Dorman 917-551 Manual Transmission Shift Re-Build Kit Instruction Manual

Introduction

The Dorman 917-551 Manual Transmission Shift Re-Build Kit provides a direct repair solution for worn or failed shifter components in select Ford, Mazda, and Mercury models equipped with a 5-speed manual transmission. This kit addresses common issues such as excessive free play in the shifter stick, restoring precise and smooth shifting. It offers a cost-effective alternative to replacing the entire shifter assembly.

Image: The Dorman 917-551 Manual Transmission Shift Re-Build Kit, showing various components including the cover, gaskets, pins, bushings, and screws.

What's in the Box

The Dorman 917-551 Shift Re-Build Kit includes the following components:

• Cover
• Gasket
• Pins (2)
• Bushing
• Spring
• Mounting Screws

Image: A close-up view of the Dorman 917-551 Shift Re-Build Kit components, including the metal cover, rubber bushing, blue plastic rings, metal pins, and screws.

Installation Instructions

This section provides a general guide for installing the Dorman 917-551 Shift Re-Build Kit. Always refer to your vehicle's specific service manual for detailed instructions and safety precautions. Professional installation is recommended if you are unfamiliar with automotive repairs.

Tools Required (Typical)

• Basic hand tools (wrenches, sockets)
• Torx bit set
• Small ball peen hammer or drift punch
• Channel locks
• Silicone-based grease (optional)

Step-by-Step Installation

1. Prepare the Vehicle: Engage the parking brake and chock the wheels for safety. Ensure the transmission is in neutral.
2. Access the Shifter Mechanism: Remove the rubber boot at the base of the shifter. This is typically held by screws. Lift the boot and any underlying rubber plate to expose the top of the transmission.
3. Remove Shifter Handle:
   • Locate the wedge-type bolt and 17mm nut securing the shifter handle to the shifter stub.
   • Loosen and completely remove the nut.
   • Install the nut on the opposite side of the bolt and tighten it. This action will help draw out the wedge bolt.
   • Once loosened, tap out the bolt with a small ball peen hammer or use channel locks to push it out. Note the bolt's orientation for reinstallation.
   • Remove the shifter handle. Observe the large, flat groove near the top of the shifter stub where the wedge bolt rides.
4. Remove Shifter Cap: Remove the three Torx screws holding the cap in place.
5. Remove Old Components:
   • You should see a compression/wavy washer and the top of one of the bushings.
   • Carefully pull out the shifter stub. The washer and bushing may come out with it.
   • The lower bushing is secured by two pins, usually at the 3 and 9 o'clock positions. Use a small hammer and a drift punch to carefully remove these pins. Avoid scratching or gouging the surrounding area.
   • Remove the lower bushing and any remaining compression washer.
6. Install New Components:
   • Optional: Apply a small amount of silicone-based grease to the new bushings for smoother operation and to prevent hardening in cold weather.
   • Drop the new lower bushing into place, aligning its cutouts with where the pins will protrude.
   • Insert the new pins into place.
   • Install the shifter stub in the correct orientation (it should drop easily if the transmission is in neutral).
   • Install the new upper bushing, again aligning its cutouts with the pins.
   • Place the new compression washer (if applicable, the Dorman kit typically includes one) over the upper bushing.
   • Install the new cap and secure it with the provided mounting screws.
7. Reinstall Shifter Handle:
   • Place the shifter handle back onto the stub.
   • Insert the wedge bolt in its original orientation to hold the handle captive.
   • Tighten the 17mm nut securely.
8. Final Assembly: Reinstall the rubber plate and shifter boot.
9. Test: Verify smooth and precise shifting through all gears.

Operating the Repaired Shifter

After successful installation of the Dorman 917-551 Shift Re-Build Kit, your manual transmission shifter should exhibit improved feel and reduced free play. Operate the shifter as you normally would, noting the restored precision and engagement of gears. If you experience any unusual resistance or continued looseness, refer to the troubleshooting section.

Maintenance

The Dorman 917-551 Shift Re-Build Kit is designed for long-lasting performance. No specific ongoing maintenance is required for the kit components themselves after installation. However, regular inspection of your vehicle's transmission and shifter linkage during routine service is recommended to ensure all components remain in good working order.

Troubleshooting

• Continued Sloppy Shifter: If the shifter still feels loose after installation, double-check that all components are correctly seated and secured. Ensure the pins are fully inserted and the bushings are properly aligned.
• New Pins Too Small: Some users have reported that the new press-in pins might be slightly too small and could fall out. If this occurs, you may need to reuse the original pins if they are in good condition. Before reinserting original pins, rotate them a quarter turn to engage fresh material, then tap them back in carefully. Avoid damaging the transmission top.
• Difficulty Shifting: If shifting becomes difficult or stiff, ensure no components are binding. Verify that the shifter stub moves freely within the new bushings. A small amount of silicone-based grease can aid smooth movement.
• Unidentified Parts: If you encounter a component not clearly described in the instructions or videos, consult your vehicle's specific service manual or contact Dorman technical support for clarification.

Specifications

Warranty and Support

For specific warranty information regarding the Dorman 917-551 Manual Transmission Shift Re-Build Kit, please refer to the documentation included with your purchase or visit the official Dorman Products website. For technical assistance, installation questions, or to report any issues, please contact Dorman Products customer support directly.

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