M5OD-R2 pops out of gear, grinds

cow_rancher · #1 11-22-2003, 11:06 AM

OK,

Background:

1988 Full Size Bronco, engine (5.0) replaced at 225K, Mazda M5OD replaced at the same time with a re-built xmission.

Two years and 20K later it pops outta gear on a downshift into 3rd, it got progressively worse, sometime not going all the way into gear and then popping out, grinding whirling sounds...it would even seem like you shifted good but didn't end up in gear.

Replaced M5OD with another re-built, similar problems, stick seems like it's not going far enough forward in gears 1,3,5. Even popped out of 5th at the crest of a hill, i.e. no load on the gears.

So is a shift lever wear problem, are there other things it could be? Are there dimension specs for the shifter available? are the adjustments in the forks, slide rods?

Thanks,

Rancher

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cow_rancher · #2 11-22-2003, 11:08 AM

OK, need more help here, I got the manual out measured the shifting fork width against the clutch hub sleave, book says max gap is .031" shifting forks apear to be new, measures .310 max, groove in sleave measures .385 on rear, .390 on front.

i.e. around .080" which is way outta tolarence.

So, new question...

Anyone know what the hub sleave should measure?

Anyone know what the shifting fork should measure?

Does the m5OD-R1 (used in the ranger) have different shifting forks? Could the R1 shifting forks been installed in the R2?

Thanks

Rancher

whitegold · #3 11-23-2003, 08:40 PM

I was having a simular problem. You'll note the post a couple of days ago. I pulled everything apart and started calling around. The problem is primarily the shifting forks. Over time the cast fork wears faster than the steel slider. This wear doesn't allow the slider to move the proper distance which can cause grinding and pop-outs. If you look at the profile of your fork you'll notice that the factory cast grooves have about .025 to .0275 inch of space between their contact surfaces. Anything smaller is abnormal wear. Also check the slider teeth to ensure they're crisp on the edges. This can be done with a good light and keen eye, without pulling them off. After replacing my forks and one slider (R/5th) everthing is back to normal. Cost was about 25.00 each for the forks and 37.00 for the slider. Mileage on the truck was 189,000.

cow_rancher · #4 11-24-2003, 03:03 PM

How did you change the R/5th fork without pulling the tansmission?

texasmotorsport · #5 11-25-2003, 06:30 PM

If you are having problems with the 5/rev then your problem is in the rev gear and the sleeve . Look at the teeth on the rev gear and i promise you they are flattened and the sleeve will look very similiar . This is a very common problem with the 88-91 model transmissions . Shoot me an email for more details .