manual transmission FORD MUSTANG 2003 Workshop Manual

3. Attach the transmission to the special tool.
4.
NOTE: Position a drain pan under the transmission.
Remove the case plug.
5. NOTE: Position the gearshift lever in NEUTRAL.
Remove the bolts and the gearshift lever.
6. CAUTION: Do not attempt to remove the gearshift offset lever with the extension
housing bolted in place. A lug, located on the bottom of the gearshift offset lever,
meshes with the detent plate preventing enough rearward movement of the gearshift
offset lever to allow removal.
Remove the split pin and the gearshift shaft bushing. Klj . 2 ba
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DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES
Selector Plate
Disassembly
1. NOTE: Mark the position of each gear shifter fork (7230).
Place the gear shift plates (7N232) and the gear selector interlock sleeve (7K201) in the neutral
position to center the gear shift plates and the selector body (7302).
2. Rotate the main shift control shaft (7358) counterclockwise and pull it rearward to access the pin. Remove the pin.
3. Using a twisting motion, remove the main shift control shaft.
4. Remove the gear shifter forks, the gear shift plates, the pin, the gear selector interlock sleeve, and the selector body.
SECTION 308-
03A: Manual Transaxle/Transmission — T5OD 2003 Mustang Workshop Manual Klj . 1 ba
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DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES
Input Shaft and Bearing
Disassembly
1. Using the special tool and a press, remove the input bearing (7025).
2. Remove the bearing race and the end play selective shims.
3. Remove the input shaft seal (7052). Assembly SECTION 308-
03A: Manual Transaxle/Transmission — T5OD 2003 Mustang Workshop Manual Special Tool(s)
Input Shaft Seal Replacer
308-
220 (T94P-7025- AH) Pinion Bearing Cone Remover
205-
D002 (D79L-4621- A) or
Equivalent Klj . 1 ba
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1. Using the special tool, install the input shaft seal.
2.
NOTE: In installing a new input shaft seal as part of a transmission overhaul, do not install the
end play selective shims at this time.
Instal the end play selective shims and the bearing race.
3. Using a press and a capped length of pipe, install the input bearing. Klj . 2 ba
32003 Mustang Workshop Manual
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DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES
Output Shaft
Disassembly
1. Using the special tool and a press, remove the third/fourth gear synchronizer assembly (7124), the third speed synchronizer blocking ring (7107), and the third gear (7B340) as an assembly.
2. Remove the third speed bearing (7B369) and the third speed gear bearing spacer (7B320).
3. Remove the snap ring.
SECTION 308-
03A: Manual Transaxle/Transmission — T5OD 2003 Mustang Workshop Manual Special Tool(s)
Pinion Bearing Cone Remove
205-
D002 (D79L-4621- A) or
Equivalent Spiral Snap Ring Replacer
308-
096 (T85P-7025- A) Klj . 1 ba
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Assembly
1. Soak the blocking rings in transmission fluid for ten minutes. zUse MERCON® Multi- Purpose ATF Transmission Fluid XT -2-QDX or equivalent.
2. Assemble the first and second synchronizer. 1. Install the synchronizer hub insert springs and the synchronizer inserts into the synchronizer hub.
2. Install the sliding sleeve onto the hub.
3. NOTE: If not done so previously, soak the blocking ring in MERCON® Multi- Purpose ATF
Transmission Fluid XT -2-QDX or equivalent for ten minutes.
NOTE: Align the slots in the synchronizer blocking ring with the tabs in the first and second
speed synchronizer.
Install the second speed synchronizer blocking ring and the inner and outer cones as an
assembly.
4. Install the second speed synchronizer thrust washer.
5. Using the special tool, install the output shaft bearing snap ring. Klj . 5 ba
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6. Install the second speed gear bearing spacer and the second speed bearing.
7.
NOTE: Align the slots in the second gear with the tabs on the synchronizer blocking ring.
Install the second gear onto the output shaft.
8. Install the thrust washer and the snap ring.
9. NOTE: If not done so previously, soak the blocking ring in MERCON® Multi- Purpose ATF
Transmission Fluid XT -2-QDX or equivalent for ten minutes. Klj . 6 ba
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17. Install the third speed gear bearing spacer and the third speed bearing.
18.
CAUTION: Before pressing the components together, verify that the synchronizer
hub faces the short end of the output shaft. Hold the third gear against the synchronizer
to maintain the synchronizer blocking ring alignment.
NOTE: If not done so previously, soak the blocking ring in MERCON® Multi- Purpose ATF
Transmission Fluid XT -2-QDX or equivalent for ten minutes.
Using a 1- 1/2 inch deep well socket and a press, install the third gear, the third speed
synchronizer blocking ring, and the third/fourth gear synchronizer assembly. Klj . 9 ba
102003 Mustang Workshop Manual
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DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES
Countershaft Bearing
Disassembly SECTION 308-
03A: Manual Transaxle/Transmission — T5OD 2003 Mustang Workshop Manual Special Tool(s)
Bearing Replacer
308-
061 (T77J-7025- L) Front Bearing Replacer
308-
062 (T77J-7025- M) Mainshaft Front Bearing
Replacer
308-
081 (T82T-7003- DH) Pinion Bearing Cone Remover
205-
D002 (D79L-4621- A) or
Equivalent Pinion Bearing Cone Replacer
205-
011 (T57L-4621- B) Remover and Replacer Tube
308-
024 (T75L-7025- B) Remover and Replacer Tube
308-
052 (T77J-7025- B) Klj . 1 ba
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1. Using the special tool and a press, remove the countershaft bearing assembly (7F431).
2.
CAUTION: Failure to correctly support the case (7005) during bearing race removal
will result in permanent distortion of the case.
NOTE: Remove the front countershaft bearing race only if damaged or worn.
Using the special tools and a press, remove the bearing race and the countershaft front bearing
seal (7693).
Assembly
NOTE: Position the countershaft in the transmission case before installing the rear countershaft
bearing.
1. Install the countershaft front bearing seal on the bearing race.
2. Coat the outside diameter of the bearing race with sealer. zUse Threadlock and Sealer E0AZ-19554- AA or equivalent meeting Ford specification WSK - M2G351 - 5A. Klj . 2 ba
32003 Mustang Workshop Manual
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