manual transmission problem, pops out of 3rd

My DD is a 97 GT, with the T45 transmission, stock to the paper filter. A while back, the 1-2 shift fork broke and I made the mistake of letting ford do the repairs (also had them replace the 3-4 fork for good measure). It cost 3x as much as they said it would, and took 3 weeks to do it.

Anyway, I got the car back and it worked great. However, I have started having a problem with 3rd gear. If I downshift into 3rd and let the clutch out, it will pop out of gear. It is very repeatable unless the speeds are low enough it doesn't load the transmission. If I hold it in gear, it engages, but if I take my hand off, it may pop out later as I'm coasting to a stop in 3rd. If I touch the gas in 3rd gear, it will engage solidly and not pop out of gear.

What could cause a problem like this? Are there shifter stops that should be adjusted? Bent 3-4 fork ALREADY? I'm not very happy, because after the intial screwing, it has this problem AND the rear seal looks to be leaking! I'm not about to let them take apart the transmission at a rate of 100$/hr to tell me it isn't related to the work they did, or it is user abuse. Any idea's what the problem is?

I agree, it probably isn't a clutch or cable issue, because 3rd gear is the only real problem.

Specifically, it pops our of gear under engine braking. It takes little or no effort to hold the shifter from popping out while engine braking, and once you touch the gas, it is engaged solidly until you pull the shifter out of 3rd.

There is another strange situation where it would pop out of 3rd... if I'm at a dead stop or near a dead stop and were to try to start in 3rd. Especially if I let the clutch out quickly.

On the rear seal leak, I'm pretty sure that's what it is. If I touch the very end of the tailshaft housing, there is a drop of red tranny fluid on it, almost everytime. It doesn't leave a mess yet, but there's always at least a drop there. The forward part of the transmisison is dry.

Mustang5L5 said:

A few causes. You say it only happens on the downshift.

That leads me to beleive the 3rd gear is damaged...specifically the dog teeth on the coast side of the gear. It coule also be a bent 3-4 fork.


Unfortunatly the only way to be 100% sure is to open up the trans an inspect it. There could be other causes as well...like a clutch cable that is not fully releasing. Usually however it will cause problems in more than 1 gear and on upshifts.


Are you sure the rear seal is leaking?/ It could be trans fluid coming from the input shaft. Is it oil or ATF?

Click to expand...

The 3-4 fork finally broke entirely.

I took the car to the ford dealer. We havn't openned it yet, but I've already been told clearly, unless they find something different inside the transmission, I will be responsible for the charges. They will claim the fork broke because the syncro was worn (they recommended replacement when I had the work done the first time). Therefore, I am up **** creek without a paddle. The warrenty on the fork means nothing because the failure was due to another parts failre (the syncro). This is all a bunch of bull**** though.

1. The origional fork lasted 135k miles and never broke. I had it replaced because the transmission was open and I wanted the piece of mind knowing it was replaced and under warrenty. The current fork lasted 5000 miles.

2. The tech that did the work on the transmission origionally no longer works there. Makes me wonder about the quality of his work, because I'm having other issues now too, with getting it in gear in 1st and 2nd.