lock FORD MUSTANG 2003 Workshop Manual

5. Remove the bolts and the lower gearshift lever.
6. Disconnect the reverse lockout solenoid electrical connector.
7. With the vehicle in NEUTRAL, raise and support the vehicle. For additional information, refer to
Section 100 - 02 .
8. Drain the transmission fluid.
9. CAUTION: Index- mark the driveshaft flange and pinion flange, and the driveshaft Klj . 2 ba
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17. Remove the reverse gear thrust washer.
18. Remove the reverse gear.
zInspect reverse gear for wear or damage. Install a new gear as necessary.
19. Remove the wave washer from the reverse gear.
20. Remove the reverse gear needle bearing and the reverse gear synchronizer blocking ring. zInspect the needle bearing for wear or damage. Install a new bearing as necessary. Klj . 6 ba
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21. Remove the reverse gear synchronizer snap ring.
22. Remove the reverse shift fork snap ring.
23. Remove the reverse shift fork, the reverse synchronizer and the thrust washer as an assembly.
24. Inspect the synchronizer for the following:
zCheck for worn, nicked or broken teeth. Install a new synchronizer as necessary.
z Check keys for wear or distortion. Check the springs for distortion. Install a new
synchronizer as necessary.
25. Inspect the synchronizer blocking ring for the following: zCheck for wear or damage. Install a new synchronizer blocking ring as necessary.
z Check the clearance between the synchronizer blocking ring and the gear.
„Position the blocking ring onto the gear. Make sure the correct blocking ring is
measured with the correct gear and that the blocking ring is fully seated on the
gear.
„ Insert a feeler gauge and measure the clearance, while applying pressure and
rotating the blocking ring. The measurement should be the same around the entire
circumference. If the clearance is less than 0.75 mm (0.030 in), install new Klj . 7 ba
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blocking ring.
26. Using the special tools, remove the fifth/sixth driven gear.
27. Remove the fifth/sixth shift fork snap ring.
28. Rotate the transmission to the horizontal position, then remove the countershaft extension as an assembly.
29. Remove the shift detent cover. Klj . 8 ba
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34. Remove the two remaining adapter-
to-transmission case bolts, then remove the transmission
case and the front offset lever.
zSlide the transmission case upward, off the mainshaft and shift rails. Hold the offset lever
against the guide plate to prevent the release of the dent ball and spring.
35. Remove the dent ball, spring and roll pin from the front offset lever.
36. Rotate the fifth/sixth and reverse shift levers from the shift interlock plate, then remove the fifth/sixth and reverse shift rail assembly. Klj . 10 ba
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37. Lift up the mainshaft, then remove the countershaft.
38. Remove the mainshaft and shift rail as an assembly. Separate the shift rail assembly from the
mainshaft on the work bench.
39. Remove the input shaft and fourth gear synchronizer blocking ring.
40. Remove the countershaft bearing cup and the countershaft shim. zInspect the cup for wear or damage. Install a new cup and bearing as necessary.
z Inspect the cup bore for wear, scratches or grooves. Install a new transmission adapter
plate as necessary. Klj . 11 ba
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1.
CAUTION: Use a vise with brass jaws or wood blocks.
Secure the input shaft in a vise. Using the special tools and a slide hammer, remove the input
shaft bearing cup. zInspect the cup for wear or damage. Install a new bearing cup and bearing as necessary.
2. Using the special tool and a press, remove the input shaft front bearing. Item Part Number Description
1 7025 Input shaft bearing
2 7017 Input shaft
3 — Input shaft bearing cup Klj . 2 ba
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1.
CAUTION: Hand tighten the special tool to prevent gear damage.
CAUTION: Support the output shaft while using the press to prevent damage to the
shaft or gears.
Using the special tool and a press, remove first gear, the output shaft rear bearing and the fifth
driven gear.
zDiscard the output shaft bearing.
z Inspect the gear for wear or damage. Install a new gear as necessary. 2 — Snap ring
3 7124 Third/fourth synchronizer assembly
4 7107 Third/fourth synchronizer blocking ring
5 7B340 Third gear
6 — Spacer
7 — Third gear needle bearing
8 7061 Output shaft
9 — Second gear needle bearing
10 7102 Second gear
11 — Thrust washer
12 — Synchronizer inner cone
13 — Synchronizer friction cone
14 7107 Second gear synchronizer blocking ring
15 7124 First/second synchronizer assembly
16 — Snap ring
17 — First gear needle bearing
18 7100 First gear
19 — Output shaft rear bearing
20 — Fifth driven gear Klj . 2 ba
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2. Remove the first gear needle bearing.
zInspect the needle bearing for wear or damage. Install a new needle bearing as
necessary.
3. Remove and discard the snap ring.
4. Remove the first gear synchronizer thrust washer, the inner cone, the friction cone and the first gear synchronizer blocking ring.
zInspect all components for wear or damage. Install new components as necessary. Klj . 3 ba
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5. Remove the synchronizer spring, then remove the synchronizer sleeve.
6.
NOTE: Install the special tool behind second gear with the flat side of the tool facing second
gear.
Using the special tool, remove the second gear, the second gear synchronizer thrust washer,
the inner cone, the friction cone, the second gear synchronizer blocking ring and the
synchronizer hub.
zInspect the gear for wear or damage. Install a new gear as necessary.
z Inspect the all synchronizer components for wear or damage. Install a new components
as necessary. Klj . 4 ba
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