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Old 04-25-2020, 02:34 PM   #1
Werner
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Default 1st gear is slightly jammed

Hallo und guten Abend.

I have revised the gearbox and the switchtower. All bearings and shafts renewed. The tooth flanks are finely grounded. The shift forks are grounded flat. The lower gear lever ball is round. Oil 680 + MoS2.

My problem: In the stopped car, the transmission can be shifted perfectly, also with the engine running. But when driving, first gear is difficult to get out. He's sticking a litttle bit. No noticeable difference if warm or cold.

Any ideas?

Much thanks in advance!


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Old 04-25-2020, 02:58 PM   #2
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Default Re: 1st gear is slightly jammed

Make sure your clutch is disengaging fully. Easy to check. I assume your detents are working ok. Ran across a detent spring that would bottom out before the bullet could clear the notch in the shaft.
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Old 04-26-2020, 09:16 AM   #3
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Default Re: 1st gear is slightly jammed

I would wonder how well it shifts into reverse? The 1st/Reverse sliding gear may be a bit tight on the shaft splines. The clutch can affect gear loading if not completely disengaged (as was mentioned). Is your clutch the single plate type? How much tension has the shift shaft detent ball spring?

Sometimes new replacement parts do not always meet the specifications of the original Ford parts.

Last edited by rotorwrench; 04-26-2020 at 09:23 AM.
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Old 04-26-2020, 11:10 AM   #4
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Default Re: 1st gear is slightly jammed

Guten Tag!


The single disc clutch separates completely.

The compression spring and the pressure pieces for snapping onto the selector shaft are new.

Yes, the reverse gear is also a little bit too tight.

And the 2nd gear sometimes jumps out on long strong climbs.

Could it be that the welded-on ball is a little too tight? I fitted them with a tolerance of 0.05 mm.
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File Type: jpg P1010995.JPG (105.5 KB, 151 views)
File Type: jpg P1020011.JPG (76.4 KB, 159 views)
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Old 04-26-2020, 11:31 AM   #5
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Default Re: 1st gear is slightly jammed

In your second picture the rail look crusty, disassemble, clean, polish the rails(shafts). As for jumping out of gear, you need to check the dents spring and cup, check for the parts in Brattons catalog and what causes transmission to jump out of gear.
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Old 04-26-2020, 12:29 PM   #6
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Default Re: 1st gear is slightly jammed

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That ball you made is not a sphere from the looks of it. I bet it is hanging up on the fingers. Try a new shift rod. On detents, make sure they are working with good snap action. With a good detent, I don't think it should jump out. Good luck and stick with it.
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Old 04-26-2020, 12:36 PM   #7
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Default Re: 1st gear is slightly jammed

This is one of the few areas where Ford parts are not interchangeable.Assemblers at the Rouge kept a stock of sliders to find the best fit during assembly..that is if your sure of your other components
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Old 04-26-2020, 03:08 PM   #8
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Default Re: 1st gear is slightly jammed

Bighammer:
The parts are new. It looks like this because they were freshly greased in the photo before assembly. -

Jackson:
The ball in the picture is not yet finished. But you give me the idea that it is not uniformly round everywhere and presses on the fork shafts. The forks are also welded on and maybe fitted too tightly.


Thanks at all!
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File Type: jpg P1020008.JPG (98.5 KB, 90 views)
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Old 08-10-2020, 06:08 AM   #9
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Default Re: 1st gear is slightly jammed

Hallo miteinander!

I have now dismantled the switch tower for the fourth time today. The problem is that 2nd gear jumps still out after about 1/8 of a mile when driving up very steep hills.

I've tried a lot in the meantime: new plungers with spring. New gear lever shifting ball. Welded on and filed the shifting forks (ball side). Used 1500, 680, ATF oil - nothing helps!

Can someone please have a look at the pictures of the shifting rail detend notches and whether the shift fork is looking good?
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File Type: jpg P1110268.JPG (111.4 KB, 48 views)
File Type: jpg P1110271.JPG (101.0 KB, 47 views)
File Type: jpg P1110272.JPG (159.5 KB, 51 views)
File Type: jpg P1110262.JPG (155.5 KB, 48 views)
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Old 08-10-2020, 07:19 AM   #10
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Default Re: 1st gear is slightly jammed

Quote:
Originally Posted by Werner View Post
Hallo miteinander!

I have now dismantled the switch tower for the fourth time today. The problem is that 2nd gear jumps still out after about 1/8 of a mile when driving up very steep hills.

I've tried a lot in the meantime: new plungers with spring. New gear lever shifting ball. Welded on and filed the shifting forks (ball side). Used 1500, 680, ATF oil - nothing helps!

Can someone please have a look at the pictures of the shifting rail detent notches and whether the shift fork is looking good?

There are several things that can be causing this in which pictures won't tell you. I have a fixture (-pictured below) that checks the fork area to ensure that it is not bent. Probably better than 50% of the shifter forks that we restore are bent.

Also, we have struggled with the detents in the new repro shift rails, so we re-machine the detents on all new shift rails. If the slot in the shift rails matches the shape of the ball on the detent, -and if the spring is providing proper pressure, then it should not jump out of gear.
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File Type: jpg ShiftForkFixture2.jpg (40.5 KB, 66 views)
File Type: jpg A-7230 Gear Shifter Fork1.jpg (40.1 KB, 72 views)
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Old 08-10-2020, 08:21 AM   #11
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Default Re: 1st gear is slightly jammed

Danke, Brent!
Quote:
Also, we have struggled with the detents in the new repro shift rails, so we re-machine the detents on all new shift rails.
I ordered just new fork rails from Brattons.
Please, what do I have to consider and / or rework?

Thanks in advance!
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Old 08-10-2020, 11:35 AM   #12
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Default Re: 1st gear is slightly jammed

On the detents, make sure the spring is not bottoming out and preventing the bullet from moving out of the way. It stops proud to the surface.
Check also that the springs are not broken or too far relaxed.
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Old 08-10-2020, 11:55 AM   #13
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Default Re: 1st gear is slightly jammed

You mention that is pops out of gear while climbing a hill. While anything is possible, most problems I've encountered are related to moving down hill while engine braking. The thrust loads change from one direction to the other when moving from a fully loaded gear to a fully unloaded gear and engine braking makes it worse. Generally a loaded gear will stay engaged. I mention this from experience so I just want to clarify that it is slipping out of gear while fully loaded (climbing the hills).

Loose bearings and worn thrust surfaces can lead to this condition (allowing too much movement). Movement between the input shaft and the main shaft due to the internal bearing having wear problems or a bad pilot bearing could be a cause. The gear engagement dogs can end up with excessive wear as well but that shouldn't affect 2nd gear. There have been problems with some of the new bearings that fit inside the main input shaft.

Last edited by rotorwrench; 08-10-2020 at 12:08 PM.
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Old 08-10-2020, 02:30 PM   #14
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Default Re: 1st gear is slightly jammed

It is true that the 2nd only jumps out in very strong mountains and that lasts about every 1/8 of a mile.

1000 miles ago I fitted the gearbox with new bearings, all shafts and sealing lip ball bearings. But the gears haven't been renewed. The cluster tooth group was visibly a bit worn, but this one part costs around 500 with freight and customs.

By the way, no gear jumped out before this revision.

The day after tomorrow I will assemble the switch tower with the new rails from Brattons. New shift forks are out of stock, but the old ones don't look bad. The right angles appear to be fine.

I will continue my report. Until then, I thank you all for the laborious helpin'!
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Old 08-15-2020, 01:04 PM   #15
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Default Re: 1st gear is slightly jammed

Guten Tag miteinander.


I have now installed the new shifting rails. In addition the two shift forks R/1 with 2/3 installed alternately.

The transmission can be shifted now much more gritty. And after 1/8 mile the 2nd jumps out again.

I've read here that the 'Mitchel seal set' can exacerbate shifting problems. I have now also dismantled it (which was a break of fingers!).

2/3 can now be shifted easily. But the problem of popping out is not solved.
I give up!

It can only be due to the transmission cluster. But to do this, the entire transmission must be removed again. Don't feel like it, it's too much work for me for this little ailment.
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Old 08-15-2020, 01:37 PM   #16
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Default Re: 1st gear is slightly jammed

Werner, I don't see where you replaced the detents.
From the look of the shafts they have to be well worn out.
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Old 08-15-2020, 02:47 PM   #17
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Default Re: 1st gear is slightly jammed

The two outboard rails appear very rough in your post. Is that due to grease on the surface, or are they really that rough.
What do you mean when you say "shifted now much more gritty"
Did you also replace the balls and springs in the shift tower?
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Old 08-15-2020, 03:06 PM   #18
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Default Re: 1st gear is slightly jammed

Guten Abend Bob,

I don't know if I understood you correctly. I exchanged the not very bad control shafts during the 4th attempt at repair in the vague hope that the 2nd would not jump out.

The large gear block - cluster - has the teeth on the front somewhat flattened due to wear. I think that this inclined plane is gradually pushing out the 2nd gear wheel.
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Citroen 11 CV, 1947
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Old 08-15-2020, 03:31 PM   #19
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Default Re: 1st gear is slightly jammed

Hi Russ,

while rep. attempt no. 3. I made the notches a little rougher, in the hope, the 2. would not easy jump out.

Yes, the spring and the ball-cylinders are also renewed.

"gritty" means that changing 1/R gears are scruffy.
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Old 08-15-2020, 03:37 PM   #20
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Default Re: 1st gear is slightly jammed

Rougher notches didn't overcome excessive wear. I see the wear to the cluster, and the reverse idler.

Last edited by Brentwood Bob; 08-15-2020 at 03:42 PM.
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