manual transmission FORD MUSTANG 2003 Workshop Manual

REMOVAL AND INSTALLATION
Bulb
Removal and Installation
1. Remove the floor console. For additional information, refer to Section 501 - 12 .
2. Remove the bolts, then position the bezel upward.
3. Remove the bulb socket from the bezel.
4. Remove the bulb.
5. To install, reverse the removal procedure.
SECTION 307-
05: Automatic Transaxle/Transmission External Controls 2003 Mustang Workshop Manual Klj . 1 ba
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REMOVAL AND INSTALLATION
Knob
Removal
1. Remove the shifter top control panel.
2. Disconnect the electrical connectors.
3. Remove the shifter bezel. 4. Remove the bulb from the bezel. SECTION 307-
05: Automatic Transaxle/Transmission External Controls 2003 Mustang Workshop Manual Klj . 1 ba
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5. Disconnect the TCS connector.
6.
CAUTION: Extra force may be needed to lift up on the handle. Do not to pull too far
or damage to the overdrive cancel button may result, as the wires may be pulled out of
the switch.
Remove the screw and the handle.
7. Remove the transmission control switch. Klj . 2 ba
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SPECIFICATIONS
SECTION 308-
00: Manual Transaxle/Transmission and Clutch — General
Information 2003 Mustang Workshop
Manual General Specifications
Item Specification
Pressure plate
Pressure spring Belleville
Sensor spring Belleville
Clutch Disc (3.8L)
Clutch diameter 280 mm (11.0 inches)
Number of springs 5
Color identification none
Clutch Disc (4.6L 2V)
Clutch diameter 280 mm (11.0 inches)
Number of springs 4
Color identification none
Lubricants (Spec and Capacity) Fluid
T50D-
MERCON® Multi- Purpose ATF Transmission Fluid XT -2-QDX 2.6L (2.8 qt)
TR3650-
Synthetic MERCON® ( ATF) Transmission Fluid E6AZ-19582- B 3.6L (7.5 pt) Klj . 1 ba
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DESCRIPTION AND OPERATION
Manual Transmission and Clutch
The primary function of the clutch is to couple and uncouple engine power to the transmission upon
driver command. For additional information, refer to
Section 308 - 01 .
Clutch Disc and Clutch Pressure Plate — 3.8L
SECTION 308-
00: Manual Transaxle/Transmission and Clutch — General
Information 2003 Mustang Workshop
Manual Item Part Number Description
1 6397 Flywheel housing to block dowel (2 req'd)
2 — Rear face of block and flywheel (part of 6010)
3 6397 Flywheel to clutch pressure plate dowel (3 req'd)
4 7600 Pilot bearing
5 7550 Clutch disc
6 7563 Clutch pressure plate Klj . 1 ba
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Clutch Disc and Clutch Pressure Plate —
4.6L (4V)
z The clutch is a single plate, dry friction clutch disc. The clutch disc has a splined hub with
integral torsional springs. The clutch disc hub attaches to the input shaft.
z Engine output is coupled to the transmission input shaft by friction existing between the clutch
disc facings and the flywheel/clutch pressure plate assembly. The extent of this friction is directly related to the composition of the facing material and the magnitude of the clamping 12 7548 Clutch release hub and bearing
13 N808969-
S100 Bolt
14 N808969-
S100 Bolt (6 req'd)
15 — Rear face of block and flywheel (part of 6010)
16 — Bolt (3 req'd)
17 6397 Flywheel housing to block dowel (2 req'd)
Item Part Number Description
1 6375 Flywheel
2 7600 Pilot bearing
3 7550 Clutch disc
4 7563 Clutch pressure plate
5 7548 Clutch release hub and bearing
6 7515 Clutch release lever
7 7B602 Clutch release lever stud
8 6392 Flywheel housing
9 N808969-S100 Clutch pressure plate bolt (6 req'd) Klj . 3 ba
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forces exerted by the clutch pressure plate and the flywheel on the facings. These factors limit
the amount of torque that can be transmitted without slippage.
z The clamping force is obtained from a diaphragm spring contained within the clutch pressure
plate assembly. This force is developed during the attachment of the clutch pressure plate
assembly to the flywheel.
z The clutch system is disengaged when the clutch pedal is pressed and is accomplished when
the release fingers are fully displaced toward the flywheel. This displacement removes the
spring load from the clutch pressure plate and eliminates the coupling friction between the
engine and the transmission.
z When the clutch pedal is depressed a cable connected to the clutch release lever, hub and
bearing actuates the clutch pressure plate diaphragm spring, releasing pressure on the clutch
disc. This eliminates the engagement between the transmission and the engine. Klj . 4 ba
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DIAGNOSIS AND TESTING
Manual Transmission and Clutch
Inspection and Verification
It is important to get an accurate description of the concern before any diagnosis can be carried out.
Ask questions as to whether it occurs when hot or cold, during shifting, driving at a particular speed or
in a particular gear. If possible, have the customer demonstrate the concern.
zWith the vehicle at a complete stop, shift through all the gears and evaluate the noise at
different engine rpm. Check for any noises in NEUTRAL at different engine rpm.
Symptom Chart SECTION 308-
00: Manual Transaxle/Transmission and Clutch — General
Information 2003 Mustang Workshop
Manual Symptom Chart
Condition
Possible Sources Action
z Clutch slippage zClutch pedal
sticking.
z Pressure plate
diaphragm
spring damaged
or weakened.
z Clutch pressure
plate damaged.
z Clutch disc
facing damaged
or worn
excessively.
z Clutch disc
facing surface
hardened or oil-
coated.
z Clutch release
hub and bearing
binding.
z Flywheel glazed
or damaged.
z loose pressure
plate to flywheel
bolts z
Go To Pinpoint Test A .
z Clutch chatter or shudder zLoose or worn
engine mount.
z Loose pressure
plate to flywheel
bolts
z Oil on clutch
disc facing.
z Clutch pressure
plate damaged z
Go To Pinpoint Test B . Klj . 1 ba
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or excessive
runout.
z Clutch disc
facing surface
hardened or
damaged.
z Flywheel
surface glazed
or damaged.
z Transmission
input shaft
eccentric or not
perpendicular.
z Clutch drag zClutch drag.
z Cable release
linkage outside
the flywheel
housing worn,
cracked, bent.
z Excessive
runout or
damaged clutch
disc.
z Clutch disc
splines rusted or
worn.
z Loose pressure
plate to flywheel
bolts. z
Go To Pinpoint Test C .
z Clutch pedal pulsation zClutch disc
damaged or
worn.
z Excessive
flywheel runout.
z Loose pressure
plate to flywheel
bolts.
z Improperly
assembled
release lever to
pivot stud. z
Go To Pinpoint Test D .
z Clutch related vibrations zEngine
component
grounding
against frame.
z Loose flywheel
bolts.
z Excessive
flywheel runout.
z Imbalanced
clutch pressure
plate.
z Accessory drive
belt loose or
damaged. z
Go To Pinpoint Test E .
z Hard shifting zManual
transmission
concern.
z Loose pressure
plate to flywheel
bolts. z
Go To Pinpoint Test F . Klj . 2 ba
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z
Excessive noise zPilot bearing
worn or
damaged.
z Excessive
crankshaft end
play. z
Go To Pinpoint Test G .
z Transmission difficult to
shift z
Lubricant. zADD or DRAIN AND
FILL with specified
lubricant.
z Internal shift
mechanism. z
CHECK the internal shift
mechanism for smooth
operation. REPAIR or
INSTALL a new
mechanism as
necessary.
z Sliding gears,
synchronizers. z
CHECK for free
movement of gears and
synchronizers. REPAIR
or INSTALL new
components as
necessary.
z Housings, shaft. zCHECK for binding
condition between the
input shaft and the
engine crankshaft pilot
bearing or bushing.
REPAIR or INSTALL
new components as
necessary. REFER to
Section 308 - 03A or
Section 308 - 03B .
z Loose pressure
plate to flywheel
bolts. z
CHECK for loose bolts
at the pressure plate.
INSTALL new
components as
necessary. REFER to
Section 308 - 01 .
z NOTE: While verifying
the condition, determine
whether the noise is gear
rollover noise, release
bearing rub or some
other transmission-
related noise. Gear
rollover noise, inherent in
manual transmissions, is
caused by the constant
mesh gears turning at the
engine idle speed while
the clutch is engaged and
the transmission is in
NEUTRAL. Release
bearing rub is sometimes
mistaken for mainshaft
bearing noise. Gear
rollover noise will
disappear when the
clutch is disengaged or
when the transmission is
engaged in gear. z
Lubricant. zADD or DRAIN AND
FILL with specified
lubricant. Klj . 3 ba
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