manual transmission FORD MUSTANG 2003 Workshop Manual

Install the output shaft and output shaft ring gear.
5. Install the No. 8 bearing.
6. Install the direct clutch.
7. NOTE: The reverse band support retaining ring is used for assembly purposes during
production. The reverse band support retaining ring is not required during assembly and it will
not affect the operation of the transmission.
Install the reverse band support retaining ring. Klj . 4 ba
252003 Mustang Workshop Manual
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23.
NOTE: Before assembly, soak the new clutch discs in clean automatic transmission fluid for 15
minutes.
Install the intermediate clutch pack and selective steel plate.
24. Using the special tool, check the intermediate clutch clearance. 1. Position the special tool on the pump case mounting surface.
2. Maintaining downward pressure, use a depth micrometer to measure and verify intermediate clutch clearance is within specification.
If the intermediate clutch is not within specification, install a correct selective plate.
25. Install the intermediate anti- rattle clip, if equipped. Selective Steel Plates
Specification
1.80-
1.70 mm (0.071- 0.067 inch) 2.05-
1.95 mm (0.081- 0.077 inch) 2.31-
2.20 mm (0.091- 0.087 inch) 2.56-
2.46 mm (0.101- 0.097 inch) Klj . 9 ba
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32. Rotate the transmission to the horizontal position.
33. Install the parking pawl.
1. Position the parking pawl return spring.
2. Position the parking pawl.
3. Install the parking pawl shaft.
34. Install a new extension housing gasket and the extension housing. 1. Position the extension housing.
2. Install the four bolts and two nuts.
35. Using the special tool, install a new extension housing seal. Klj . 12 ba
252003 Mustang Workshop Manual
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36. Install the output shaft speed (OSS) sensor.
1. Position the OSS sensor.
2. Install the bolt.
37. Using the special tool, install the manual control lever seal.
38. NOTE: Lubricate the electronic pressure control (EPC) solenoid O- rings with clean automatic
transmission fluid.
Install the EPC solenoid.
1. Install the EPC solenoid.
2. Install the EPC solenoid bracket and bolt. Klj . 13 ba
252003 Mustang Workshop Manual
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62. Install the fluid filter and seal assembly.
63. Position the pan magnet onto the fluid pan.
64.
NOTE: The pan gasket is reusable; clean and inspect for damage. If not damaged, the gasket
should be reused.
Install the fluid pan.
1. Position the transmission fluid pan.
2. Install the 14 transmission fluid pan bolts. Klj . 22 ba
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65. Install the digital transmission range (TR) sensor.
1. Install the digital TR sensor.
2. Loosely install the digital TR bolts.
66. NOTE: The tool is designed to fit snugly.
NOTE: Manual shift lever must be in the neutral position.
Using the special tool, align the digital TR sensor slots.
67. Tighten the bolts. Klj . 23 ba
252003 Mustang Workshop Manual
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68. Lightly lubricate the converter hub with clean automatic transmission fluid.
69.
WARNING: The torque converter can fall out if the transmission is tipped.
CAUTION: Make sure the converter hub is fully engaged in the front pump support
and gear and rotates freely. Do not damage the hub seal.
CAUTION: If the torque converter slides out, the hub seal may be damaged.
Using the special tools, install the torque converter.
70. Lubricate the torque converter pilot hub with multi- purpose grease. Klj . 24 ba
252003 Mustang Workshop Manual
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INSTALLATION
Transmission
1. CAUTION: During this move, to avoid damage, do not allow the transmission to get
into a nose- down position as this will cause the torque converter to move forward and
disengage from the pump gear. The converter housing is piloted into position by dowels
in the rear of the engine block. The torque converter must rest squarely against the
flexplate. This indicates that the converter pilot is not binding in the engine crankshaft.
Position and secure the transmission on the high- lift transmission jack.
2. CAUTION: Make sure the torque converter is fully seated in the transmission before
positioning the transmission to the engine.
Using the special tool, install the transmission to the engine.
zAlign the orange balancing marks on the converter stud and the flexplate bolt hole. 3. Reconnect the harness. SECTION 307-
01: Automatic Transaxle/Transmission 2003 Mustang Workshop Manual Special Tool(s)
Retainer, Torque Converter
307-
346 (T97T-7902- A)
Material Item Specification
Multi-
Purpose Grease
D0AZ- 19584- AA ESB-
M1C93-
B MERCON® V Automatic
Transmission Fluid
XT
-5-QM, XT -5-DM MERCON® V Klj . 1 ba
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8. Install the bolts.
9. Reconnect the connectors.
10. Connect the transmission fluid cooler tubes.
11. Install the shift cable. Klj . 3 ba
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15. Install the cover.
16. Reconnect the connector.
17. Reconnect the connector.
18. Install the dual converter Y pipe.
19.
NOTE: The output shaft and the drive shaft are a balanced assembly.
Install the driveshaft. zAlign the yellow dots and position the driveshaft on the transmission.
z Position the driveshaft to the rear differential. Klj . 5 ba
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