FORD MUSTANG 2003 Workshop Manual

Transmission Case and Shift Components — Disassembled View 45 — Selector gate
46 7025 Mainshaft rear bearing and cup
47 7K316 Mainshaft fifth gear
48 — Retaining ring
49 7H150 Output shaft speed (OSS) sensor
50 — Retaining ring
51 7L172 Shim
52 7025 Countershaft front bearing and cup
53 7113 Countershaft
54 7025 Countershaft rear bearing and cup
55 — Thrust bearing
56 7144 Countershaft fifth gear
57 — Countershaft fifth gear needle bearing
58 — Countershaft fifth gear bearing spacer
59 — Retaining ring
60 7124 Fifth gear synchronizer assembly
61 7107 Fifth gear synchronizer blocking ring
62 — Fifth gear synchronizer spring (part of 7124)
63 — Fifth gear synchronizer hub (part of 7124)
64 — Fifth gear synchronizer insert (part of 7124)
65 — Fifth gear synchronizer sleeve (part of 7124)
66 — Fifth gear clutch cone
67 — Retaining ring
68 — Reverse idler gear support
69 7140 Reverse idler gear shaft
70 7141 Reverse idler gear
71 7E169 Reverse idler gear needle bearing
72 — Reverse idler gear bearing spacer Klj . 4 ba
72003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2308/S3B~us~en~ ...

Item Part Number Description
1 7358 First/second shift rail
2 7239 First/second shift fork
3 7L082 Shift fork inserts
4 — First/second shift finger
5 7241 Third/fourth shift rail
6 7230 Third/fourth shift fork
7 7L082 Shift fork inserts
8 — Third/fourth shift finger
9 7242 Fifth/reverse shift rail
10 — Reverse gear shift fork
11 — Fifth gear shift fork
12 7L082 Shift fork inserts
13 — Shift arm bearing
14 — Spacer
15 — Shift arm selector inhibitor Klj . 5 ba
72003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2308/S3B~us~en~ ...

Transmission Identification
The transmission identification tag is located under the lower bolt that retains the extension housing to
the main case.
The five speed overdrive (TR3650) transmission is available for the Mustang 4.6L (2V).
Transmission Identification 16 7240 Main shift rail
17 7F018 Gearshift offset lever
18 — Spacer
19 — Bearing
20 7210 Gearshift lever
21 — Gearshift plate and spring
22 — Shipping seal
23 7052 Output shaft seal
24 — Extension housing bushing
25 7A039 Extension housing
26 7034 Vent
27 — Vehicle speed sensor (VSS)
28 — Fifth/reverse gear lockout
29 7L027 Magnet
30 7K201 Shift interlock plate
31 7005 Transmission main case
32 — Interlock pins
33 7A010 Drain plug
34 15520 Reverse lamp switch
35 — Detent plug
36 — Detent spring
37 — Detent
38 6392 Clutch housing
39 7B602 Ball stud
40 — Bearing
Part Klj . 6 ba
72003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2308/S3B~us~en~ ...

Item Number Description
1 — Transmission assembly number
2 — Build date code—
month 3 — Build date code—
day 4 — Build date code—
year 5 — Shift number
6 — Serial number
7 — Service repair code
8 — Identification number located on left lower side of
transmission case Klj . 7 ba
72003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2308/S3B~us~en~ ...

DIAGNOSIS AND TESTING
Manual Transmission
Refer to
Section 308 - 00 .
SECTION 308-
03B: Manual Transaxle/Transmission — TR3650 2003 Mustang Workshop Manual Klj . 1 ba
12003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2308/S3B~us~en~ ...

GENERAL PROCEDURES
Bearings —
Inspection
NOTE: If any of the following conditions exist, install a new bearing.
1. Inspect the bearing for a bent cage.
2. Inspect bearings for galling (metal smears on roller ends). zGalling is caused by overheating, poor lubrication or an overload situation.
z If galling is found, install a new bearing and inspect the seals.
3. Inspect the bearing for brinelling (surface indentations in the raceway).
4. Inspect bearing for cracked inner race.
SECTION 308-
03B: Manual Transaxle/Transmission — TR3650 2003 Mustang Workshop Manual Klj . 1 ba
32003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2308/S3B~us~en~ ...

5. Inspect the bearing and raceway for etching.
zIf etching is present, inspect the seals.
6. Inspect the bearing for heat discoloration (dark blue). zIf heat discoloration is evident, check the bearing and race for loss of temper. Draw a file
across the component. If the file cuts the metal, there is a loss of temper.
7. Inspect the bearing for fatigue spalling (metal flaking). Klj . 2 ba
32003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2308/S3B~us~en~ ...

Klj . 3 ba
32003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2308/S3B~us~en~ ...

IN-
VEHICLE REPAIR
Seal
Removal 1. With the vehicle in NEUTRAL, raise and support the vehicle. For additional information, refer to Section 100 - 02 .
2. CAUTION: Index- mark the driveshaft flange and pinion flange, and the driveshaft
slip yoke and transmission output shaft.
Remove the driveshaft. For additional information, refer to Section 205 - 01 .
3. Using the special tools, remove the extension housing fluid seal.
Installation 1. Using the special tool, install the extension housing fluid seal.
SECTION 308-
03B: Manual Transaxle/Transmission — TR3650 2003 Mustang Workshop Manual Special Tool(s)
Installer, Transmission
Extension Housing Oil Seal
308-
227 (T94P-7657- A) Slide Hammer
100-
001 (T50T-100- A) Remover, Bushing
307-
001 (TOOL- 1175-AC) or
Equivalent Klj . 1 ba
22003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2308/S3B~us~en~ ...

2.
CAUTION: Align the index marks.
Install the driveshaft. For additional information, refer to Section 205 - 01 .
3. Check the transmission fluid level, add fluid if necessary.
4. Lower the vehicle. Klj . 2 ba
22003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2308/S3B~us~en~ ...