FORD MUSTANG 2003 Workshop Manual

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
102003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2308/S3B~us~en~ ...

NOTE:
Align the slot in the synchronizer blocking ring with the tab on the first and second
synchronizer.
Install the first speed synchronizer blocking ring and the inner and outer cones as an assembly.
10. Install the first and second speed synchronizer hub ball.
11. NOTE: Align the notch in the first gear bearing spacer with the first and second speed
synchronizer ball.
Install the first gear bearing spacer and the first gear bearing.
12. NOTE: Align the slots on the synchronizer blocking ring with the slots on the first gear.
Install the first gear. Klj . 7 ba
102003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2308/S3B~us~en~ ...

13. Install the output shaft rear bearing.
14. Lubricate the splines of the fifth speed driven gear with petroleum jelly.
15.
CAUTION: Align the output shaft splines and the splines of the fifth speed driven
gear or damage will occur.
Position the fifth speed driven gear on the output shaft. Using a press and a capped length of
pipe 31.7 mm (1.26 in) inside diameter X 356 mm (14.24 in) long, install the fifth speed driven
gear.
16. Install the snap ring. Klj . 8 ba
102003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2308/S3B~us~en~ ...

17. Install the third speed gear bearing spacer and the third speed bearing.
18.
CAUTION: Before pressing the components together, verify that the synchronizer
hub faces the short end of the output shaft. Hold the third gear against the synchronizer
to maintain the synchronizer blocking ring alignment.
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.
Using a 1- 1/2 inch deep well socket and a press, install the third gear, the third speed
synchronizer blocking ring, and the third/fourth gear synchronizer assembly. Klj . 9 ba
102003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2308/S3B~us~en~ ...

Klj . 10 ba
102003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2308/S3B~us~en~ ...

DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES
Countershaft Bearing
Disassembly SECTION 308-
03A: Manual Transaxle/Transmission — T5OD 2003 Mustang Workshop Manual Special Tool(s)
Bearing Replacer
308-
061 (T77J-7025- L) Front Bearing Replacer
308-
062 (T77J-7025- M) Mainshaft Front Bearing
Replacer
308-
081 (T82T-7003- DH) Pinion Bearing Cone Remover
205-
D002 (D79L-4621- A) or
Equivalent Pinion Bearing Cone Replacer
205-
011 (T57L-4621- B) Remover and Replacer Tube
308-
024 (T75L-7025- B) Remover and Replacer Tube
308-
052 (T77J-7025- B) Klj . 1 ba
32003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2308/S3B~us~en~ ...

1. Using the special tool and a press, remove the countershaft bearing assembly (7F431).
2.
CAUTION: Failure to correctly support the case (7005) during bearing race removal
will result in permanent distortion of the case.
NOTE: Remove the front countershaft bearing race only if damaged or worn.
Using the special tools and a press, remove the bearing race and the countershaft front bearing
seal (7693).
Assembly
NOTE: Position the countershaft in the transmission case before installing the rear countershaft
bearing.
1. Install the countershaft front bearing seal on the bearing race.
2. Coat the outside diameter of the bearing race with sealer. zUse Threadlock and Sealer E0AZ-19554- AA or equivalent meeting Ford specification WSK - M2G351 - 5A. Klj . 2 ba
32003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2308/S3B~us~en~ ...

3.
CAUTION: Failure to correctly support the case during bearing race installation will
result in permanent distortion of the case.
Using the special tools and a press, install the bearing race.
4. Using the special tool and a press, install the front countershaft bearing. Klj . 3 ba
32003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2308/S3B~us~en~ ...

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
22003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2308/S3B~us~en~ ...

positioned over the hub inserts.
2. CAUTION: Match the alignment marks made during disassembly. The sleeve and
the hub have an extremely close fit. Hold the sleeve and hub square to prevent jamming.
Do not force the sleeve onto the hub.
On the third/fourth speed synchronizer and the fifth speed synchronizer, install the sliding
sleeve. Klj . 2 ba
22003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2308/S3B~us~en~ ...