FORD MUSTANG 2003 Workshop Manual

8. Install the second gear synchronizer thrust washer, the inner cone, the friction cone and the
second gear synchronizer blocking ring.
zAlign the blocking ring tabs with the second gear slots.
9. Install the first/second gear synchronizer assembly. Position the output shaft with the output end facing downward. Using the special tools, press the first/second gear synchronizer assembly
into place.
zInstall the synchronizer with the groove on the sleeve facing first gear.
z Stop press operation before keys engage the blocking ring slots. Lift and rotate the
second gear and the blocking ring until the keys are seated in the blocking ring. Klj . 9 ba
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10. Install the first gear synchronizer thrust washer, the inner cone, the friction cone and the first
gear synchronizer blocking ring.
11. Install a new snap ring. Klj . 10 ba
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12. Install the first gear needle bearing.
zApply petroleum jelly to the bearing.
13. Install first gear. zRotate the gear to align the gear slots with the inner cone tabs.
14. Install a new rear output shaft bearing.
15. Using the special tools, install the fifth driven gear. Klj . 11 ba
122003 Mustang Workshop Manual
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Klj . 12 ba
122003 Mustang Workshop Manual
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DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES
Countershaft
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) Remover/Installer, Bearing
Tube
308-
025 (T75L-7025- C) Installer, Output Shaft Rear
Bearing
308-401
Adapter for 303-
224 (Handle)
205- 153 (T80T-4000- W) Klj . 1 ba
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1. Remove the thrust washer. Item Part Number Description
1 7025 Countershaft front bearing
2 7113 Countershaft
3 — Countershaft rear bearing
4 — Thrust washer
5 — Sixth gear needle bearing
6 — Sixth gear
7 — Synchronizer blocking ring
8 — Spacer
9 — Snap ring
10 — Fifth/sixth synchronizer assembly
11 — Fifth gear
12 — Fifth gear needle bearing
13 — Countershaft extension
14 — Countershaft extension bearing Klj . 2 ba
82003 Mustang Workshop Manual
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2. Using the special tool and a press, remove the countershaft rear bearing.
3. Using the special tool and a press, remove the countershaft front bearing.
4. Place the special tool in a vise. Position the countershaft extension in the tool with the sixth
drive gear facing upward. Remove the fifth/sixth shift fork.
5. Remove the sixth drive gear.
6. Remove the sixth drive gear needle bearing. Klj . 3 ba
82003 Mustang Workshop Manual
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7. Remove the sixth drive gear synchronizer blocking ring.
8. Remove and discard the fifth/sixth synchronizer snap ring.
9. Using the special tool, press the fifth/sixth synchronizer and the fifth drive gear off the shaft.
10. Remove the fifth drive gear needle bearing. Klj . 4 ba
82003 Mustang Workshop Manual
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11. Using the special tool, remove the countershaft extension bearing.
12. Inspect the countershaft and countershaft extension.
zCheck the shaft surface for wear or damage. Install a new shaft as necessary.
z Check the gear teeth for wear, pitting, scoring, spalling or fractures. Install new
components as necessary.
13. Disassemble the fifth/sixth gear synchronizer assembly.
14. Inspect the fifth/sixth synchronizer. 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.
15. Inspect the fifth/sixth 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 Klj . 5 ba
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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.
16. Using the special tools, install the countershaft rear bearing.
17. Using the special tools, install the countershaft front bearing. Klj . 6 ba
82003 Mustang Workshop Manual
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