May 112016
 

2005 Ford Ranger 4x4My 2005 ford ranger supercab 4×4 doesn’t want to shift into second gear ,it shifts alright first ,third,fourth and OD.It is a manual transmission.


RESPONSE

If it shifts OK when the engine isn’t running then the most likely problem is the clutch system. Most common would be the hydraulic clutch slave/master cylinder assembly. I recommend replacing the entire unit and using a factory ford assembly. They come pre-bled and saves time trying to bleed air from the system.

If it doesn’t want to shift when the engine isn’t running, the synchronizer is worn/damaged internal in the transmission.

Clutch

The primary function of the clutch system is to connect and disconnect engine power to the transmission upon driver command.

The clutch control system disengages the clutch when the clutch pedal is depressed and engages the clutch when the clutch pedal is released. When the clutch pedal is depressed, it pushes the clutch master cylinder plunger, which transmits hydraulic pressure to the clutch slave cylinder. The clutch slave cylinder engages and compresses the clutch pressure plate diaphragm spring, releasing the pressure on the clutch disc, which in turn disengages the transmission from the engine.

  • The clutch is a single-plate, dry friction clutch disc with a self-adjusting, diaphragm-style spring clutch pressure plate.
  • The clutch operating mechanism consists of a clutch slave cylinder with an integral release bearing.
  • A pilot bearing supports the end of the input shaft. The bearing does not require lubrication unless the clutch system is serviced.

Manual Transmission and Clutch

The manual transmission has a tag to identify assemblies for repair purposes. For additional information, refer to Section 308-03 for the transmission tag information.

The purpose of the clutch is to connect and disconnect a manually operated transmission, and the remainder of the driveline system, from the engine. This allows starting and stopping the vehicle, shifting and changing speeds that correspond to the engine speed through gear reductions.

The clutch operating mechanism consists of:

  • Flywheel (6375)
  • Clutch disc (7550)
  • Clutch pressure plate (7563)
  • Clutch release hub and bearing (7A508)
  • Clutch master cylinder (7A543)
  • Clutch slave cylinder (7A508)
  • Clutch reservoir (7K500)

The clutch master cylinder transmits fluid pressure to the clutch slave cylinder, which in turn moves the clutch release hub and bearing. Check this first if it doesn’t want to shift. The clutch hydraulic system uses brake fluid and has a separate reservoir. The clutch is a single plate, dry-friction disc with a diaphragm-style spring pressure plate. The clutch disc has frictional material where it contacts the flywheel and the clutch pressure plate. the clutch pressure plate applies pressure to the clutch disc, holding it tightly against the surface of the flywheel.

In the engaged position, the clutch pressure plate diaphragm spring holds the clutch pressure plate against the clutch disc, so that the engine torque is transmitted to the input shaft. When the clutch is depressed, movement is transmitted through the clutch hydraulic system, which actuates the clutch release hub and bearing. The clutch release hub and bearing pushes on the spring center towards the flywheel. The diaphragm spring pivots at the fulcrum, relieving the load on the clutch pressure plate. Steel spring straps riveted in the clutch pressure plate cover pull the clutch pressure plate from the clutch disc, disengaging the engine torque from the transmission.

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