Aerostar AWD V6-183 3.0L (1991)
Synchronizer Ring: All Technical Service Bulletins
M/T - M50D Hard Shift Condition
Article No.
91-10-15
5/15/91
TRANSMISSION - M50D - HARD SHIFT TO REVERSE OR
FIFTH GEAR
LIGHT TRUCK:
1988-89 ECONOLINE
1988-90 BRONCO II
1988-91 AEROSTAR, BRONCO, F-150, F-250, RANGER
1991 EXPLORER
ISSUE:
The 5-R synchronizer sliding sleeve clutching teeth may wear on the reverse side. This may cause a hard to engage or partial engagement of
fifth or reverse gear and could result in the transmission jumping out of gear. If the wear is allowed to continue, it may become difficult or
impossible to engage 1-2-3 or 4th gear.
ACTION:
Inspect the 5-R synchronizer sliding sleeve for wear and replace if excessive wear is found. Refer to the following procedure for service
details.
INSPECTION PROCEDURE:
1. Remove necessary components so that the transmission extension housing can be removed without removing the entire transmission. Refer to the
Light Truck Shop Manual Section 07-03A for service details.
NOTE:
COMPACT VEHICLES MAY REQUIRE REMOVAL OF TRANSMISSION
2. Remove the transmission extension housing.
3. Inspect the 5-R synchronizer sliding sleeve for wear of the reverse clutching teeth.
REPAIR PROCEDURE
1. If wear is observed, remove speedometer drive gear (4 x 2 only).
2. Remove the top cover (if repairing on the bench).
3. Carefully remove the main shaft and counter shaft locking nuts.
4. Remove and replace the following transmission parts. Refer to the Light Truck Shop Manual for service procedures.
^
5th Counter Shaft Gear
^
5-R Synchronizer, hub and ring assembly
NOTE:
INSTALL WITH THE DOT ON THE SYNCHRONIZER SLEEVE FACING REVERSE GEAR.
^
Reverse counter shaft gear
^
5-R Counter Lever
^
5-R Shift fork and rod
NOTE:
USE THE SPRING AND BALL FROM THE EXISTING ASSEMBLY.
^
Replace the idler shaft in the reverse idler gear assembly (R1 only).
NOTE:
THERE ARE EXTRA ADJUSTING SHIMS PROVIDED IN CASE IT IS NECESSARY TO RESET THE 5-R SYNCHRONIZER HUB
AND CONTROL REVERSE GEAR END PLAYS TO SPECIFICATION. USE THE NEW MAIN SHAFT AND COUNTER SHAFT
LOCKING NUTS UPON ASSEMBLY.
CAUTION: USE ALL THE PARTS CONTAINED IN THE SERVICE KIT INCLUDING THE COUNTER REVERSE LEVER. ALTHOUGH THE
