TRANSMISSION - T-45 MANUAL TRANSMISSION - STUCK IN REVERSE - DIFFICULT TO SHIFT INTO REVERSE - POPS OUT OF REVERSE
Publication Date: NOVEMBER 15, 2001
Some vehicles equipped with the T45 transmission may exhibit a condition of being stuck in reverse, difficult to shift into reverse or may pop out of reverse. This may be caused by the 5th/Reverse Gear Shift Fork. This article does not apply to the condition of "unable to get into reverse" or "reverse block out".
Verify which shift fork is in the transmission, measure the reverse engagement, and replace the shift fork with the proper part number. Refer to the following Service Procedure for details.
Please follow the procedure in the appropriate Mustang Workshop Manual, for the T45 transmission removal. Refer to the appropriate section in that Workshop Manual for the disassembly of the transmission. In this section, complete the steps up to and including the removal of the Fifth/Reverse Synchronizer Sleeve, the Fifth/Reverse Gear Shifter Fork and the Reverse Synchronizer sleeve. After this is complete, continue with the following steps.
While viewing the extension housing from the front, place a small amount of standard modeling clay on the reverse idler bracket (7723) near the 5th/reverse shift rail support hole (near the exterior wall of the housing Figure 1).
Place a standard 9/16" hole diameter plain washer on the 5th/reverse shift rail and against the rear face of the 5th/reverse shift fork. The washer is placed behind the fork as installed on the rail.
Re-install the extension housing (7A039), offset lever (7F018), spring (7E172), ball (7234) and roll pin (35749-S15). Attach securely with only two (2) bolts.
Attach the shifter assembly (7A039) securely and (with the appropriate upper lever) make a high effort, quick shift into reverse.
Remove the extension assembly (7A039) as before and conduct the reverse engagement inspection.
Using an appropriate depth gage, carefully measure from the case mounting face of the extension housing to the face of the plain washer, which should be stuck in the modeling clay. Take three (3) readings and calculate the average. This is the measure of reverse engagement.
Using the following criteria, select the correct 5th/reverse fork. This fork should replace the current fork in the transmission.
If the measurement is less than 68.1158mm (2.682 inches), use the "long" fork (F8ZZ-7230-EA).
If the measurement is greater than 69.233mm (2.726 inches), use the "short" fork (F8ZZ-7230-DE).
If the measurement falls between the above values, then install the "nominal" fork (F6ZZ-7230-C).
Remove and replace the current fork with the new fork, per the Workshop Manual procedure.
Clean the joint surfaces of the castings (main and extension housing) and shifter.
Re-assemble per Workshop Manual.
5th/Reverse Fork - Long
5th/Reverse Fork - Short
5th/Reverse Fork - Nominal
OTHER APPLICABLE ARTICLES:
Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage
Replace The Reverse Shift Fork (Includes Time To Remove, Disassemble, Measure And Reinstall Transmission)