manual transmission FORD MUSTANG 2003 Workshop Manual

13. Install the countershaft.
zLift the mainshaft upward, tilt the countershaft and install.
14. Install the case with two opposing bolts.
15. NOTE: Rotate the transmission so that the input shaft is pointing upward.
NOTE: Rotate the input shaft to seat the bearings.
Using the special tools, measure the input shaft end play by applying an upward load on the Klj . 5 ba
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output shaft. Record the measurement.
16. Rotate the transmission so that the input shaft is pointing downward.
17. NOTE: Rotate the countershaft to seat the bearings.
Using the special tools, measure the countershaft gear end play by pulling upward on the
countershaft. Record the measurement.
18. Remove the two bolts and lift the transmission main case off. Klj . 6 ba
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28. Install the countershaft.
29. Clean the mating surfaces of the transmission main case and the clutch housing. Apply a bead
of silicone rubber to the sealing surface on the clutch housing then install the transmission main
case. Tighten the bolts in a star pattern. Klj . 10 ba
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47. Install a new OSS sensor tone wheel retaining ring.
48. Install the fifth/reverse gear lockout.
49. Install the bolt.
50. Clean the mating surfaces of the transmission main case and the extension housing. Apply a
bead of silicone rubber to the sealing surface of the transmission case.
51. Install the extension housing and at the same time install the gear shift off- set lever. Klj . 16 ba
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52. Install the shift spring and bracket.
53. Install a new split pin in the gear shift off-
set lever.
z The split pin should be flush in the gear shift off- set lever.
54. Seat the extension housing and tighten the bolts to specification. zFill the gear shift off- set lever with petroleum jelly.
55. Using the special tool, install a new extension housing seal. zLubricate the seal with transmission fluid. Klj . 17 ba
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56. Install the shipping seal.
57. Rotate the transmission to a horizontal position.
58. Clean the mating surfaces of the shift cover opening surface and the shift cover. Apply a bead
of silicone rubber to the shift cover opening surface.
59. Install the gear shift lever.
60. NOTE: Before installing the transmission, the ball stud, the clutch release lever and the input Klj . 18 ba
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shaft guide tube must be cleaned and lubricated.
Install the clutch release hub and bearing and the clutch release lever. For additional
information, refer to Section 308-
01.
61. Fill the transmission with transmission fluid to the specified level. zTransmission capacity is 3.6 liters (7.5 pints). Klj . 19 ba
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INSTALLATION
Transmission
1. NOTE: Before installing the transmission, the ball stud, clutch release lever and the input shaft
must be cleaned and lubricated. Use Motorcraft Premium Long-Life Grease XG-1- C or XG-1-K
or equivalent meeting Ford specification ESA- M1C75-B.
To install, reverse the removal procedure. For additional information, refer to Transmission in
this section.
zCheck, and as necessary, fill the transmission with transmission fluid. The total fill
capacity is 3.6L (7.5 pt).
2. Apply sealant to the fill plug threads and install the fill plug. zUse pipe sealant with Teflon® .
SECTION 308-
03B: Manual Transaxle/Transmission — TR3650 2003 Mustang Workshop Manual Material
Item Specification
Motorcraft MERCON® Multi-
Purpose (ATF) Transmission
Fluid
XT
-2-QDX MERCON
Pipe Sealant with Teflon®
D8AZ-
19554- A or equivalent WSK-
M2G350-
A2 Premium Long Life Grease
XG
-1-C, K or T or equivalent ESA-
M1C75- B Klj . 1 ba
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SPECIFICATIONS
SECTION 308-
03C: Manual Transaxle/Transmission — T56 2003 Mustang Workshop Manual General Specifications
Item Specification
Lubricants and Sealants
Premium Long-
Life Grease
XG -1-C, K or T ESA-
M1C75- B Threadlock and Sealer
E0AZ-
19554- AA WSK-
M2G351- A5 Black Non-
Acid Cure Silicone Rubber
E7TZ- 19562- A ESL-
M4G273- A Pipe Sealant with Teflon®
D8AZ-
19554- A ESR-
M18P7-A Preload
Input/output shaft preload 0.0 mm (in) -
0.05 mm (0.002 in) Countershaft cluster gear preload 0.0 mm (in) -
0.05 mm (0.002 in) Countershaft extension preload 0.05 mm (in) -
0.13 mm (0.005 in) Fluid
DEXRON III® (
ATF) Transmission Fluid
XT -2-QDX DEXRON III®
Capacity 3.9 L (4.1 qt.)
Synchronizer
Synchronizer blocking ring to conical face runout
1st, 2nd, 3rd, 4th, 5th & 6th gear 0.38 mm (0.01 in)
Synchronizer blocking ring to conical face runout
Reverse gear 0.75 mm (0.03 in)
Torque Specifications Description Nm lb-
ft lb-
in Transmission-to-
clutch adapter housing bolts 35 26 —
Crossmember-
to-frame bolts 41 30 —
Crossmember-
to-
transmission support bolts 58 43 —
OSS sensor bolt 10 — 7
Gearshift lever boot bolts 10 — 89
Lower gearshift lever bolts 20 15 —
Upper gearshift lever bolts 37 27 —
Shift dent 40 30 —
Shift lever guide bolts 27 20 — Klj . 1 ba
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DESCRIPTION AND OPERATION
Manual Transmission
The T56 six-
speed manual transmission features the following:
z six forward speeds and one reverse speed.
z forward gears are synchronized and helical cut.
z a reverse gear operates through a constant- mesh, fully synchronized system.
z a shift interlock system prevents the engagement of more than one gear.
z a countershaft with two sections, the countershaft cluster and the countershaft extension. The
countershaft cluster is serviced as an assembly, the countershaft extension components are
serviced.
z two tapered roller bearings on the output shaft.
z two tapered roller bearings on the countershaft cluster.
z a tapered roller bearing on the input shaft.
z a tapered roller bearing on the countershaft extension.
z countershaft cluster endplay controlled by shims located in the transmission adapter plate.
z countershaft extension endplay controlled by shims located in the extension housing.
z input/output shaft endplay is controlled by shims located in the transmission adapter plate.
z removable wear pads on the shift forks.
z an aluminum main case, extension housing, adapter plate and clutch housing.
Transmission Identification
The transmission identification tag is located under the lower bolt that retains the extension housing to
the main case.
The six speed (T56) transmission is available for the Mustang 4.6L (4V).
Transmission Identification SECTION 308-
03C: Manual Transaxle/Transmission — T56 2003 Mustang Workshop Manual Item Part
Number Description
1 — Transmission assembly number
2 — Build date code —
month Klj . 1 ba
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