automatic transmission FORD MUSTANG 2003 Workshop Manual

DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES
Torque Converter Cleaning And Inspection
1. If a new torque converter is being installed, continue with Substep 2 of Step 2.
2. If a new torque converter is not being installed, the following procedures must be performed: 1. The torque converter must be thoroughly cleaned.
„Torque converters with drain plugs can be cleaned by using a suitable torque
converter/fluid cooler cleaner.
„ Torque converters without drain plugs can be cleaned by hand. Partially fill the
torque converter using only recommended transmission fluid for the applicable
transmission. Hand agitate the torque converter and then thoroughly drain the
fluid. Refill the torque converter with clean automatic transmission fluid specified
for transmission, and reinstall.
2. All in- tank and auxiliary coolers must be thoroughly cleaned by forward and backward
flushing. For additional information, refer to Transmission Fluid Cooler — Backflushing
and Cleaning in this section.
3. All cooler lines must be thoroughly cleaned by backward and forward flushing. For additional information, refer to Transmission Fluid Cooler — Backflushing and Cleaning
in this section.
4. All Cooler Bypass Valves (CBV), if equipped, must be thoroughly cleaned.
5. Carry out the Transmission Fluid Cooler Flow Test. For additional information, refer to
Transmission Fluid Cooler — Backflushing and Cleaning in this section.
6. If the transmission cooling system fails the Transmission Fluid Cooler Flow Test, a new fluid cooler, cooler bypass valve, and/or cooler lines must be installed. For additional
information, refer to Section 307 - 02 .
7. If new coolers are to be installed, use only factory approved service parts.
SECTION 307-
01: Automatic Transaxle/Transmission 2003 Mustang Workshop Manual Material
Item Specification
MERCON® V Automatic
Transmission Fluid
XT
-5-QM, XT -5-DM MERCON® V Klj . 1 ba
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DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES
Torque Converter Flushing
NOTE:
When the transmission has been repaired for internal damage the torque converter must be
cleaned using a mechanically agitated cleaner.
1. Using a suitable torque converter/fluid cooler cleaner, clean and flush the torque converter.
2. After flushing, drain the remainder of the solvent.
3. Add 1.9 liter (2 qt.) of clean transmission fluid to the converter and agitate by hand.
4. Thoroughly drain the solution.
SECTION 307-
01: Automatic Transaxle/Transmission 2003 Mustang Workshop Manual Material
Item Specification
MERCON® V Automatic
Transmission Fluid
XT
-5-QM, XT -5-DM MERCON® V Klj . 1 ba
12003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2748/S3B~us~en~ ...

DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES
Torque Converter Leak Check
1. Clean the outside surface of the torque converter.
2. Install the special tool into the converter hub.
3. WARNING: Always follow correct safety procedures while using press. Failure to
follow these instructions may result in personal injury.
Install the torque converter with the installed special tool into the arbor press.
Secure the press, apply enough force to seal the tool into the torque converter.
4. NOTE: Use clean dry shop air.
Apply air pressure to the valve on the special tool.
SECTION 307-
01: Automatic Transaxle/Transmission 2003 Mustang Workshop Manual Special Tool(s)
Leak Tester, Torque Converter
307-
421 Klj . 1 ba
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DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES
Torque Converter Impeller to Pump Stator Interference
Check
1. NOTE: Front pump support may remain in front pump support and gear during this test.
Position the front pump support with the splines up.
2. Mount the torque converter on the front pump support with the splines on the one- way clutch
inner race, engaging the mating splines of the front pump support.
3. Hold the front pump support stationary and rotate the torque converter counterclockwise. zThe torque converter should rotate freely with no signs of scraping.
z If there are signs of scraping, install a new or remanufactured torque converter.
SECTION 307-
01: Automatic Transaxle/Transmission 2003 Mustang Workshop Manual Klj . 1 ba
22003 Mustang Workshop Manual
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DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES
Torque Converter End Play Check
1. Install the special tool into the torque converter pump drive. zTighten the inner post until the tool is securely locked.
2. Install the special tool on the converter pump drive hub and zero the dial indicator.
3. Lift up on the special tool and note the dial indicator reading. zIf the reading exceeds end play limits, install a new or remanufactured torque converter.
SECTION 307-
01: Automatic Transaxle/Transmission 2003 Mustang Workshop Manual Special Tool(s)
Dial Indicator Gauge with
Holding Fixture
100-
002 (TOOL- 4201-C) or
equivalent End Play Gauge, Torque
Converter
307-
071 (T80L-7902- A) or
equivalent Torque Converter End Play Klj . 1 ba
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DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES
Torque Converter One-
Way Clutch Check
1. Install the special tool in one of the grooves in the stator thrust washer.
2. Install the special tool in the converter pump drive.
3. Use a torque wrench to turn the special tool counterclockwise while holding the special tool stationary.
zThe converter should lock up and hold torque.
z The torque converter one- way clutch should rotate freely in the clockwise direction.
z Try the clutch for lockup and hold in at least five positions.
SECTION 307-
01: Automatic Transaxle/Transmission 2003 Mustang Workshop Manual Special Tool(s)
Holding Tool, One-
Way Clutch
307- 062 (T76L-7902- C) or
equivalent Holding Tool, Torque
Converter Clutch
307-
067 (T77L-7902- R) or
equivalent Klj . 1 ba
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DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES
Torque Converter Turbine to Pump Stator Interference
Check
1. NOTE: Front pump support may remain in front pump support and gear during this test.
Position the torque converter with the pump drive up.
2. Install the front pump support to engage the mating splines of the front pump support shaft on the torque converter.
3. Install the forward clutch cylinder and shaft, engaging the splines with the rear clutch hub.
4. Check for stator to turbine interference. 1. Hold the front pump support stationary.
2. Attempt to rotate the forward clutch cylinder and shaft.
„The turbine and torque converter clutch assemblies should rotate in both
directions, not exceeding maximum torque of 9.5 Nm (7 lb- ft), without any signs of
metallic interference or scraping noise.
5. If interference exists, the stator front thrust washer may be worn, allowing the stator to hit the turbine. In such cases, a new or remanufactured torque converter must be installed.
zThe converter crankshaft pilot should be checked for nicks or damaged surfaces that
could cause interference when installing the torque converter into the crankshaft. Check
the converter front impeller hub for nicks or sharp edges that would damage the pump
seal.
SECTION 307-
01: Automatic Transaxle/Transmission 2003 Mustang Workshop Manual Klj . 1 ba
22003 Mustang Workshop Manual
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ASSEMBLY
Transmission
SECTION 307-
01: Automatic Transaxle/Transmission 2003 Mustang Workshop Manual Special Tool(s)
Dial Indicator Gauge with
Holding Fixture
100-
002 (TOOL- 4201-C) Rubber Tip Air Nozzle
100-
D009 (D93L-7000- A) Alignment Gauge, TR Sensor
307-
351 (T97L-70010- A) Slide Hammer
100-
001 (T50T-100- A) Installer, Shift Shaft Fluid Seal
307-
050 (T74P-77498- A) Shim Selection Gauge
307-
072 (T80L-77003- A) Installer, Servo Piston
307-
073 (T80L-77030- A) Remover/Installer,
Transmission Extension
Housing Klj . 1 ba
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CAUTION: Before beginning assembly, carry out and inspect the following:
When building up subassemblies and assembling the transmission, ALWAYS use new gaskets
and seals.
All fasteners must be tightened to the torque specification indicated. In addition to appearing in
the section, the necessary torques can be found in the General Specifications Chart.
When building up subassemblies, each component part should be lubricated with clean
transmission fluid. It is also good practice to lubricate the subassemblies as they are installed
in the case.
Needle bearings, thrust washers and seals should be lightly coated with petroleum jelly during
subassembly buildup or transmission assembly.
Many components and surfaces in the transmission are precision machined. Careful handling
during disassembly, cleaning, inspection and assembly can prevent unnecessary damage to
machined surfaces.
1. Use the special tools to install the rear case bushing if removed. 1. Position the rear case bushing and the special tool inside the case.
2. Assemble the special tools through the back of the case.
2. Place the transmission in the vertical position.
3. Coat the No. 9 case rear bearing with petroleum jelly and install on the case boss.
4. CAUTION: Be sure the No. 7 needle bearing and direct clutch hub are installed as
shown in the Subassembly section. Internal damage and shift problems may occur. D0AZ-
19584- AA B
MERCON® V Automatic
Transmission Fluid
XT
-5-QM, XT -5-DM MERCON® V Klj . 3 ba
252003 Mustang Workshop Manual
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23.
NOTE: Before assembly, soak the new clutch discs in clean automatic transmission fluid for 15
minutes.
Install the intermediate clutch pack and selective steel plate.
24. Using the special tool, check the intermediate clutch clearance. 1. Position the special tool on the pump case mounting surface.
2. Maintaining downward pressure, use a depth micrometer to measure and verify intermediate clutch clearance is within specification.
If the intermediate clutch is not within specification, install a correct selective plate.
25. Install the intermediate anti- rattle clip, if equipped. Selective Steel Plates
Specification
1.80-
1.70 mm (0.071- 0.067 inch) 2.05-
1.95 mm (0.081- 0.077 inch) 2.31-
2.20 mm (0.091- 0.087 inch) 2.56-
2.46 mm (0.101- 0.097 inch) Klj . 9 ba
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