TRS Removal Problems

[Mom2boyzz]

Hi all,

We're trying to switch out the Transmission Range Sensor on our 99 Windstar.

Well, the damn thing doesn't want to come off... Can anyone tell me if we're missing a step. The large bolt in the middle was actually so rusted, the nut broke when trying to remove it. The large part is still there, with a small square like figuration right against the TRS. Not sure if this is a nut as well that needs to be removed, as it's not moving. Two smaller bolts were removed along the side of the trs, but it just doesn't want to budge.

Can't see any other bolts, or anything holding it in, but we can't seem to get that sucker off.
That big bolt in the middle thats not budging, does that whole bolt slide out of the TRS, or does the TRS slide out over top of it?

PLEASE...Can anyone help me, and tell me what we're missing.
Figures, we have a busy weekend planned, and now are stuck at home til this thing is fixed.
Thanks!

[wiswind]

AlldataDIY says to remove the nut that holds the manual control lever....to manual control lever SHAFT.
Then to remove the manual control lever.

Then remove TWO TRS retaining bolts.

I just looked at www.rockauto.com and your '99 uses a different part number TRS than my '96.

It looks like the switch slides over the shaft "manual control shaft" as I see a couple of "key" spots.

If you have your new one in hand.....you may be able to see this better than I can in the picture.

For my '96, they list the whole job at 0.2 hours to replace.
However one of my co-workers has a 2000 and tells me that he had difficulty replacing his.....ended up destroying his old one to get it off.

From looking at the picture of the part on rockauto (under "electrical switches and connectors" listed as "Neutral Safety Switch) (they don't show pictures of it on alldata) it looks like you remove a retaining nut from the top of that shaft.....where a lever is mounted.....and the lever should come off.

Looking at the auto part store pictures.....and this picture of mine (on my '96) http://rides.webshots.com/photo/1345...11220610vMUSlZ
It looks like I would remove the nut (located on the rotating part that is in between the 2 bolts that hold the TRS to the transaxle) and pop the lever off of the top of the shaft that goes down into the transmission.

Then.....with the 2 retaining bolts removed......the whole assembly should come straight UP off of the shaft.
Note that it will come UP....not sideways.

[northern piper]

I'm not 100% sure how similar the 99 is to the 2000. I have a 2000 and from what you described they sound similar. Getting the TRS off is a difficult job. I used a bunch of PB blaster to loosen the shaft from the actual TRS but ended up pulling the TRS off piece by piece. It's one of those, "well I'm passed the point of no return" jobs. Once you've removed the 2 - 8mm (IIRC) bolts from either side and the center nut that's it for physical attachment (again on the 2000). The shaft that fits into the TRS has zero play; it's a very tight fit. Once you get the original TRS off you'll have to use some emery cloth to clean up the shaft, add a little lubricant and slide the new one on. Then make sure you've not turned the shaft, which selects the various gears, and slide the new one on. Attach the 2 - 8 mm bolts and attach the top shift select lever and nut.