FORD MUSTANG 2003 Workshop Manual

36. Lift the mainshaft 13 mm (0.50 in) upward, tilt the countershaft outward and remove the
countershaft.
37. Remove the mainshaft and shift assembly. Klj . 11 ba
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38. Remove the input shaft. For input shaft disassembly, refer to
Input Shaft and Bearing in this
section.
39. Remove the shift rails and shift forks from the main shaft. For gearshift rail and fork disassembly, refer to Gearshift Rail and Fork in this section.
40. Remove the reverse idler shaft bolt. Remove and discard the seal. Klj . 12 ba
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41. Remove the reverse idler gear assembly.
42. Remove the reverse idler gear from the shaft.
zInspect the gear for wear or damage. Install a new gear as necessary.
43. Remove the reverse idler gear bearing. zThe reverse idler gear is three separate pieces: bearing, spacer, bearing.
z Inspect the bearing for wear or damage. Install new bearings as necessary.
44. Disassemble the clutch housing. 1. Remove the countershaft bearing cup and shim.
2. Remove the input shaft bearing cup and shim.
3. Remove the input shaft seal.
„Carefully pry out from the inside of the case. Klj . 13 ba
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45. Remove the rear countershaft bearing.
46. Remove the rear countershaft bearing cup and the rear output shaft bearing cup. Klj . 14 ba
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Klj . 15 ba
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DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES
Input Shaft and Bearing
Disassembly and Assembly
1. Disassemble the input shaft. 1. Remove the third/fourth synchronizer blocking ring.
2. Remove the input shaft thrust washer.
3. Remove the input shaft thrust bearing.
4. Remove the input shaft pocket bearing.
z Inspect all components for wear or damage. Install new components as necessary.
SECTION 308-
03B: Manual Transaxle/Transmission — TR3650 2003 Mustang Workshop Manual Special Tool(s)
Remover, Driver Pinion
Bearing Cone
205-
D002 (D79L-4621- A) or
equivalent Installer, Drive Pinion Bearing
Cone
205-
011 (T57L-4621- B) Remover/Installer, Bearing
Tube
308-
024 (T75L-7025- B) Klj . 1 ba
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2. Using the special tool and a press, remove the input shaft front bearing assembly. Discard the
bearing.
3. Inspect the input shaft and bearings for wear or damage. Install new components as necessary.
4. Using the special tools and a press, install the new input shaft front bearing.
5. Install the input shaft pocket bearing, the washer, input shaft bearing and the third/fourth synchronizer blocking ring.
zLubricate the bearing and bearing race with petroleum jelly. Klj . 2 ba
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Klj . 3 ba
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DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES
Output Shaft
Disassembly
1. Remove the retaining ring above fifth gear.
2. CAUTION: Hand tighten the special tool to prevent gear damage.
CAUTION: Support the output shaft while using the press to prevent damage to the
shaft or gears.
Using the special tool, press fifth gear, the spacer, the output shaft bearing and reverse gear
from the output shaft.
zDiscard the output shaft bearing.
SECTION 308-
03B: Manual Transaxle/Transmission — TR3650 2003 Mustang Workshop Manual Special Tool(s)
Remover, Drive Pinion Bearing
Cone
205-
D002 (D79L-4621- A) or
equivalent Installer, Drive Pinion Bearing
Cone
205-
011 (T57L-4621- B) Klj . 1 ba
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3. Remove reverse gear needle bearing.
zInspect the needle bearing for wear or damage. Install a new needle bearing as
necessary.
4. Remove the check ball and the blocking ring. zInspect the blocking ring for wear or damage. Install new blocking rings as necessary.
5. NOTE: Install the special tool with the flat side facing first gear. Klj . 2 ba
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