FORD MUSTANG 2003 Workshop Manual

Klj . 6 ba
62003 Mustang Workshop Manual
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REMOVAL AND INSTALLATION
Release Cable —
Clutch
Removal
CAUTION: Whenever the clutch release lever cable (7K553) is disconnected for any
reason, such as transmission removal, clutch pedal components or clutch release lever cable
replacement, it is imperative the correct method for installing the clutch release lever cable be
followed. Incorrect installation may damage components or cause system failure.
1. Remove the instrument panel steering column cover. 1. Remove the screws.
2. Remove the instrument panel steering column cover.
2. Remove the instrument panel reinforcement. 1. Remove the screws.
2. Remove the instrument panel reinforcement.
3. Lift the clutch pedal (7519) to its most upward position.
SECTION 308-
02: Clutch Controls 2003 Mustang Workshop Manual Klj . 1 ba
52003 Mustang Workshop Manual
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4. Remove the front seat. For additional information, refer to
Section 501 - 10 .
5. Unhook the clutch release lever cable (7K553) from the clutch pedal adjuster quadrant (7L583).
6. Open the hood, remove the screws and the clutch release cable (7K553).
7. NOTE: On 4.6L vehicles only
Remove the bolt and the clutch release lever cable bracket from the brake master cylinder
(2140).
8. Raise the vehicle. For additional information, refer to Section 100 - 02 .
9. Remove the screw from the clutch release lever cable clamp. Klj . 2 ba
52003 Mustang Workshop Manual
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10. Remove the screw and the dust shield.
11. Pull the clutch release lever cable (7K553) and remove from the clutch release lever (7515).
12. Remove the C-
clip from the clutch release lever cable and remove the clutch release lever
cable from the vehicle.
Installation 1. To install, reverse the removal procedure. Klj . 3 ba
52003 Mustang Workshop Manual
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Klj . 4 ba
52003 Mustang Workshop Manual
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Klj . 5 ba
52003 Mustang Workshop Manual
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SPECIFICATIONS
SECTION 308-
03A: Manual Transaxle/Transmission — T5OD 2003 Mustang Workshop Manual General Specifications
Item Specification
Lubricants and Sealants
Multi-
Purpose Grease
D0AZ- 19584- AA ESB-
M1C93- B Threadlock and Sealer
E0AZ-
19554- AA WSK-
M2G351- A5 Clear Silicone Rubber
D6AZ-
19562- AA ESB-
M4G92- A Pipe Sealant with Teflon®
D8AZ-
19554- A ESR-
M18P7-A MERCON® Multi-
Purpose ATF Transmission Fluid
XT -2-QDX Mercon®
Preload
Output shaft preload 0.0127 mm ( 0.0005 in) - 0.1016 mm ( 0.004 in)
Synchronizer
Synchronizer blocking ring to conical face runout 0.5 mm (0.02 in)
End Play
Countershaft cluster gear end play 0.0254 mm ( 0.001 in) -
0.127 mm ( 0.005 in) Output shaft end play 0.0127 mm ( 0.0005 in) - 0.1016 mm ( 0.004 in)
Torque Specifications Description Nm lb-
ft lb-
in Bolt retaining gearshift lever to extension housing 18 13 —
Screw retaining inner shift boot to floor pan 10 — 89
Bolt retaining gear shift lever to gear shift stub shaft 37 27 —
Bolt retaining OSS to case 10 — 89
Bolt retaining countershaft rear bearing retainer to case 21 15 —
Shift lever reverse pin 40 30 —
Reversing lamp switch 37 27 —
Bolt retaining case cover to case 12 9 —
Bolt retaining extension housing to case 54 40 —
Bolt retaining input shaft bearing retainer to case 21 15 —
Drain plug 23 17 —
Bolt retaining transmission to block 75 55 —
Bolt retaining engine plate to transmission 27 20 — Klj . 1 ba
22003 Mustang Workshop Manual
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Bolt retaining crossmember to frame 41 30 —
Bolt retaining crossmember to transmission support 58 43 —
Nut retaining dual converter Y-
pipe to exhaust manifold 40 30 —
Nut retaining dual converter Y-
pipe flange to muffler 35 26 —
Bolt retaining driveshaft centering yoke to pinion flange 112 83 — Klj . 2 ba
22003 Mustang Workshop Manual
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DESCRIPTION AND OPERATION
Manual Transmission
The T5OD 5-
speed transmission:
z fifth speed gear functions as an overdrive gear.
z forward gears are synchronized and helical cut.
z shift interlock system prevents the engagement of more than one gear. Transmission, Manual Five - Speed SECTION 308-
03A: Manual Transaxle/Transmission — T5OD 2003 Mustang Workshop Manual Klj . 1 ba
52003 Mustang Workshop Manual
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Item Part Number Description
1 E602162-S71 Bolt
2 N800037-S2 Bolt
3 87038-S91 O-
ring 4 7358 Main shift control shaft
5 7222 Case cover
6 74113-
S Plug
7 7230 Gear shifter fork 1-
2 shift 8 7L082 Gear shift fork insert Klj . 2 ba
52003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2308/S3B~us~en~ ...