lock FORD MUSTANG 2003 Workshop Manual

7. Remove the second gear needle bearing.
zInspect the needle bearing for wear or damage. Install a new needle bearing as
necessary.
8. NOTE: Reposition the output shaft on the press with the input shaft end facing upward.
Remove and discard the snap ring, then using the special tool, remove the third/fourth gear
synchronizer assembly, the third gear synchronizer blocking ring and the third gear. zInspect the gear for broken or cracked teeth. Install a new gear as necessary. Klj . 5 ba
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9. Remove the third gear needle bearing.
zInspect the needle bearing for wear or damage. Install a new needle bearing as
necessary.
10. NOTE: Install the special tool with the flat side facing the bearing.
Using the special tool, press the output shaft front bearing from the output shaft.
11. Inspect the synchronizers. zCheck for worn, nicked or broken teeth. Install a new synchronizer as necessary.
z Check keys for wear or distortion. Install a new synchronizer as necessary.
z Check springs for distortion. Install a new synchronizer as necessary.
12. Inspect the synchronizer blocking rings. zCheck for wear or damage. Install new synchronizer blocking rings 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 0.38 mm (0.015 in), install new
blocking rings. Klj . 6 ba
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13. Inspect the output shaft for scoring or worn or damaged splines. Install a new output shaft as
necessary.
Assembly
1. Lubricate all components with the recommended transmission fluid when reassembling.
2. Using the special tools, press the output shaft front bearing on the output shaft.
3. Install the third gear bearing. zApply petroleum jelly to the bearing.
4. Install third gear, the third gear synchronizer blocking ring and the third/fourth gear synchronizer assembly. Position the output shaft with the output end facing upward. Using the special tool,
press the third/fourth gear synchronizer assembly into place.
zInstall the synchronizer body with the groove facing third gear.
z Stop press operation before keys engage the blocking ring slots. Lift and rotate the third
gear and the blocking ring until the keys are seated in the blocking ring. Klj . 7 ba
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8. Install the second gear synchronizer thrust washer, the inner cone, the friction cone and the
second gear synchronizer blocking ring.
zAlign the blocking ring tabs with the second gear slots.
9. Install the first/second gear synchronizer assembly. Position the output shaft with the output end facing downward. Using the special tools, press the first/second gear synchronizer assembly
into place.
zInstall the synchronizer with the groove on the sleeve facing first gear.
z Stop press operation before keys engage the blocking ring slots. Lift and rotate the
second gear and the blocking ring until the keys are seated in the blocking ring. Klj . 9 ba
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10. Install the first gear synchronizer thrust washer, the inner cone, the friction cone and the first
gear synchronizer blocking ring.
11. Install a new snap ring. Klj . 10 ba
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1. Remove the thrust washer. Item Part Number Description
1 7025 Countershaft front bearing
2 7113 Countershaft
3 — Countershaft rear bearing
4 — Thrust washer
5 — Sixth gear needle bearing
6 — Sixth gear
7 — Synchronizer blocking ring
8 — Spacer
9 — Snap ring
10 — Fifth/sixth synchronizer assembly
11 — Fifth gear
12 — Fifth gear needle bearing
13 — Countershaft extension
14 — Countershaft extension bearing Klj . 2 ba
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7. Remove the sixth drive gear synchronizer blocking ring.
8. Remove and discard the fifth/sixth synchronizer snap ring.
9. Using the special tool, press the fifth/sixth synchronizer and the fifth drive gear off the shaft.
10. Remove the fifth drive gear needle bearing. Klj . 4 ba
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11. Using the special tool, remove the countershaft extension bearing.
12. Inspect the countershaft and countershaft extension.
zCheck the shaft surface for wear or damage. Install a new shaft as necessary.
z Check the gear teeth for wear, pitting, scoring, spalling or fractures. Install new
components as necessary.
13. Disassemble the fifth/sixth gear synchronizer assembly.
14. Inspect the fifth/sixth synchronizer. zCheck for worn, nicked or broken teeth. Install a new synchronizer as necessary.
z Check keys for wear or distortion. Install a new synchronizer as necessary.
z Check springs for distortion. Install a new synchronizer as necessary.
15. Inspect the fifth/sixth synchronizer blocking rings. zCheck for wear or damage. Install new synchronizer blocking rings 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 Klj . 5 ba
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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 0.38 mm (0.015 in), install new
blocking rings.
16. Using the special tools, install the countershaft rear bearing.
17. Using the special tools, install the countershaft front bearing. Klj . 6 ba
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DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES
Synchronizers
Disassembly and Assembly
NOTE:
This procedure applies to all synchronizer assemblies.
1. NOTE: Synchronizer components are not interchangeable. During disassembly, mark each
individual synchronizer for assembly. Synchronizer hubs and sleeves are a selected assembly
and should be kept together as originally assembled. Blocking rings are not interchangeable, do
not mix.
Scribe an alignment mark on the sliding sleeve and the hub for assembly reference.
2. Using a screwdriver, remove the spring. Turn the synchronizer over and remove the second spring. Remove the sliding sleeve and the synchronizer struts from the hub.
3. CAUTION: Match the alignment marks made during disassembly. The sleeve and
the hub have an extremely close fit. Hold the sleeve and hub square to prevent jamming.
Do not force the sleeve onto the hub.
Assemble the synchronizer as follows:
zPosition the synchronizer sleeve on the hub. Make sure to align key openings in the hub
with the synchronizer sleeve.
z Install the keys with the slots facing the hub.
z Install the spring. Locate the tang to one of the key slots and position into place. Install
the second spring. Locate the spring tang on the same key but position in the opposite
direction.
SECTION 308-
03C: Manual Transaxle/Transmission — T56 2003 Mustang Workshop Manual Klj . 1 ba
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