FORD MUSTANG 2003 Workshop Manual

DISASSEMBLY
Transmission
Disassembly
NOTE:
During disassembly, if any roll pins, retaining rings or bearings are removed, install new
components. Install bearings and bearing cups as a set.
1. Remove the clutch release hub and bearing and the clutch release lever. For additional information, refer to Section 308 - 01 .
2. WARNING: Make sure protective eye wear is in place.
Clean the transmission exterior with solvent and dry with compressed air. During disassembly,
clean all components with solvent and dry with compressed air.
3. Attach the transmission to the special tool.
SECTION 308-
03B: Manual Transaxle/Transmission — TR3650 2003 Mustang Workshop Manual Special Tool(s)
Remover, Mainshaft Bearing
308-
058 (T77J-7025- H) Screw, Bearing Removal tube
308-
092 (T84T-7025- B) Holding Fixture, Transmission
307-
003 (T57L- 500-B) Remover, Bushing
307-
001 (TOOL- 1175-AC) Remover/Installer, Bearing
Tube
308-
024 (T75L-7025- B) Klj . 1 ba
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4.
NOTE: Position a drain pan under the transmission.
Remove the case plug, then rotate the transmission to a horizontal position.
5. Using the special tools, remove the extension housing fluid seal.
6. NOTE: Rotate the transmission to a vertical position. NOTE: Position the gearshift lever in NEUTRAL. Klj . 2 ba
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Remove the bolts and the gearshift lever.
7. Inspect the gearshift offset lever insert and O- ring for wear or damage. Install a new insert as
necessary.
8. NOTE: If necessary, remove the spring and plate for disassembly.
Remove the bolts and the shift spring and plate.
9. Using a 5/32- inch drift and a hammer, drive the split pin downward. Klj . 3 ba
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10. Remove the 12 bolts.
11. Using a flat-
blade screwdriver, separate the extension housing, then remove the gearshift offset
lever from the transmission case.
zRemove and discard the split pin from the gearshift offset lever during removal.
12. Remove the fifth/reverse gear lockout bolt.
13. Remove the fifth/reverse gear lockout. Klj . 4 ba
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14. Remove the shipping seal.
15. Remove the OSS sensor tone wheel retaining ring.
16. Using the special tools, remove the OSS sensor tone wheel.
17. Remove the OSS sensor tone wheel check ball. Klj . 5 ba
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18. Remove and discard the fifth gear synchronizer retaining ring.
19. Using a 5/32-
inch drift and a hammer, remove and discard the pin from the fifth gear shift fork.
20. Remove the fifth gear shift fork, synchronizer assembly, synchronizer cone and the fifth gear as an assembly. 21. Remove the fifth gear clutch cone. Klj . 6 ba
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22. Remove the fifth gear synchronizer blocking ring.
zInspect the blocking ring for wear or damage. Install new blocking rings as necessary.
23. Remove the fifth gear synchronizer sleeve from the synchronizer hub.
24. Remove the synchronizer inserts and the springs.
25. Remove the needle bearings and the thrust washer. zThe fifth gear needle bearing is three separate pieces: bearing, spacer, bearing Klj . 7 ba
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z
Inspect the needle bearing for wear or damage. Install new bearings as necessary.
26. Remove the check ball.
27. Using a 5/32- inch drift and a hammer, drive out the split pin, then remove the third/fourth shift
finger. Discard the split pin.
28. Using a 5/32- inch drift and a hammer, drive out the split pin, then remove the first/second shift
finger. Discard the split pin. Klj . 8 ba
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29. Remove the main shift rail and the plastic spacer.
30. Remove the bolts and the shift interlock plate.
31. Using a magnet, remove the interlock pins.
zOne lock pin in the center rail, two between the rails.
32. Remove the three detent plugs, springs and the detents. Klj . 9 ba
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33.
CAUTION: Do not remove all the bolts while in the horizontal position.
Remove the bolts. zRotate the transmission to a horizontal position. Remove 12 bolts, leaving two opposing
bolts in. Rotate the transmission to a vertical position, then remove the remaining two
bolts.
34. Carefully pry the clutch housing from the transmission main case. 35. Remove the transmission main case from the clutch housing. Klj . 10 ba
152003 Mustang Workshop Manual
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