lock FORD MUSTANG 2003 Workshop Manual

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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2. Assemble the gear shifter forks.
1. Install the gear shift plate into the gear shifter fork.
2. Install the gear shift fork inserts.
3. NOTE: Position the narrow side of the C- shaped gear selector interlock sleeve in the case
cover slot. Position the roll pin hole in the selector body toward the rear of the cover.
Install the gear selector interlock sleeve and the selector body as an assembly.
4. Lubricate the main shift control shaft with petroleum jelly.
5. NOTE: The 1-2 gear shifter fork is the larger shifter fork. The gear shifter fork offset lever must
face the cover. Position the gear shift plate attached to the 3- 4 gear shifter fork under the gear
shift plate attached to the 1- 2 gear shifter fork.
Position the gear shifter forks and the main shift control shaft in the cover. zSlide the shaft through the cover and shift the components until the shaft stops against
the cover.
6. CAUTION: Install the pin slightly below the selector body surface. Failure to
countersink the pin may result in interference between the pin and the gear selector interlock sleeve during shifts. Klj . 3 ba
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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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8. Remove the first and second speed synchronizer hub ball (7K218).
9. Remove the first speed synchronizer inner cone (7175), the first speed synchronizer outer cone
(7174), and the first speed synchronizer blocking ring (7107) as an assembly.
10. Remove the snap ring and the thrust washer (7119).
11. Remove the second gear (7102), the second speed bearing (7B369), and the second speed gear bearing spacer (7728). Klj . 3 ba
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12. Remove the output shaft bearing snap ring and the second speed synchronizer thrust washer
(7117).
13. Remove the second speed synchronizer inner cone (7175), the second speed synchronizer outer cone (7174), and the second speed synchronizer blocking ring (7107) as an assembly.
14. Remove the first and second gear synchronizer sliding sleeve (7124).
15. CAUTION: Note the orientation of the synchronizer hub insert springs (7109) and
the synchronizer hub inserts (7A044) for assembly reference.
NOTE: The first and second gear synchronizer sliding sleeve, the hub, and the output shaft are
an assembly. Do not attempt to separate the hub from the output shaft. Only the synchronizer
hub insert springs and the synchronizer hub inserts are available separately. Remove the synchronizer hub insert springs and the hub inserts. Klj . 4 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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NOTE:
Align the slot in the synchronizer blocking ring with the tab on the first and second
synchronizer.
Install the first speed synchronizer blocking ring and the inner and outer cones as an assembly.
10. Install the first and second speed synchronizer hub ball.
11. NOTE: Align the notch in the first gear bearing spacer with the first and second speed
synchronizer ball.
Install the first gear bearing spacer and the first gear bearing.
12. NOTE: Align the slots on the synchronizer blocking ring with the slots on the first gear.
Install the first gear. Klj . 7 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
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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
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