manual transmission FORD MUSTANG 2003 Workshop Manual

1. Remove the special tool.
2. Using the special tools, remove torque converter.
3. Using the special tool, mount the transmission to the bench. 307-
309 (T94P-77001- BH) Retainer, Torque Converter
307-
346 (T97T-7902- A) Remover, Bearing Cup
308-
047 (T77F-1102- A) Klj . 2 ba
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4.
NOTE: If the transmission fluid pan gasket is not damaged, it may be reused.
Remove the transmission fluid pan and transmission fluid pan gasket. 1. Remove the bolts.
2. Remove the transmission fluid pan and transmission fluid pan to case gasket.
5. Clean the transmission fluid pan and pan magnet.
6. CAUTION: If installing a new filter, and grommet remains in the main control bore,
carefully use a small screwdriver to remove the grommet. Use care not to damage the
main control bore.
NOTE: If transmission is being repaired for a contamination- related failure, use a new filter and
seal. The filter may be reused if no excessive contamination is present. Remove the fluid filter and grommet. Klj . 3 ba
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9. Remove the digital transmission range (TR) sensor.
1. Remove the bolts.
2. Remove the digital TR sensor.
10. Remove the manual control valve detent lever spring. 1. Remove the bolt.
2. Remove the manual control valve detent lever spring.
11. Remove the 24 main control valve body bolts and the main control valve body.
12. Remove and discard the pump outlet screen. Klj . 5 ba
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13.
NOTE: Use a shop cloth to protect the transmission case surface.
Remove the manual lever shaft retaining pin.
14. Remove the manual lever shaft inner nut. zSlide the manual control lever shaft out of the case while removing the inner nut.
15. Remove the parking lever actuating rod. 1. Remove the manual valve detent.
2. Remove the parking lever actuating rod. Klj . 6 ba
162003 Mustang Workshop Manual
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26. Using the special tools, remove the extension housing seal.
27.
NOTE: These bolts have been coated with a sealant. High break torque may be required to
remove these bolts.
Remove the extension housing.
1. Remove the four bolts and two nuts.
2. Remove the extension housing and the extension housing gasket.
28. Remove the parking pawl. 1. Remove the parking pawl shaft.
2. Remove the parking pawl return spring.
3. Remove the parking pawl.
29. Rotate the transmission to the vertical position with the output shaft towards the floor.
30. CAUTION: Extreme care must be taken during transmission connector removal. Do
not use a hammer on the connector body.
Place a screwdriver on the flat portion of the connector and push the connector out through the
bottom of the case. Klj . 10 ba
162003 Mustang Workshop Manual
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DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES
Main Control Valve Body
Disassembly
Main Control Valve Body —
Disassembled View
SECTION 307-
01: Automatic Transaxle/Transmission 2003 Mustang Workshop Manual Item Part
Number Description
1 — Valve plug retainer (part of 7A100)
2 — Main pressure booster valve sleeve (part of
7A100)
3 — Main pressure booster valve (part of 7A100)
4 — Main pressure regulator valve spring (part of
7A100)
5 — Main regulator valve (part of 7A100) Klj . 1 ba
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Assembly
1. CAUTION: Before beginning assembly, carry out and inspect the following:
When building up subassemblies and assembling the transmission, ALWAYS use new
gaskets and seals.
All fasteners must be tightened to the torque specification indicated. In addition to
appearing in the section, the necessary torques can be found in the General
Specifications Chart.
When building up subassemblies, each component part should be lubricated with clean
transmission fluid. It is also good practice to lubricate the subassemblies as they are
installed in the case.
Needle bearings, thrust washers and seals should be lightly coated with petroleum jelly
during subassembly buildup or transmission assembly.
Many components and surfaces in the transmission are precision machined. Careful
handling during disassembly, cleaning, inspection and assembly can prevent
unnecessary damage to machined surfaces.
Install the valve body cover plate. 1. Position the valve body cover plate gasket and cover plate.
2. Install the two guide pin bolts.
3. Install the bolts.
2. Tighten the bolts in the sequence shown. Klj . 5 ba
82003 Mustang Workshop Manual
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DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES
Pump and Intermediate Clutch Piston
Pump and Intermediate Clutch Piston —
Disassembled View
SECTION 307-
01: Automatic Transaxle/Transmission 2003 Mustang Workshop Manual Special Tool(s)
Installer, Front Pump Fluid
Seal
307-
014 (T63L-77837- A) Protector, Piston Seal
307-
339 (T95L-77005- A) Item Part Number Description
1 7902 Torque converter
2 7A248 Front pump O-
ring 3 N605789-S101 Bolt
4 — Pump body assembly
5 N605787-S1000 Front pump support bolt
6 7D014 No. 1 pump support thrust washer
7 7D020 Reverse clutch cylinder seal
8 7D019 Forward clutch cylinder seal
9 7E005 Intermediate clutch piston
10 7F224 Intermediate clutch piston outer seal Klj . 1 ba
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4. Using the special tool, install the intermediate clutch piston.
1. Position the intermediate clutch piston and the special tool onto the pump body.
2. Push the intermediate clutch piston to the bottom of the pump body bore, exerting even pressure and remove the special tool.
5. CAUTION: The piston bleed hole must be located at 12 o'clock position (towards
the top of the transmission). Shift problems may occur if installed incorrectly.
NOTE: The piston bleed hole is the only round hole in the pump body.
Locate the piston bleed hole.
6. Install by snapping the spring retainer assembly on pump body. Klj . 5 ba
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DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES
Intermediate One-
Way Clutch
Intermediate Clutch Cylinder Disassembled View
Disassembly 1. NOTE: One tab that locks the reverse clutch drum into the reverse sun shell may be removed.
This is done for balancing purposes.
Remove the intermediate one- way clutch.
1. Remove the snap ring.
2. Remove the intermediate one- way clutch.
Assembly 1. NOTE: The intermediate one- way clutch must rotate counterclockwise when installed on the
reverse clutch drum and will make a ratchet sound.
Install the intermediate one- way clutch.
1. Install the intermediate one- way clutch.
2. Install the snap ring.
SECTION 307-
01: Automatic Transaxle/Transmission 2003 Mustang Workshop Manual Item Part Number Description
1 391267-
S Retaining ring
2 7A089 Intermediate one-
way clutch assembly 3 7D044 Reverse clutch drum Klj . 1 ba
22003 Mustang Workshop Manual
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