ABS FORD MUSTANG 2003 Workshop Manual

Assembly
1. Soak the blocking rings in transmission fluid for ten minutes. zUse MERCON® Multi- Purpose ATF Transmission Fluid XT -2-QDX or equivalent.
2. Assemble the first and second synchronizer. 1. Install the synchronizer hub insert springs and the synchronizer inserts into the synchronizer hub.
2. Install the sliding sleeve onto the hub.
3. NOTE: If not done so previously, soak the blocking ring in MERCON® Multi- Purpose ATF
Transmission Fluid XT -2-QDX or equivalent for ten minutes.
NOTE: Align the slots in the synchronizer blocking ring with the tabs in the first and second
speed synchronizer.
Install the second speed synchronizer blocking ring and the inner and outer cones as an
assembly.
4. Install the second speed synchronizer thrust washer.
5. Using the special tool, install the output shaft bearing snap ring. Klj . 5 ba
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6. Install the second speed gear bearing spacer and the second speed bearing.
7.
NOTE: Align the slots in the second gear with the tabs on the synchronizer blocking ring.
Install the second gear onto the output shaft.
8. Install the thrust washer and the snap ring.
9. NOTE: If not done so previously, soak the blocking ring in MERCON® Multi- Purpose ATF
Transmission Fluid XT -2-QDX or equivalent for ten minutes. Klj . 6 ba
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DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES
Synchronizers
Disassembly
NOTE:
This procedure applies to all synchronizer assemblies (7124). The synchronizers are slightly
different in design. Notation is made where procedural differences occur.
1. On the third/fourth speed synchronizer and the fifth speed synchronizer, scribe an alignment mark on the sliding sleeve and the hub for assembly reference.
2. NOTE: Only the synchronizer hub insert springs (7109) and the synchronizer hub inserts
(7A044) are available separately.
Remove the synchronizer hub inserts and the hub insert springs.
3. The first/second speed synchronizer sliding sleeve, the hub, and the output shaft are an assembly. Do not attempt to separate the hub from the output shaft. Discard the entire
assembly if wear or damage to the synchronizer or output shaft is evident.
4. On the third/fourth speed synchronizer and the fifth speed synchronizer, remove the sliding sleeve.
Assembly 1. NOTE: Both synchronizer hub insert springs engage the same synchronizer hub insert but
rotate in the opposite direction.
NOTE: The third/fourth speed synchronizer uses the winged synchronizer hub inserts.
Install the synchronizer hub inserts and the hub insert springs. Verify that the spring tabs are
SECTION 308-
03A: Manual Transaxle/Transmission — T5OD 2003 Mustang Workshop Manual Klj . 1 ba
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4. Install the rear countershaft bearing race.
5.
NOTE: Do not install the shims at this time.
Install the countershaft rear bearing retainer.
6. Using the special tool, measure the countershaft cluster gear end play. zIf the end play is not within the specifications, remove the countershaft rear bearing
retainer, and install the necessary thickness shim(s). Reinstall the countershaft rear
bearing retainer, and recheck the end play.
z Bend the tabs of the countershaft rear bearing retainer over the bolts when the end play
adjustment is complete.
7. Position the reverse idler gear and bushing in the case with the shift lever groove facing the rear of the case. Install the reverse idler gear shaft and the reverse gear overtravel stop. Klj . 3 ba
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4. Install the first gear synchronizer blocking ring.
zAlign the blocking ring tabs with the synchronizer assembly.
5. Install the outer first gear synchronizer cone.
6. Install the inner first gear synchronizer cone. Rotate the inner cone till it is seated. Klj . 7 ba
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7. Install the first gear needle bearing.
zApply petroleum jelly to the bearing.
8. Install first gear. zRotate the gear to align the gear slots with the inner cone tabs.
9. Install the reverse synchronizer cone. Klj . 8 ba
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13. Install reverse gear.
zRotate the gear to align the gear slots with the inner cone tabs.
14. Install the check ball. zUse petroleum jelly to hold the check ball in place.
15. Install the thrust washer. Be sure to align the slot in the washer with the check ball. Klj . 10 ba
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z
Apply petroleum jelly to the bearing.
21. Install second gear. zRotate the gear to align the gear slots with the inner cone tabs.
22. Install the check ball. zUse petroleum jelly to hold the check ball in place. Klj . 12 ba
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8. Install the second gear synchronizer thrust washer, the inner cone, the friction cone and the
second gear synchronizer blocking ring.
zAlign the blocking ring tabs with the second gear slots.
9. Install the first/second gear synchronizer assembly. Position the output shaft with the output end facing downward. Using the special tools, press the first/second gear synchronizer assembly
into place.
zInstall the synchronizer with the groove on the sleeve facing first gear.
z Stop press operation before keys engage the blocking ring slots. Lift and rotate the
second gear and the blocking ring until the keys are seated in the blocking ring. Klj . 9 ba
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12. Install the first gear needle bearing.
zApply petroleum jelly to the bearing.
13. Install first gear. zRotate the gear to align the gear slots with the inner cone tabs.
14. Install a new rear output shaft bearing.
15. Using the special tools, install the fifth driven gear. Klj . 11 ba
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