FORD MUSTANG 2003 Workshop Manual

32. Install the identification tag and the bolts.
33. Install the split pin and the gearshift shaft bushing.
34. Using the special tools, measure the output shaft end play.
1. Place the transmission in a vertical position.
2. Install the special tool.
3. Push upward on the input shaft and record the dial indicator reading. Klj . 11 ba
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35.
CAUTION: Install the thickest shim closest to the front bearing cup to provide
support for the cup.
CAUTION: Although zero end play is the ideal, end play up to mm (0.002 in) is an
acceptable tolerance. Do not overload the bearings with a shim that is too thick as
damage may occur.
NOTE: Select a shim with a thickness equal to the dial indicator reading. This will provide zero
end play.
Rotate the transmission to the horizontal position and remove the input shaft bearing retainer.
Remove the bearing race and install the necessary shim(s).
36. CAUTION: Do not cover the notch in the input shaft bearing retainer with sealer.
Apply a 3.2- mm (1/8-inch) bead of silicone rubber to the sealing surface on the input shaft
bearing retainer.
37. Install the input shaft bearing retainer and the four bolts. Klj . 12 ba
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38. Apply a 3.2-
mm (1/8-inch) bead of silicone rubber to the sealing surface on the gearshift lever.
39. Install the gearshift lever.
40. Using the special tool, install the extension housing fluid seal.
41. Install the case plug.
42. NOTE: Before installing the transmission, the ball stud, clutch release lever and the input shaft
must be cleaned and lubricated with grease.
Install the clutch release hub and bearing and the clutch release lever. For additional
information, refer to Section 308 - 01 . Klj . 13 ba
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Klj . 14 ba
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INSTALLATION
Transmission
1. NOTE: Before installing the transmission, the ball stud, clutch release lever and the input shaft
must be cleaned and lubricated. Use Motorcraft Premium Long-Life Grease XG-1- C or XG-1-K
or equivalent meeting Ford specification ESA- M1C75-B.
To install, reverse the removal procedure. Refer to Transmission in this section.
z Check, and as necessary, fill the transmission with MERCON® Multi- Purpose ATF
Transmission Fluid XT -2-QDX or equivalent. The total fill capacity is 2.6L (2.8 qt).
SECTION 308-
03A: Manual Transaxle/Transmission — T5OD 2003 Mustang Workshop Manual Klj . 1 ba
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SPECIFICATIONS
SECTION 308-
03B: Manual Transaxle/Transmission — TR3650 2003 Mustang Workshop Manual General Specifications
Item Specification
Lubricants and Sealants
Premium Long-
Life Grease
XG -1-C, K or T ESA-
M1C75- B Threadlock and Sealer
E0AZ-
19554- AA WSK-
M2G351- A5 Black Silicone Rubber
D6AZ-
19562- BA ESB-
M4G92- A Pipe Sealant with Teflon®
D8AZ-
19554- A ESR-
M18P7- A Motorcraft MERCON® Multi-Purpose (ATF)
Transmission Fluid
XT -2-QDX MERCON®
Synchronizer
Synchronizer blocking ring to conical face runout 0.5 mm (0.02 in)
End Play
Input shaft end play 0.02286 mm (0.0009 in) -
0.0508 mm
(0.002 in) Countershaft cluster gear end play 0.0 mm (0.0 in) -
0.076 mm (0.003 in) Output shaft end play 0.0012 mm (0.0005 in) -
0.100 mm (0.004
in)
Torque Specifications Description Nm lb-
ft lb-
in Gearshift lever to extension housing bolt 23 13 —
Gear shift lever to gear shift stub shaft bolt 37 27 —
OSS to case bolt 10 — 89
Reverse idler gear bolt 27 20 —
Fifth/reverse lockout bolt 20 15 —
Clutch housing to transmission main case bolt 31 23 —
Extension housing to transmission main case bolt 31 23 —
Drain plug 23 17 —
Reversing lamp switch 37 27 —
Fill plug 17 13 —
Transmission to engine bolt 75 55 —
Engine plate to transmission bolt 27 20 —
Crossmember to frame bolt 41 30 — Klj . 1 ba
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Crossmember to transmission support bolt 58 43 —
Driveshaft flange to pinion flange bolt 112 83 — Klj . 2 ba
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DESCRIPTION AND OPERATION
Manual Transmission
The TR3650 five-
speed manual transmission features the following:
z The fifth speed gear functions as an overdrive gear.
z The forward gears are synchronized and helical cut.
z The reverse gear operates through a constant- mesh, fully synchronized system.
z The shift interlock system prevents the engagement of more than one gear.
z The countershaft is serviced as an assembly.
z An aluminum main case, extension housing and bell housing. Transmission Internal Components — Disassembled View SECTION 308-
03B: Manual Transaxle/Transmission — TR3650 2003 Mustang Workshop Manual Klj . 1 ba
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Item Part
Number Description
1 7052 Input shaft seal
2 7L172 Shim
3 7025 Input shaft front bearing and cup
4 7017 Input shaft
5 7025 Input shaft pocket bearing
6 — Input shaft thrust bearing
7 — Input shaft thrust washer Klj . 2 ba
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8 7064 Retaining ring
9 7124 Third/fourth gear synchronizer assembly
10 7107 Third/fourth gear synchronizer blocking ring
11 — Third/fourth gear synchronizer spring (part of
7124)
12 — Third/fourth gear synchronizer insert (part of
7124)
13 — Third/fourth gear synchronizer hub (part of 7124)
14 — Third/fourth gear synchronizer sleeve (part of
7124)
15 7B340 Third gear
16 7B369 Third gear needle bearing
17 — Third gear bushing
18 — Check ball
19 — Thrust washer
20 — Second gear needle bearing
21 7102 Second gear
22 7175 First/second gear synchronizer inner cone
23 7174 First/second gear synchronizer outer cone
24 7061 Output shaft
25 — Retaining ring
26 7124 First/second gear synchronizer assembly
27 7107 First/second gear synchronizer blocking ring
28 — First/second gear synchronizer spring (part of
7124)
29 — First/second gear synchronizer hub (part of 7124)
30 — First/second gear synchronizer insert (part of
7124)
31 — First/second gear synchronizer sleeve (part of
7124)
32 7127 First gear needle bearing
33 7100 First gear
34 — Reverse clutch cone
35 7124 Reverse gear synchronizer assembly
36 7107 Reverse gear synchronizer blocking ring
37 — Reverse gear synchronizer spring (part of 7124)
38 — Reverse gear synchronizer hub (part of 7124)
39 — Reverse gear synchronizer insert (part of 7124)
40 — Reverse gear synchronizer sleeve (part of 7124)
41 — Retaining ring
42 7N168 Reverse needle bearing
43 7C238 Reverse driven gear
44 — Reverse gear bushing Klj . 3 ba
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