore.

INSTALLATION:
The new second and third shifter rail, shifter detent spring, and detent plug are color coded green for easy identification. Reassemble the transmission using these new parts as follows.
    1. Place the new detent plug spring and plug in the case (Fig. 11, Section 16-11, of the Shop Manual). Place the second and third speed synchronizer in the second speed position (toward rear of transmission). Align the fork and install the new second and third speed shift rail. It will be necessary to depress the detent plug to enter the rail in the bore. Move the rail inward until the detent plug engages the forward notch (second speed position).
    2. Secure the fork to the rail with the set screw. Move the synchronizer to the neutral position.
    3. Install the interlock pin in the case. If the second and third speed shift rail is in the neutral position the top of the interlock will be slightly lower than the surface of the first and reverse shift rail bore.
    4. Move the first and reverse synchronizer forward to the first speed position. Rotate the first and reverse shift fork into position and install the first and reverse shift rail. Move the rail inward until the center notch (neutral) is aligned with the detent bore. Secure the fork to the rail with the set screw.
    5. Install a new shift rail expansion plug in the front of the case.
    6. Position the extension housing gasket on the case.
    7. Install lock washers on the five attaching screws. Dip the threads of the cap screws in sealer. Secure the housing to the case and torque the cap screws to specification.
    8. Place the transmission in gear. Pour lubricant over the entire gear train while rotating the input or output shaft.
    9. Install the remaining detent plug in the case. Install the long spring (which is retained by the case) to secure the detent plug.
    10. Place cover gasket and cover in position.
    11. Secure the cover with cap screws. Torque the screws to specification.
    12. Check the operation of the transmission in all of the gear positions.
    13. Reinstall the transmission using procedures specified in the shop manual.

PART NO.PART NAME CLASS
D2TZ-7241-CShift Rail Kit C


PRODUCTION CORRECTION: 11/1/71
WARRANTY STATUS:
Reimbursable within the provisions of the Warranty and Policy Manual.
OPERATION: 7003-A and 7003-A-6
TIME: Refer to the Service Labor Time Standards Manual.

DLR. CODING: Basic Part No. 7003 - Code 09