FORD MUSTANG 2003 Workshop Manual

17. Remove the reverse gear thrust washer.
18. Remove the reverse gear.
zInspect reverse gear for wear or damage. Install a new gear as necessary.
19. Remove the wave washer from the reverse gear.
20. Remove the reverse gear needle bearing and the reverse gear synchronizer blocking ring. zInspect the needle bearing for wear or damage. Install a new bearing as necessary. Klj . 6 ba
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21. Remove the reverse gear synchronizer snap ring.
22. Remove the reverse shift fork snap ring.
23. Remove the reverse shift fork, the reverse synchronizer and the thrust washer as an assembly.
24. Inspect the synchronizer for the following:
zCheck for worn, nicked or broken teeth. Install a new synchronizer as necessary.
z Check keys for wear or distortion. Check the springs for distortion. Install a new
synchronizer as necessary.
25. Inspect the synchronizer blocking ring for the following: zCheck for wear or damage. Install a new synchronizer blocking ring as necessary.
z Check the clearance between the synchronizer blocking ring and the gear.
„Position the blocking ring onto the gear. Make sure the correct blocking ring is
measured with the correct gear and that the blocking ring is fully seated on the
gear.
„ Insert a feeler gauge and measure the clearance, while applying pressure and
rotating the blocking ring. The measurement should be the same around the entire
circumference. If the clearance is less than 0.75 mm (0.030 in), install new Klj . 7 ba
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blocking ring.
26. Using the special tools, remove the fifth/sixth driven gear.
27. Remove the fifth/sixth shift fork snap ring.
28. Rotate the transmission to the horizontal position, then remove the countershaft extension as an assembly.
29. Remove the shift detent cover. Klj . 8 ba
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30. Remove the shift detent assembly.
31. Using a 5/32-
inch drift and a hammer, drive the roll pin downward.
32. Remove nine of the adapter- to-transmission case bolts.
33. NOTE: Rotate the transmission to a vertical position.
Remove the shift lever guide bolts. Klj . 9 ba
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34. Remove the two remaining adapter-
to-transmission case bolts, then remove the transmission
case and the front offset lever.
zSlide the transmission case upward, off the mainshaft and shift rails. Hold the offset lever
against the guide plate to prevent the release of the dent ball and spring.
35. Remove the dent ball, spring and roll pin from the front offset lever.
36. Rotate the fifth/sixth and reverse shift levers from the shift interlock plate, then remove the fifth/sixth and reverse shift rail assembly. Klj . 10 ba
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37. Lift up the mainshaft, then remove the countershaft.
38. Remove the mainshaft and shift rail as an assembly. Separate the shift rail assembly from the
mainshaft on the work bench.
39. Remove the input shaft and fourth gear synchronizer blocking ring.
40. Remove the countershaft bearing cup and the countershaft shim. zInspect the cup for wear or damage. Install a new cup and bearing as necessary.
z Inspect the cup bore for wear, scratches or grooves. Install a new transmission adapter
plate as necessary. Klj . 11 ba
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41. Remove the input shaft bearing cup and input shaft shim.
zInspect the cup for wear or damage. Install a new cup and bearing as necessary.
z Inspect the cup bore for wear, scratches or grooves. Install a new transmission adapter
plate as necessary.
42. Remove and discard the input shaft seal.
43. WARNING: Make sure protective eye wear is in place.
Clean the transmission adapter plate with solvent and dry with compressed air. Inspect the
adapter plate for cracks. Clean and check the sealing surface for nicks or scratches. zIf the adapter plate is cracked, install a new plate. If the sealing surface has nicks or
scratches, use a soft stone or crocus cloth to remove. Klj . 12 ba
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Klj . 13 ba
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DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES
Input Shaft and Bearing
Disassembly and Assembly
SECTION 308-
03C: Manual Transaxle/Transmission — T56 2003 Mustang Workshop Manual Special Tool(s)
Plate, Bearing/Oil Seal
205-
090 (T75L-1165- B) Puller, Bearing
205-
D064 (D84L-1123- A) Installer, Drive Pinion Bearing
Cone
205-
004 (T53T-4621- B) Adapter Set, Step Plate
205-
DS011 (D80L-630- A) Universal Puller Set
303-
DS005 (D80L-100- A) Klj . 1 ba
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1.
CAUTION: Use a vise with brass jaws or wood blocks.
Secure the input shaft in a vise. Using the special tools and a slide hammer, remove the input
shaft bearing cup. zInspect the cup for wear or damage. Install a new bearing cup and bearing as necessary.
2. Using the special tool and a press, remove the input shaft front bearing. Item Part Number Description
1 7025 Input shaft bearing
2 7017 Input shaft
3 — Input shaft bearing cup Klj . 2 ba
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