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Home >> Ford >> 2003 >> Explorer Sport 4.0 E, RWD, Standard >> Repair and Diagnosis >> Transmission >> Manual Trans >> Manual Transaxle/Transmission >> Disassembly And Assembly Of Subassemblies >> Shift Control Housing >> Assembly

Shift Control Housing: Assembly

  1. Inspect the contact surface of the shift fork and the synchronizer sleeve for wear or damage.
    Fig 1: Inspecting Contact Surface Of Shift Fork And Synchronizer Sleeve For Wear Or Damage
    G01300648Courtesy of FORD MOTOR CO.
  2. Install the gear selector interlock sleeve.
    1. Position the gear selector interlock sleeve.
    2. Install the bolts.
    Fig 2: Installing Gear Selector Interlock Sleeve
    G01300649Courtesy of FORD MOTOR CO.
  3. Install the interlock pins into their original shift rails.
    NOTE: Incorrect installation of the interlock pins will prevent activation of the backup lamp switch.
    Fig 3: Installing Interlock Pins
    G01300650Courtesy of FORD MOTOR CO.
  4. Position the detent ball and spring, the shift gate, the shift fork and spring, then install the third/fourth shift rail.
    Fig 4: Installing Third/Fourth Shift Rail
    G01300651Courtesy of FORD MOTOR CO.
  5. Position the detent ball and springs, the shift gate, the shift fork and spring, then install the first/second shift rail.
    Fig 5: Installing First/Second Shift Rail
    G01300652Courtesy of FORD MOTOR CO.
  6. Position the fifth/reverse shift control, the detent ball and spring and the shift gate, then install the fifth/reverse shift rail.
    Fig 6: Installing Fifth/Reverse Shift Rail
    G01300653Courtesy of FORD MOTOR CO.
  7. Install the three rubber service bore plugs.
    Fig 7: Installing Rubber Service Bore Plugs
    G01300654Courtesy of FORD MOTOR CO.
  8. Install new shift gate spring pins.
    • Leave 1-2 mm (0.04-0.08 in) of the pin showing above the shift gate.
    Fig 8: Installing New Shift Gate Spring Pins
    G01300655Courtesy of FORD MOTOR CO.
  9. Install new shift fork spring pins.
    • Leave 1-2 mm (0.04-0.08 in) of the pin showing above the shift fork.
    Fig 9: Installing Shift Fork Spring Pins
    G01300656Courtesy of FORD MOTOR CO.
  10. Install the backup lamp switch.
    1. Install the backup lamp switch pin.
    2. Install the backup lamp switch.
    Fig 10: Installing Backup Lamp Switch
    G01300657Courtesy of FORD MOTOR CO.
  11. Install the lower gearshift lever.
    1. Position the gearshift lever.
      • The notch on the gearshift lever must be installed facing the front of the transmission.
    2. Position the dust cover.
    3. Install the bolts.
    Fig 11: Installing Lower Gearshift Lever
    G01300658Courtesy of FORD MOTOR CO.
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