Check synchronizer insert spring for tension.
Section 07-03A: Transmission, Manual, M5OD | 1996 F-Series and Bronco (under 8500 lbs. GVW) with 4.9L and 5.0L Engines Workshop Manual |
Inspect gear teeth on synchronizer blocking ring (7107). If there is evidence of chipping or excessively worn teeth, replace with new parts.
NOTE: First/second, third/fourth and fifth/reverse synchronizer-to-gear clearance specifications are the same.
Inspect synchronizer blocking ring for wear. To check the wear of synchronizer blocking ring, fit synchronizer blocking ring evenly to gearcone. Measure clearance between side faces of synchronizer blocking ring and gear with a feeler gauge. If clearance is less than 0.8mm (0.031 inch), replace synchronizer blocking ring or gear.
NOTE: Make note of the differences between the third gear synchronizer blocking ring and the first, second and fourth gear synchronizer blocking rings. The third gear synchronizer blocking ring, has three teeth cut out 120 degrees apart from each other. Directly adjacent to one side the missing teeth, two teeth have been bridged together. This is to help eliminate any upshift "crunch" that may occur.
Inspect contact between inner surface of synchronizer blocking ring and cone surface of gear. To inspect, apply a thin coat of Prussian Blue or equivalent on cone surface of gear and fit it into the synchronizer blocking ring. If the contact pattern is poor, correct this by applying compound and lapping surfaces together.
Make sure clutch sleeve slides easily onto clutch hub.
Check synchronizer inserts (keys), inner surface of clutch sleeve, and insert groove on clutch hub for wear.
Check synchronizer insert spring for tension.
Shift Fork/Clutch Hub Sleeve
Check the contact surfaces of the shift fork and clutch hub sleeve for evidence of wear or damage. Measure from shift fork to the clutch hub sleeve. Clearance should not exceed 0.8mm (0.031 inch).
| Standard | Maximum |
|---|---|
| 1st/2nd 0.1-0.4mm (0.003-0.015 In.) | 0.8mm (0.0314 In.) |
| 3rd/4th 0.1-0.4mm (0.003-0.015 In.) | 0.8mm (0.0314 In.) |
| 5th/Rev 0.1-0.4mm (0.003-0.015 In.) | 0.8mm (0.0314 In.) |
Clutch Hub
Check operation of clutch hub sleeve installed onto hub.
Position clutch hub and sleeve horizontally. Lift the hub approximately three-quarters of the way off the sleeve. Release the hub, and observe downward motion. Hub should slide downward into sleeve on its own. It should not be necessary to push hub into sleeve. Service as necessary.
