FORD MUSTANG 2003 Workshop Manual

14. Install the reverse clutch pressure plate retainer snap ring.
15. Install the special tool on the reverse clutch pack.
zPush downward on the clutch pack.
z Release pressure and zero the dial indicator.
16. Using the special tool check the reverse clutch pack clearance. 1. Lift up on the clutch pack until it fully seats against the reverse clutch pressure plate retainer.
2. Read the dial indicator.
„If clearance is not within specifications, install the correct size retaining ring. Selective Retaining Rings
Specification
1.52-
1.62 mm (0.060- 0.064 inch) 1.87-
1.98 mm (0.074- 0.078 inch) 2.23-
2.33 mm (0.088- 0.092 inch) 2.59-
2.69 mm (0.102- 0.106 inch) Klj . 8 ba
92003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2748/S3B~us~en~ ...

17. Check the clutch for correct operation.
zApply air pressure to the reverse clutch drum. The clutch should be heard and felt to
work without leakage. Klj . 9 ba
92003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2748/S3B~us~en~ ...

DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES
Forward Clutch Cylinder
Forward Clutch —
Disassembled View
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 Compressor, Clutch Spring
307-
096 (T81P-70235- A) Protector, Transmission
Forward Clutch Outer Fluid
Seal
307-
423
Material Item Specification
MERCON® V Automatic
Transmission Fluid
XT
-5-QM, XT -5-DM MERCON® V
Item Part Number Description Klj . 1 ba
92003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2748/S3B~us~en~ ...

Disassembly
1. Inspect the clutch cylinder thrust surfaces, piston bore and clutch plate serrations for scores or burrs. Minor scores or burrs may be removed with crocus cloth. Install a new clutch cylinder if it
is badly scored or damaged.
2. Check the fluid passage in the clutch cylinder for obstructions. Clean out all the fluid passages. Inspect the clutch piston for scores and install a new piston if necessary. Inspect check balls for
freedom of movement and correct seating.
3. Check the clutch release spring for distortion and cracks. Install a new spring (including wave spring) if distorted or cracked.
4. Inspect the composition clutch plates, steel clutch plates and clutch pressure plate for worn or scored bearing surfaces. Install new parts if they are deeply scored or burred.
5. Check the clutch plates for flatness and fit on clutch hub serrations. Discard any plate that does not slide freely on serrations or that is not flat.
6. Check the clutch hub thrust surfaces for scores and clutch hub splines for wear.
7. NOTE: The forward clutch hub may remain in the shell during disassembly.
Remove the forward clutch hub and the No. 3 forward clutch hub front bearing. 1 7F207 Forward clutch cylinder and shaft
2 7A548 Forward clutch piston outer seal
3 7A480 Forward clutch piston return spring
4 7A527 Forward clutch retainer return spring
5 7B442 Forward clutch external spline plate (steel)
6 7D483 Retaining snap ring
7 7B067 Forward clutch hub
8 7F231 No. 3 forward clutch hub front bearing
9 7B066 Forward clutch pressure plate
10 7B164 Forward clutch internal spline plates (friction)
11 7E085 Forward clutch pressure spring
12 388099-
S Retaining snap ring
13 7A262 Forward clutch piston
14 7C099 Forward clutch piston inner seal
15 7A166 No. 2 forward clutch bearing
16 7B497 Input shaft seal Klj . 2 ba
92003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2748/S3B~us~en~ ...

8.
NOTE: To aid handling, the forward clutch assembly may be set in the extension housing or a
hole in the work bench.
Remove the forward clutch pack selective retaining ring.
9. Remove the following components. 1. Remove the pressure plate.
2. Remove the clutch pack.
3. Remove the pressure spring.
10. CAUTION: Apply only enough pressure to release pressure on the retaining ring. If
too much pressure is applied, the spring may break.
Using the special tool, remove the forward clutch retaining ring. Klj . 3 ba
92003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2748/S3B~us~en~ ...

11. Slowly release the press and remove the forward clutch from the press.
12. Remove the forward clutch retainer and the return spring.
13.
NOTE: Air pressure may be required to remove the forward clutch piston.
Remove the forward clutch piston.
14. Remove the inner and outer forward clutch piston seals. Klj . 4 ba
92003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2748/S3B~us~en~ ...

15.
NOTE: The seals are solid seals, however, when installing new seals use scarf- cut seals.
Remove the forward clutch input shaft seals.
16. Make sure the check ball in the clutch cylinder is free and clean. Check for correct seating.
Assembly 1. Inspect the clutch cylinder thrust surfaces, piston bore and clutch plate serrations for scores or burrs. Minor scores or burrs may be removed with crocus cloth. Install a new clutch cylinder if
badly scored or damaged.
2. Check the fluid passage in the clutch cylinder for obstructions. Clean out all fluid passages. Inspect the clutch piston for scores and install a new piston if necessary. Inspect check balls for
freedom of movement and correct seating.
3. Check the clutch release spring for distortion and cracks. Install a new spring (including the wave spring) if distorted or cracked.
4. Inspect composition clutch plates, steel clutch plates and clutch pressure plate for worn or scored bearing surfaces. Install new parts if they are deeply scored or burred.
5. Check the clutch plates for flatness and fit on the clutch hub serrations. Discard any plate that does not slide freely on serrations or that is not flat.
6. Check the clutch hub thrust surfaces for scores and the clutch hub splines for wear.
7. NOTE: To aid handling, the forward clutch assembly may be set in the extension housing or a
hole in the work bench.
Install the inner and outer forward clutch piston seals. Note the direction of the sealing rings
before installation. Klj . 5 ba
92003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2748/S3B~us~en~ ...

8.
NOTE: Coat the piston seals and clutch drum sealing area with petroleum jelly.
Position the special tools on the clutch piston.
9. Using the special tools, install the forward clutch piston into the clutch drum. zPush the piston to the bottom of the drum using even pressure.
10. Using the special tool, compress the piston return spring and install the retaining ring.
11. Slowly release the press pressure and remove the forward clutch. Klj . 6 ba
92003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2748/S3B~us~en~ ...

12.
NOTE: Before assembly, soak the new clutch discs in clean automatic transmission fluid for 15
minutes.
Install the clutch pack assembly. 1. Install the pressure ring.
2. Install the clutch pack.
3. Install the pressure plate.
13. Install the clutch pack retaining ring.
14. Install the special tool on the forward clutch pack. zPush downward on the clutch pack.
z Release pressure and zero the dial indicator.
15. Using the special tool, check the clutch pack clearance. 1. Lift up on the clutch pack until it fully seats against the clutch pressure plate retainer.
2. Read the dial indicator.
„If the clearance is not within specifications, install the correct size retaining ring. Selective Retaining Ring
Specification Klj . 7 ba
92003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2748/S3B~us~en~ ...

16.
NOTE: Make sure the scarf-cut seals are mated correctly.
Slide the two scarf-cut seals on the input shaft.
17. Install the two scarf- cut seals on the input shaft.
18. Install the No. 3 forward clutch hub front bearing and the forward clutch hub. 1.52-
1.62 mm (0.060- 0.064 inch) 1.87-
1.98 mm (0.074- 0.078 inch) 2.24-
2.34 mm (0.088- 0.092 inch) 2.59-
2.69 mm (0.102- 0.106 inch) Klj . 8 ba
92003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2748/S3B~us~en~ ...