Fixing a Manual Shifter - How To Repair And Service Manual Shifters

Because this is a complete rebuild where all parts will be cleaned and replated, the trunnion pin, which is a pinch fit, is driven out to release the shifter handle trunnion.

Mustangs Etc. rebuilt shifters are stripped down, zinc plated like new, and reassembled using new parts where required. If you want to rebuild your own shifter, Mustangs Etc. has everything you need to get the job done.

Three- and four-speed shifter supports are basically the same except for bolt hole positions. In fact, you can use a four-speed shifter support as a three-speed donor if necessary.

The straight shaft, or tang, is pressed into the selector shaft. Sometimes the zinc coating makes this challenging, which means you have to dress the surface if the fit is too tight.

Shift levers get a dressing of white lithium grease for good slip-slide performance. Typically, these shifters malfunction due to road grime. Once they are clean and well lubricated, function becomes smooth again.

The shifter is assembled using new locking hardware. Although these look like new-old-stock Ford parts, they're restored and replated Ford pieces from Mustangs Etc.

With all moving parts lubricated with white lithium grease, the return spring is installed using a new C-clip and washer.

The shifter trunnion pin is pressed in at this time. Again, because there's fresh zinc plating and this is an interference fit, sometimes the pin has to be dressed with a file or course sandpaper so it will fit. Shifter trunnions should be inspected for stress cracks that can cause failure during the rebuild process.

Adjustment is easy. Use a #2 Phillips screwdriver to lock the shift levers. Then make sure both shift levers on the transmission are in neutral. Adjust the rods as they appear here (centered). Tighten the locknuts and adjustment is complete.

New shift handle grommets are installed next. They absorb vibration and provide bolts with a snug fit.

Three-speed manual shifters get these aluminum discs, or cups, which ride the shifter support when you're on each side of the H-pattern. Cup pockets are packed with white grease and each cup is installed as shown. Grease provides lubrication and takes up vibration.

The shifter handle is installed by first starting the bolt threads, then depressing the cups for a nice fit inside the shifter support. Bolts are run down using a non-permanent thread locker for security. You can use flat washers underneath the bolt heads for even greater security and performance.

Three- and four-speed shifters are virtually the same with a couple of exceptions. Four-speed shifters have one additional shift lever for Reverse, which is a spot occupied by a thick spacer on the three-speed shifter. Four-speed shifters have a cable-controlled reverse lockout where three-speed shifters do not. What we are unable to show you here are the more uncommon Dagenham four-speed (six-cylinder) and Borg-Warner T-10 ('64 1/2 and '65) shifters. They have shift levers in the same locations as our Ford Top Loader, however there are some minor differences in mounting

Assembly begins with the long Reverse gear shift lever.

Here's where a four-speed shifter differs-this stamped steel spacer, which is installed next.

Next is the First and Second gear shift lever.

Last is the Third/Fourth shift lever, which has an offset.

Like the three-speed shifter, the four-speed gets this thrust washer last before retainer and spring installation.

Four-speed shifters get stamped aluminum cups and springs. White grease is packed around them for lubrication and vibration absorption. These little pieces take the rattle out of a Mustang shifter.

Reverse lockout consists of a control just below the shift knob, cable, and lockout lever at the bottom. Reverse lockouts fail when cables break or stretch and you can't get the shifter into Reverse. When you squeeze the Reverse lockout, you're lifting the lockout lever to where the tab enters the shifter support. Release the lockout and the tab won't clear the support, making it impossible to shift into Reverse.

Although most are gone these days, Mustang shifters were originally equipped with dust boots. Heat, ozone, and road grime take a toll on these boots. If you want to use the dust boot, be prepared for what it takes to install one. The shifter must be disconnected so the boot can be installed. Shifter handle and boot must also be removed to allow dust boot installation.