FORD MUSTANG 2003 Workshop Manual

18. Using the special tools, install the countershaft extension bearing.
19. To assemble, reverse the disassembly procedure.
zAssemble the synchronizer assembly before installing. Klj . 7 ba
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DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES
Synchronizers
Disassembly and Assembly
NOTE:
This procedure applies to all synchronizer assemblies.
1. NOTE: Synchronizer components are not interchangeable. During disassembly, mark each
individual synchronizer for assembly. Synchronizer hubs and sleeves are a selected assembly
and should be kept together as originally assembled. Blocking rings are not interchangeable, do
not mix.
Scribe an alignment mark on the sliding sleeve and the hub for assembly reference.
2. Using a screwdriver, remove the spring. Turn the synchronizer over and remove the second spring. Remove the sliding sleeve and the synchronizer struts from the hub.
3. CAUTION: Match the alignment marks made during disassembly. The sleeve and
the hub have an extremely close fit. Hold the sleeve and hub square to prevent jamming.
Do not force the sleeve onto the hub.
Assemble the synchronizer as follows:
zPosition the synchronizer sleeve on the hub. Make sure to align key openings in the hub
with the synchronizer sleeve.
z Install the keys with the slots facing the hub.
z Install the spring. Locate the tang to one of the key slots and position into place. Install
the second spring. Locate the spring tang on the same key but position in the opposite
direction.
SECTION 308-
03C: Manual Transaxle/Transmission — T56 2003 Mustang Workshop Manual Klj . 1 ba
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DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES
Gearshift Rail and Fork
Disassembly and Assembly
1. Disassemble the first/second and third/fourth shift rail as follows: zRotate the interlock plate until it is opposite of the shift links.
z Slide off the third/fourth shift fork and shift link. Separate the link from the fork.
z Slide off the first/second shift fork and shift link. Separate the link from the fork.
SECTION 308-
03C: Manual Transaxle/Transmission — T56 2003 Mustang Workshop Manual Item Part Number Description
1 — First/second shift fork pad
2 — First/second shift fork
3 — Interlock plate
4 — Shift link
5 — First/second, third/fourth shift rail
6 — Gear select solenoid lever
7 — Roll pin
8 — Selector pin
9 — Roll pin
10 — Shift link
11 — Third/fourth shift fork pad
12 — Third/fourth shift fork
13 — Shift rail collar
14 — Roll pin
15 — Fifth/sixth shift rail
16 — Roll pin
17 — Fifth/sixth shift rail lever
18 — Reverse shift rail lever Klj . 1 ba
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z
Remove the interlock plate.
z Using a 5/32- inch drift and a hammer, remove and discard the roll pins. Slide the gear
select solenoid lever and the selector pin from the shift rail.
2. Disassemble the fifth/sixth and reverse shift rail as follows: zUsing a 5/32- inch drift and a hammer, remove and discard the roll pins. Slide the collar
and the reverse shift lever from the shift rail.
z Slide off the fifth/sixth shift lever and shift link.
3. Inspect the shift rail components. zCheck the rails, shift forks, shift levers and shift links for wear or damage. Install new
components as necessary.
z Check the shift fork pads for wear. Install new pads as necessary.
4. To assemble, reverse the disassembly procedure. zInstall new roll pins. Klj . 2 ba
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DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES
Extension Housing
Disassembly and Assembly
SECTION 308-
03C: Manual Transaxle/Transmission — T56 2003 Mustang Workshop Manual Special Tool(s)
Installer, Bearing Cup
204-
039 (T77F-1217- B) Adapter for 303-
224 (Handle)
205- 153 (T80T-4000- W) Klj . 1 ba
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Item Part Number Description
1 — Countershaft extension bearing cup
2 — Countershaft extension bearing shim
3 — Fluid funnel
4 — Case plug
5 — Reverse idler shaft bracket
6 — Reverse idler gear thrust washer
7 7141 Reverse idler gear
8 — Reverse idler gear needle bearing
9 7140 Reverse idler gear shaft
10 7052 Extension housing seal
11 — Snap ring
12 — Mainshaft bearing cup
13 — Output shaft speed (OSS) sensor
14 — Reverse lockout solenoid
15 — O-
ring Klj . 2 ba
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1. Remove the bolt and the output shaft speed (OSS) sensor.
2. Remove the bolt and the reverse lockout solenoid.
3. Remove the bolts and the reverse idler shaft bracket.
4. Remove the reverse idler gear thrust washer. 16 7A039 Extension housing Klj . 3 ba
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