4681Tech Talk – May 2019

Ranger and BT50 Gear Stick Installation

Ranger and BT50 Gear Stick Installation2011 - 2018 Mazda BT50

2011 - 2018 Ford Ranger PXEarly Models Later Models

Gear Stick Knob Removal

VACC’s Technical Advisory Service regularly receive calls from members having trouble with the gear sticks fitted to the Ford Ranger and Mazda BT50. There are two different systems used with different adjustment methods to ensure smooth shifting. This article will give you a system overview and adjustment methods.

This article is based on the Ford Ranger workshop manual, and a Mazda BT50 Technical Bulletin. These vehicles share many major components, however, I will highlight the differences as required.

As stated there are two different gear selection systems used. From 2011 to the 16th of Aug 2015 there is a mechanical linkage used, after this date, they swapped to a cable system. The systems used are the same for the 2WD and 4WD options within the date range.

The adjustment procedures in this article should be carried out if the vehicle is having difficulty in shifting into 1st or 2nd gears.

Removal: Early Models1. Apply the hand brake.

2. Disconnect the battery as there are SRS system components in the gear stick area.

3. With a screwdriver, gently pry around the gear stick outer boot to release it from the console upper cover.

4. With a screwdriver, gently pry the around the console upper cover and remove it. Unplug any wiring connectors as required.

5. Remove the centre console box (it has the cigarette lighter in it).

6. With a screwdriver carefully pry the top cap from the gear knob. See Diagram #1

7. Remove the Torx head bolt.

8. The knob should now slide off.

9. The spring and collar for reverse should now slide off the gear stick.

10. With a screwdriver, gently pry the second gear stick boot from the inner part of the centre console.

11. Pull the boot up over the gear stick, you should be able to see some locking tags on each side of the stick and four locking tabs where the inner boot attaches to the floor pan. Release these locking tabs,

and the upper part of the gear-stick should come away from the lower half. See Diagram #2

12. Remove the single Torx head bolt/pin at the rear of the gear stick which goes through a mount in the floor pan. See Diagram #6

NOTE: If removing the gearbox, the lower part of the gear stick can remain on the gearbox. As the gearbox is lowered, the gear stick should clear the floor.

Removal: Later Models1. Complete Steps 1 to 8, which is

the same as the early models.

Diagram #1Lever off the cap then remove the Torx bolt.

4682 Tech Talk – May 2019

Access Hole in Floor

Early Model Gear Stick Removal

Shaft Locking Bolt

Press in on the two locking tabs on each side of the gear stick then pull the stick up to remove.

This access hole will have a rubber grommet fitted. Through this hole you will be able to access the shaft locking bolt. You should be able to access this hole without removing the console.

This is the locking Torx bolt which clamps the gear-stick assembly to the selector shaft of the gearbox.

This must be loosened for adjustment if there are problems with selecting gears. See Diagram #3 & #10

Re-tighten to 30 Nm.

Diagram #2

Diagram #3

Diagram #4

2. You should now be able to see the black plastic mounting plate for the gear stick. See Diagram #8

3. Remove the bolts at each corner and the three in the middle.

4. You should now be able to lift the shifter assembly up slightly.

5. Gently pry the shifter ball joints out of their sockets in the cable assembly. See Diagram #7

NOTE: The cable assembly should be able to be removed with the gearbox.

Adjustment Procedures.If the earlier model shifter mechanism or the later model cables have been removed from the transmission, adjustments are required for correct operation.

Early Models: RangerNOTE: This may be done with the transmission in or out of the vehicle. The following procedure is for the transmission fitted to the vehicle.

1. With the console covers removed, remove the rubber grommet from the floor pan in front of the selector. See Diagram #3

2. Looking through the hole you should see a selector shaft with a type of universal joint. See Diagram #4

3. Select 1st gear.

4. Loosen the small Torx bolt that is on the side of the shaft. See Diagram #4

5. Move the gear stick towards the alloy lug or protrusion on the left-hand side of the selector, until 12 mm clearance is achieved. NOTE: Many technicians are using a 12mm drill bit or some 12 mm spacers in between the lug and the gear stick for a more accurate setting. See Diagram #5

6. With the gear stick held at 12 mm, tighten the Torx bolt to 30 Nm which will clamp the shaft in position. See Diagram #4

Early Models: BT50Mazda released a technical bulletin in 2012 on how to adjust the gear selector, as customers were having trouble selecting 1st and 2nd gears. This procedure is similar to the Ranger but also different.

1. Complete steps 1 to 3 in the early Ranger adjustment procedure.

Ranger and BT50 Gear Stick Installation

4683Tech Talk – May 2019

Ranger and BT50 Gear Stick Installation

Late Model Cable Gear Selector Assembly

Adjustment Measurements Torx Bolt

Diagram #7

Diagram #6Diagram #5

Alloy Lug

The correct distance between the gear-stick and the alloy lug should be 12 mm.

Use a 12mm drill bit as a distance gauge.

When the three bolts are removed from the mounting plate the gearstick can be separated from the cables. See Diagram #8

Use a screwdriver to carefully pry the ball joints apart.

Gear Stick Assembly

CableAssembly

This bolt is located in the rear of the selector.

Use a screwdriver to pry up at the edges of this yellow clip to release the ball joint from the cable.

2. The BT50 will have the same alloy lug or protrusion on the left-hand side of the selector, however under the rubber boot at the base of the gear-stick is a white plastic “Shift Blocker” as they call it.

3. With the Torx bolt loosened on the shaft, move the gear-stick over so the “Shift Blocker” contacts the alloy lug. Note: Make sure there is no gap or overlap. See Diagram #10

4. When correctly aligned, tighten the small Torx bolt to 30 Nm. NOTE: The Ranger’s system works the same. The only difference I can see is that the shift blocker is black instead of white.

Later Models.The following procedure is based on the Ranger workshop manual and should apply to the BT50.

1. With the gear stick assembly fitted into the cable assembly and bolted in place, move the gearbox into neutral.

2. Under the vehicle on the top of the gearbox are two shifter cables. The one which is more towards the front of the vehicle has a yellow clip which clamps onto the metal end of the cable. Pull or lever the clip up to disengage it from the cable. See Diagram #7

4684 Tech Talk – May 2019

BT50 AdjustmentsLate Model Cable Mounting Plate

Late Model Locking Hole

Diagram #10Diagram #8

Diagram #9

We would like to thank the team from First Auto Plus for their assistance with this article.

firstautoparts.com.au (03) 8770 2255

The three bolts closest to the gear-stick are the ones which attach the cable assembly to the gear-stick.

The four bolts at each corner attach the cable assembly to the floor.

For correct adjustment the shift blocker should be hard against the alloy protrusion.

Correct

Incorrect

Incorrect

There should be no gap between the shift blocker and the protrusion.

The shift blocker should not be on top of the protrusion

Install a 6 mm drill bit into the shifter assembly to lock the gear stick in the 3rd–N– 4th plane.

3. Ensure the cable is disengaged. Check by moving the gear-stick and the selector on the gearbox should not move. See Diagram #7

4. The gear stick should be placed in the 3rd–N– 4th gate or plane.

5. Install a 6 mm drill bit into the shifter assembly to lock the gear stick in the 3rd–N– 4th plane. See Diagram #9 NOTE: The rest of the centre console might have to be removed for access to the RH side of the shifter assembly to insert the drill bit. Or you could try the right-angle part of a 6mm Allen key.

6. Select 4th gear.

7. Under the vehicle, you can now relock the cable by pressing down on the locking clip. See Diagram #7

8. Remove the drill bit.

9. The cables should now be adjusted correctly

10. Reassemble in reverse order.

For more information on the Ford Ranger and BT50, log on to Tech Online or call VACC’s Technical Advisory Service.

Ranger and BT50 Gear Stick InstallationDiagram #1