FORD MUSTANG 2003 Workshop Manual

Using the special tools, press the bearing spacer, the reverse gear synchronizer cone and first
gear from the output shaft.
6. Remove the first gear needle bearing. zInspect the needle bearing for wear or damage. Install a new needle bearing as
necessary.
7. Remove the first gear synchronizer inner cone, the first gear synchronizer outer cone and the first gear synchronizer blocking ring.
zInspect all components for wear or damage. Install new components as necessary. Klj . 3 ba
172003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2308/S3B~us~en~ ...

8.
NOTE: Reposition the output shaft on the press with the input shaft end facing upward.
Remove and discard the retaining ring.
9. Remove the third/fourth synchronizer hub.
10. Remove the third/fourth blocking ring.
11. Remove the third gear. zInspect the gear for wear or damage. Install a new gear as necessary. Klj . 4 ba
172003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2308/S3B~us~en~ ...

12. Remove the third gear needle bearing.
zInspect the needle bearing for wear or damage. Install a new needle bearing as
necessary.
13. NOTE: Install the special tool behind second gear with the flat side of the tool facing second
gear.
Using the special tool, remove the spacer, second gear thrust washer and second gear.
zInspect the gear for wear or damage. Install a new gear as necessary.
14. Remove the check ball and second gear needle bearing. zInspect the needle bearing for wear or damage. Install a new needle bearing as
necessary.
15. Remove the second gear synchronizer inner cone, second gear synchronizer outer cone and the second gear synchronizer blocking ring.
zInspect all components for wear or damage. Install new components as necessary. Klj . 5 ba
172003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2308/S3B~us~en~ ...

16. Remove the snap ring, then using the special tool, press off the first/second gear synchronizer.
Assembly 1. Carry out the following before reassembling: zInspect the gears for broken or cracked teeth. Check for unusual wear patterns.
z Inspect the thrust washers for face wear, cracks, scoring and for signs of heat damage.
z Inspect the bearings, bearing cups and the synchronizers for wear or damage.
z Inspect the output shaft for scoring or worn or damaged splines. Install new components
as necessary.
2. Lubricate all components with the recommended transmission fluid when reassembling.
3. NOTE: Position the output shaft with the output end facing upward.
NOTE: Install the synchronizer assembly with the deeper center flange of the synchronizer hub
facing toward the rear of the output shaft.
Install the first/second synchronizer assembly on the output shaft, then install a new retaining
ring.
zIt may be necessary to press the hub into position on the shaft. Klj . 6 ba
172003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2308/S3B~us~en~ ...

4. Install the first gear synchronizer blocking ring.
zAlign the blocking ring tabs with the synchronizer assembly.
5. Install the outer first gear synchronizer cone.
6. Install the inner first gear synchronizer cone. Rotate the inner cone till it is seated. Klj . 7 ba
172003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2308/S3B~us~en~ ...

7. Install the first gear needle bearing.
zApply petroleum jelly to the bearing.
8. Install first gear. zRotate the gear to align the gear slots with the inner cone tabs.
9. Install the reverse synchronizer cone. Klj . 8 ba
172003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2308/S3B~us~en~ ...

10. Install the reverse gear blocking ring.
11. Using the special tools, install the reverse gear bearing spacer.
12. Install reverse gear needle bearing.
zApply petroleum jelly to the bearing. Klj . 9 ba
172003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2308/S3B~us~en~ ...

13. Install reverse gear.
zRotate the gear to align the gear slots with the inner cone tabs.
14. Install the check ball. zUse petroleum jelly to hold the check ball in place.
15. Install the thrust washer. Be sure to align the slot in the washer with the check ball. Klj . 10 ba
172003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2308/S3B~us~en~ ...

16. Install a new rear output shaft bearing, then fifth gear. Using the special tool, press both the
bearing and gear into place.
17. Reposition the output shaft with the input end facing upward.
18. Install the second gear synchronizer blocking ring. Rotate the blocking ring until seated.
19. Install the second gear synchronizer outer cone and the second gear synchronizer inner cone.
20. Install the second gear bearing. Klj . 11 ba
172003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2308/S3B~us~en~ ...

z
Apply petroleum jelly to the bearing.
21. Install second gear. zRotate the gear to align the gear slots with the inner cone tabs.
22. Install the check ball. zUse petroleum jelly to hold the check ball in place. Klj . 12 ba
172003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2308/S3B~us~en~ ...