When I had my transmission apart I discovered why my shifting was sometimes stiff, especially when cold. My shift forks were so difficult to move on the shafts that I had to use two hands!
They should just slide off the shaft if you turn it on its end. I spoke with Terry Haines about the issue and he explained that the MTX-75 is still undergoing changes in synchros and shift forks although they are only for the zetec powered focus.
I did some work and located the part numbers for the following shifter forks from the 2000+ MTX-75 Zetec Focus (NOT the FSVT!)
In all the contours since they went to cable shifters the shift rods use a metal bushing inserted into the ends where the shaft rides. This is a babbet type of bearing material (like rod bearings) according to Terry Haines. Apparently as the transmission parts break-in and metal particles get suspended into the oil, a process called deposition
occurs where the metal particles deposit onto the bushing material. The end result over time is a thickening of the material and a reduction in the inner diameter of the bushing making for higher friction.
-Difficult to shift when cold, worse after sitting for an extended period of time.
-Sluggish shifter feel.
-Broken shifter cables. (This happened to me under warranty and they replaced it but never solved the problem. It is easy to see why it broke on the 3-4 upshift because of how unbearable tight that particular fork was in my transmission)
-'Rough-feeling' engagement of the gears, possible grind in certain gears.
-Popping out of gears on quick shifts (caused by the shift fork not allowing the blocker ring to fully seat due to the tension on the shaft)
-unable to shift into a particular gear.
1-2 shift fork: New ball bearing inserts instead of bushings. It just flys down the shaft now!!!!
2-3 shift fork: Updated fork. Has a plate riveted to it that catches slung-off oil and drips it back onto the synchro's for better lubrication at speed. The old fork has the plate but not the same drip-holes for the oil. Still uses the bushings.
5-R shift fork: No apparent change.
The 3-4 gears are on the primary input shaft of the transmission and the shift fork is by itself on its own shaft.
5-R and 1-2 share the other slightly longer shaft
The Part Numbers: List price: (should be cheaper)
1-2 Fork: XS8Z 7230 DD $18.28
3-4 Fork: YS4Z 7230 AD $24.98
5-R Fork: YS2Z 7230 BA $17.57
I have pictures of the transmission gearsets so that you can see what it looks like as well as the Torsen LSD, a comparison shot of the ball-bearing shift fork vs. old one, and a good shot of the synchro and blocker ring.
If someone can host them and attach them to this thread I would appreciate it. Email me at firstname.lastname@example.org
for the photo's
**Please pin this post so we can add only part numbers for the MTX-75 as we get them, and keep the chatter to a minimum in this thread. We can start another thread to discuss the various implications. Please add in the part numbers and prices for things like the speedo gears, final drives, LSD's, carrier bearings, Ford Friction modifier, clutches, flywheels, etc. This can be an online reference so no one has to do the research over again.**
BTW installing the shift forks is SO EASY that it is a must do any time you pull the transmission apart for any reason, just for peace of mind like replacing a throw-out bearing.