FORD MUSTANG 2003 Workshop Manual

3. Inspect the input shaft and bearing for wear or damage. Install new components as necessary.
4. Using the special tools and a press, install a new input shaft bearing.
zLubricate the bearing with petroleum jelly.
5. Using a suitable driver and the press, install the input shaft bearing cup. zLubricate the bearing cup with petroleum jelly. Klj . 3 ba
42003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2308/S3B~us~en~ ...

Klj . 4 ba
42003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2308/S3B~us~en~ ...

DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES
Output Shaft
Disassembly
SECTION 308-
03C: Manual Transaxle/Transmission — T56 2003 Mustang Workshop Manual Special Tool(s)
Puller, Bearing
205-
D064 (D84L-1123- A) Adapter for 303-
224 (Handle)
205- 153 (T80T-4000- W) Installer, Output Shaft Rear
Bearing
308-401
Remover/Installer, Bearing
Tube
308-
025 (T75L-7025- C) Item Part Number Description
1 7025 Output shaft front bearing Klj . 1 ba
122003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2308/S3B~us~en~ ...

1.
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 and a press, remove first gear, the output shaft rear bearing and the fifth
driven gear.
zDiscard the output shaft bearing.
z Inspect the gear for wear or damage. Install a new gear as necessary. 2 — Snap ring
3 7124 Third/fourth synchronizer assembly
4 7107 Third/fourth synchronizer blocking ring
5 7B340 Third gear
6 — Spacer
7 — Third gear needle bearing
8 7061 Output shaft
9 — Second gear needle bearing
10 7102 Second gear
11 — Thrust washer
12 — Synchronizer inner cone
13 — Synchronizer friction cone
14 7107 Second gear synchronizer blocking ring
15 7124 First/second synchronizer assembly
16 — Snap ring
17 — First gear needle bearing
18 7100 First gear
19 — Output shaft rear bearing
20 — Fifth driven gear Klj . 2 ba
122003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2308/S3B~us~en~ ...

2. Remove the first gear needle bearing.
zInspect the needle bearing for wear or damage. Install a new needle bearing as
necessary.
3. Remove and discard the snap ring.
4. Remove the first gear synchronizer thrust washer, the inner cone, the friction cone and the first gear synchronizer blocking ring.
zInspect all components for wear or damage. Install new components as necessary. Klj . 3 ba
122003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2308/S3B~us~en~ ...

5. Remove the synchronizer spring, then remove the synchronizer sleeve.
6.
NOTE: Install the special tool behind second gear with the flat side of the tool facing second
gear.
Using the special tool, remove the second gear, the second gear synchronizer thrust washer,
the inner cone, the friction cone, the second gear synchronizer blocking ring and the
synchronizer hub.
zInspect the gear for wear or damage. Install a new gear as necessary.
z Inspect the all synchronizer components for wear or damage. Install a new components
as necessary. Klj . 4 ba
122003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2308/S3B~us~en~ ...

7. Remove the second gear needle bearing.
zInspect the needle bearing for wear or damage. Install a new needle bearing as
necessary.
8. NOTE: Reposition the output shaft on the press with the input shaft end facing upward.
Remove and discard the snap ring, then using the special tool, remove the third/fourth gear
synchronizer assembly, the third gear synchronizer blocking ring and the third gear. zInspect the gear for broken or cracked teeth. Install a new gear as necessary. Klj . 5 ba
122003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2308/S3B~us~en~ ...

9. Remove the third gear needle bearing.
zInspect the needle bearing for wear or damage. Install a new needle bearing as
necessary.
10. NOTE: Install the special tool with the flat side facing the bearing.
Using the special tool, press the output shaft front bearing from the output shaft.
11. Inspect the synchronizers. zCheck for worn, nicked or broken teeth. Install a new synchronizer as necessary.
z Check keys for wear or distortion. Install a new synchronizer as necessary.
z Check springs for distortion. Install a new synchronizer as necessary.
12. Inspect the synchronizer blocking rings. zCheck for wear or damage. Install new synchronizer blocking rings 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 0.38 mm (0.015 in), install new
blocking rings. Klj . 6 ba
122003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2308/S3B~us~en~ ...

13. Inspect the output shaft for scoring or worn or damaged splines. Install a new output shaft as
necessary.
Assembly
1. Lubricate all components with the recommended transmission fluid when reassembling.
2. Using the special tools, press the output shaft front bearing on the output shaft.
3. Install the third gear bearing. zApply petroleum jelly to the bearing.
4. Install third gear, the third gear synchronizer blocking ring and the third/fourth gear synchronizer assembly. Position the output shaft with the output end facing upward. Using the special tool,
press the third/fourth gear synchronizer assembly into place.
zInstall the synchronizer body with the groove facing third gear.
z Stop press operation before keys engage the blocking ring slots. Lift and rotate the third
gear and the blocking ring until the keys are seated in the blocking ring. Klj . 7 ba
122003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2308/S3B~us~en~ ...

5. Install a new snap ring.
6. Install the second gear needle bearing.
zApply petroleum jelly to the bearing.
7. Install second gear. Klj . 8 ba
122003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2308/S3B~us~en~ ...