Shifter Linkage

Shifter Linkage

REMOVAL & INSTALLATION

1983–86 Pick-Ups and Monteros

Access to the underside of the vehicle will be needed throughout the procedure.

Disconnect the negative battery cable from the battery.
Remove the selector handle assembly while pushing the button in from the selector lever by loosening the set screw.
Remove the console box, then remove the position indicator assembly upward and out by loosening the attaching screws.
Disconnect the indicator light and inhibitor switch wiring.
Disconnect the control rod from the control arm by loosening the nut from under the floor.

Remove the lever bracket assembly by loosening the attaching screws.

Fig. 1: Shifter linkage removal and installation — MA 904A transmissions

Fig. 2: Grease the transmission control arm in the position shown before installing it to the selector lever — MA 904A transmissions

To install:

Install the lever bracket assembly and tighten the mounting screws until snug.
Before installing the transmission control arm to the selector lever, apply a suitable quantity of multipurpose grease (SAE J310a, NLGI grade #3) to the sliding part.
Tighten the attaching nut.
Check that the control arm moves smoothly without looseness. Replace the bushing if the arm is loose.
Attach the inhibitor switch and position indicator light wiring.
Adjust the inhibitor switch — refer to the previous procedures for this.
Set the position indicator assembly into position, then secure it in place with the mounting screws.
Install the console box.
Push the selector handle back onto the selector lever and secure it in place with the set screw.
If the control rod was removed from the control arm, set the selector lever to the N position. Then move the control rod to place the transmission in the neutral position.
CAUTION
Before moving the transmission into the Neutral position make sure that the wheels are chocked to keep the vehicle from rolling.
NOTE: Tighten the rod to the lever locknut. When attaching the control rod to the arm, apply as much multipurpose grease as required to allow the parts to slide easily.
Make certain that the selector lever moves smoothly and that the lever on the transmission side moves properly to each selector position.
Pull the parking brake lever. Fasten the seat belt. Depress the brake pedal, then confirm that the engine does not start while the selector lever is in the D, L, 2 or R positions. Make sure the engine starts when the lever is in the P or N position.
Place the selector lever in the R position and confirm that the back up light is illuminated in this position (but not in any other position).
Use the following procedure to adjust the rod adjusting cam.
1. Set the selector lever to N.
2. Turn the rod adjusting cam to adjust the distance from the end of the selector lever to the end of the rod adjusting cam (the distance should be 0.45–0.49 in. (11.3–12.7mm).
3. After adjustment, move the selector lever through all the ranges to confirm that it moves smoothly and operates correctly.

1987–89 Pick-Ups

Disconnect the negative battery cable from the battery.
Move the transmission selector lever to the Park position.
Remove the screw fitted to the horn pad and pull the lower part of the horn pad out to remove.
Unscrew the retaining screws, then lift the column covers up and down off of the column assembly.
Unplug the shift indicator illumination harness connector.
Remove the retaining screws from the column switch and unplug the column switch harness connectors, then slide the column switch off of the column.
Remove the link assembly connection from the column bracket.
Remove the boot covering the cable-to-lever control assembly connecting cotter pin.
Remove the cotter pin and slide the cable end off of the lower end of the lever control assembly.
Unplug the over drive switch harness connector.
To remove the lever control assembly:
1. Remove the change lever guide attaching nut (located on the upper end of the control lever rod).
2. Remove the bottom guide bolt from the control lever rod.
3. Push the change lever guide and remove the control rod assembly so that the control rod assembly does not catch the detent plate portion. Make sure to account for the steel ball, the ball support and the spring.
Loosen the locking nut from the upper end of the control cable, then slide the cable out of the column mounting bracket.
Using a pair of needle-nose pliers, remove the cotter pin from the transmission lever. Disconnect the lower end of the selector cable.
Remove the retaining clip near the bottom of the cable.
Remove the selector cable from the vehicle.
If neither the selector lever nor the transmission lever is moved, the selector cable linkage should not need to be adjusted. However, the linkage should be checked and adjusted if not correct.

Fig. 3: Shifter linkage removal and installation — AW372 transmissions

Fig. 4: Install the clip so that the opening faces the direction shown — AW372 transmissions

Fig. 5: When installing the upper column cover, make sure that the pointer engages the linkage correctly

To install:
To install, route the cable in the vehicle the same way it was before it was removed.
Install the retaining clip to the retaining bracket in such a way so that the opening in the retaining clip is facing the opposite direction than the opening in the retaining bracket. Make sure before installing the clip, that the indent on the cable is set into the retaining bracket.
If the selector lever or transmission lever was moved during repairs, then set the control lever (when installed) and the transmission lever to the N position.
Install the adjusting nuts loosely; adjusting will need to be performed once the control lever assembly is installed.
Slide the upper end of the cable into the column retaining bracket and tighten the locknut.
Apply Multipurpose grease SAE J310, NLGI No.2 to the following areas of the control lever assembly before installation: The guide bolt shaft, the outside edge of the lower control lever assembly bracket (right around the edge where the guide bolt is inserted), the upper cable mounting pin, bottom face of the tang next to the steel ball assembly.
Slide the control lever assembly back into the vehicle, install the guide bolt, set the upper stud through the column bracket, then tighten the upper change lever guide attaching nut until tight.
Plug the over drive switch harness connector together.
Install the upper cable end to the control lever assembly, using a new cotter pin.
Push the boot back over the cable connection.
Adjustment of the link assembly may be needed. Measure the adjustable rod (not the short one) from the center of the stud to the center of the pivot shaft. The distance should be 2.098–2.114 in. (53.3–53.7mm). If it is not this length, adjust by loosening the nut and rotating the rod so that the dimension of the link assembly matches the standard.
Install the link assembly to the column bracket and the control lever assembly.
Slide and mount the column switch in place; secure it there with the mounting screws. Plug the harness connectors back together.
Plug the shift indicator illumination harness connector together.
Install the upper and lower column covers. When installing the upper column cover, make sure that the link assembly and the pointer of the select indicator are securely connected.
Install the steering wheel and the horn cover.
Connect the negative battery cable to the battery.
If the transmission lever was moved during repairs, set the control lever assembly and the control lever sub assembly in the N position and install the adjuster locknuts so that each position of the control lever assembly matches with each position of the control lever sub assembly and they operate normally.

1987–89 Pick-Ups (4WD) and Monteros

Access to the underside of the vehicle will be needed throughout this procedure.

Disconnect the negative battery cable from the battery.
Press the selector lever cover downward.
Unplug the overdrive switch harness connector from the selector handle.
Unscrew the handle retaining screw, then lift the handle off of the shift lever.
Unplug the lower end of the shift handle over drive harness connector.
Pull the shift lever cover up and off of the lever.
Unscrew the indicator panel retaining screws, lift the panel up high enough to unplug the inhibitor switch and position indicator light harness connectors, then remove the indicator panel from the shift assembly.
Remove the bracket assembly, which consists of the shift lever mechanism. From under the vehicle, remove the transmission control rod from the transmission control arm by loosening the nut. Disconnect the select cross shaft from the heat protector, then from the control rod. Make sure to retain the nut, lockwasher, flat washer, connecting pin and bushings, flat washer and the heat shield.
Remove the dust cover from the end of the select cross shaft. Using snap ring pliers remove the snap ring (located under the just removed dust cap), then slide the two springs, the two cross shaft bushings and the cross shaft boot off of the end of the select cross shaft.
Remove the cross shaft bracket bolts from the transfer case.
Disconnect both ends of the select cross shaft from the transmission control rod A and transmission control rod B by removing the cotter pin. Remove the two bushings and the flat washer and remove the rods.
Remove the select cross shaft from the vehicle.

Disconnect transmission control rod A from the transmission connection also, by first removing the cotter pin, then by removing the two bushings and the flat washer.

Fig. 6: Shifter linkage removal and installation — KM148 transmissions

Fig. 7: Make sure, when installing the transmission control rod B, that the washers and bushings are in the correct order — KM148 transmissions

To install:

Before or during installation apply grease to all of the points shown in the illustration. The grease should be applied to the bushing inner surfaces and the sliding parts shown in the figure. Use multipurpose grease SAE J310, NLGI No.2.
Using a new cotter pin, connect the transmission control rod (A) to the transmission lever. Make sure the bushings and flat washer are used.
Attach the select cross shaft to the vehicle with the bracket bolts. Tighten the bracket bolts to 7–9 ft. lbs. (10–13 Nm). Attach the cross select shaft to transmission rod (A). Use the bushings and the flat washer, and make sure to use a new cotter pin.
Install the transmission control rod (B) to the other end of the select cross shaft.
Install the components to the end of the select cross shaft in the following order: cross shaft boot, spring, bushing, spring, flat washer, snapring, dust cover.
Install the lever pin to the removed bracket and shift lever assembly. Insert the pin into the lever, slide the bushing and washer over the pin. Secure with a new cotter pin. Mount the heat shield over the pin end and secure with the mounting screw.
Install the bracket and shift lever assembly, then secure it in place with the mounting brackets. Move the shift lever to the Neutral position.
Once again from under the vehicle, move the transmission to the Neutral position, and then connect the transmission control arm and transmission control rod B together.
Set the indicator panel over the shifter lever, then plug the inhibitor and the indicator light harness connectors together. Mount the indicator panel to the bracket and shift lever assembly.

Slide the shifter cover over the shifter lever.

Fig. 8: After installing the select cross lever, install the heat shield to cover the ends of the two rods — KM148 transmissions

Fig. 9: Always use new cotter pins when reassembling the rod junctions — all transmissions

Fig. 10: Before reassembly, grease the pivot points and sliding components (arrows) with multipurpose grease — KM148 transmissions

Hook the lower end of the over drive wire to the connector.
Plug the upper end of the over drive harness connector into the shifter handle, then install the shifter handle to the shifter lever. Secure it in place with the retaining screw.
Install the floor console.
Connect the negative battery cable to the battery.
Check, while driving, to be sure that the transmission is set to each range when the selector lever is shifted to each position. Make sure the over drive is activated and cancelled correctly when the over drive switch is activated.

1990–95 Pick-Ups

Remove the cotter pin at the upper end of the transmission cable. Remove the flat washer, the bushing and then pull the cable end off of the selector lever attachment.
Loosen the locking nut and then pull the cable out of the column bracket.
Pull the retaining clip off of the lower retaining bracket, located by the transmission.
Remove the cotter pin holding the lower cable end onto the transmission control arm.
Remove the flat washer, the cable end and the bushing from the control arm. At this point the transmission cable can be removed from the vehicle.
The transmission control arm and rod can be removed at this time.

Fig. 11: Shifter linkage removal and installation — R4AC1 transmissions

Fig. 12: Install the transmission control rod with the marked section as shown — R4AC1 transmissions

To install:
Before reassembly, grease the pivot points and sliding parts.
Install the control arm and rod to the transmission. Install the transmission control rod with the marked position upward.
Route the transmission control cable in the same position as it was when removed.
Attach the lower end of the cable to the control arm, making sure to use a new cotter pin. Use the bushing and the flat washer.
Slide the cable into the lower retaining bracket, then install the clip to hold it in place.
Slide the cable into the upper bracket and retain it there with the locknut. Tighten the locknut to 12–19 ft. lbs. (17–26 Nm).
Insert the upper cable pin through the selector control lever assembly bracket. Secure the pin with the bushing, the flat washer and the new cotter pin.

1990–95 Monteros

Disconnect the negative battery cable from the battery.
Disconnect the key-interlock cable, the shift-lock cable and the transmission control cable from the selector lever assembly.
Unscrew the mounting bolts, then remove the selector lever assembly from the vehicle.
From under the vehicle, remove the four retaining bolts and the transfer case protector.
Remove the nut and washers holding the transmission control upper lever to the bracket on the transmission. Pull the cotter pin out of the end of the transmission end of the cable, then remove the washer and the transmission control upper lever from the cable.
Remove the transmission cable bracket nuts/bolts. This usually consists of 6–8 nuts/bolts along the length of the cable and at the end bracket (shifter end of cable). Remove the cable bracket and the cable end bracket, both located near the transmission end of the cable.
Remove the cable from the vehicle.

Fig. 13: Shifter linkage removal and installation — V4AW2 (V4AW3) transmissions

Fig. 14: Gently pull the cable in the direction shown to adjust the shifter cable — V4AW2 (V4AW3) transmissions

To install:
To install, install the cable end bracket and the cable brackets to the body of the vehicle.
Route the transmission control cable in the vehicle, then attach to the body with the brackets and various mounting screws along its length.
Attach the transmission end of the cable to the transmission control upper lever. Make sure to use the flat washer and a new cotter pin. Grease any pivot points with multipurpose grease.
Connect the transmission upper control lever to the bracket, using the flat washer, the lockwasher and the nut. Tighten the nut to 17 ft. lbs. (24 Nm).
Install the transfer case protector.
Install the selector lever assembly with the retaining bolts. Tighten the bolts to 8 ft. lbs. (12 Nm).
Install the transmission control cable. Move the selector lever to the N position. Loosen the adjusting nut (from under the vehicle), gently pull the end of the transmission control cable in the direction toward the front of the transmission. Tighten the adjusting nut until tight.

Fig. 15: The shift lock cable adjusting mechanism — V4AW2 (V4AW3) transmissions

Fig. 16: Install the components as shown in the illustration — V4AW2 (V4AW3) transmissions
Install the shift-lock cable. Move the selector lever to the P position. Adjust the shift-lock cable so that the end of the cable (red mark) is at the position shown in the illustration, and then tighten the nut until tight to clamp the shift lock cable.
Install the key interlock cable. With the selector lever still in the P position, install the spring and washer that are inserted onto the key interlock cable as shown in the illustration. Gently push the lock cam until the pin stops in the direction of the arrow, and then tighten the nut to clamp the key interlock cable.