1992 ford manual transmission forks?

Lou from Wi.

Well-known Member
We have a 92 F150 4X4 with the Mazda 5 speed transmission, the first gear jumps out gear when starting out. From what I have read, it is a common problem, resulting from fork wear.
So the question is, should I replace both forks for 1 & 2nd and also 3rd and 4th, even though 3 &4 are still working fine,but I would hate to do this in the middle of winter if they decide to go down. I'm not sure it's aluminum forks, but if it's steel is it possible to weld/braze on the forks and re make the worn out area? Also we will be ordering on line from a auto warehouse and would like to have the parts on hand in case it is bad.

This truck was a mudder truck,we rebuilt it in 08 and put all new clutch, hydraulic throwout bearing,slave cylinder for the clutch,etc.It ran fine up until a few weeks ago and started with first gear not holding in.I'll bet some of you guys have done some of this,so any of your opinions and thoughts would be appreciated. Son will be doing the work,as usual,lol.
Regards,
LOU
 
Are you sure it the forks or does the transmission have maybe a synchronizer going out( if it's a synchronized tranny)?
 
DBeatty,
Nope its the shifter fork, I understand it's a constant problem with this type of transmission,one of the weaker points in this transmission. I miss the old 4 speed cast iron transmissions,almost bullet proof.
Thanks,
LOU
 
Lou, I worked in a Ford dealership parts dept. from 1993 to 2003 and do not recall any specific problem such as you mention. My first thought was in agreement with D beatty, that you have a bad synchronizer. Can you hold it in gear with the stick without much pressure, or does it put a lot of pressure against the stick when holding it in gear this way? If you feel a lot of pressure, or if you can't hold it in gear this way, likely it is the synchronizer. If you do order shifter forks, since they both have the same amount of miles on them, I believe I would replace them both and be done with it.
 
Lou,

I normally don't hang out over here, but happen to see this. Yes, go ahead and change the forks while you have it out, no sence in pulling it twice. Also, check the shifter housing plugs. The get dry and fall out, sometimes in pieces and those can fall into the trans. I was having problems with my old 89 doing similar to yours. After researching I too thought the shifter rails were wore. After dropping the trans, I found pieces of one of the plugs in the shifter housing. Already had it out, so just changed the forks anyways. Well, had them changed. Was the plug particles my problem, I don't know, but the guy who put the forks in said the old ones weren't too bad.Bit this truck had originally been owned by my Dad, and I was going to try and fix it up for my son to drive, but the previous owner really neglected it, so I sold it to someone who had the time to work with it. It had already gotten to be a money pit just getting it running right again, then the trans issues, then issues with the dual tanks, and on and on.
 
Interesting, I have a 1989 E-150 van with the 300-6 and the 5 speed transmission. I bought it new and don't want to part with it. However I got rear-ended a couple ago, and it ruined the step bumper and bent the rear frame. The body shop can not find a replacement step bumper, and are not sure about the frame.
I'm not sure what I'm going to do. I need to tow my trailer occasionally.
I'm thinking of getting a new hitch that fastens to the frame and putting a channel iron in place of the step bumper.
But if this transmission is going to fail not too far down the road???????????

Sorry about stealing/borrowing this thread.
Dusty
 
I have a 1995 F150 with the 4.9 and 5 speed. I lost first and second gear once and it was the shifter fork. It had worn so much it just didn't catch anything. I replaced only that one and never had anymore problems. I replaced mine by pulling the top off through the floor board not a big deal. I would look at the shifter while you have it out the plastic parts wear out and thats where you get the wobble in the shifter. They aren't that expensive and while you have it out might as well look at it. I have 328,000 on mine now.
 
dusty, try car-part dot com. it is a web search of salvage yard databases. shows what is available, where located, condition and price. should be able to find a replacement bumper for you.
 
Change the two bushings the shifter ball swivels in, and the two wave washers and the two flat washers with tangs, that go with the bushings. Probably costs a $130 or so now. Also replace the three rubber plugs on the back of the shifter rails. They fail and the trans throws out the fluid and burns itself up.

I change the fluid in mine (Ranger, same basic trans) ever 20K miles. 3 Qts of synthetic auto trans fluid, cheap insurance.

I have a thread about the shifter bushing replacement at the link below. You have to be a forum member to see the pics, but well worth signing up.

Charles
Replacing Mazda 5 spd shifter bushings
 
I've got an 88 F150 w/ the 300 and Mazda 5 speed that I'm selling. Only issue with the trans is that the slave cylinder leaks. I drove it all the way from home to my inlaws without clutching once because of that issue. Made sure to take the route with mostly right turns...

Donovan from Wisconsin
 
Ive probably done a hundred of these it is always a gear and synchronize to repair it. However if you are certain the fork will fix it I have a parts transmission. I would sell you whatever parts you wanted from it. Im in central il.
 

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