lock FORD MUSTANG 2003 Workshop Manual

DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES
Gearshift Rail and Fork
Disassembly and Assembly
1. Disassemble the first/second and third/fourth shift rail as follows: zRotate the interlock plate until it is opposite of the shift links.
z Slide off the third/fourth shift fork and shift link. Separate the link from the fork.
z Slide off the first/second shift fork and shift link. Separate the link from the fork.
SECTION 308-
03C: Manual Transaxle/Transmission — T56 2003 Mustang Workshop Manual Item Part Number Description
1 — First/second shift fork pad
2 — First/second shift fork
3 — Interlock plate
4 — Shift link
5 — First/second, third/fourth shift rail
6 — Gear select solenoid lever
7 — Roll pin
8 — Selector pin
9 — Roll pin
10 — Shift link
11 — Third/fourth shift fork pad
12 — Third/fourth shift fork
13 — Shift rail collar
14 — Roll pin
15 — Fifth/sixth shift rail
16 — Roll pin
17 — Fifth/sixth shift rail lever
18 — Reverse shift rail lever Klj . 1 ba
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z
Remove the interlock plate.
z Using a 5/32- inch drift and a hammer, remove and discard the roll pins. Slide the gear
select solenoid lever and the selector pin from the shift rail.
2. Disassemble the fifth/sixth and reverse shift rail as follows: zUsing a 5/32- inch drift and a hammer, remove and discard the roll pins. Slide the collar
and the reverse shift lever from the shift rail.
z Slide off the fifth/sixth shift lever and shift link.
3. Inspect the shift rail components. zCheck the rails, shift forks, shift levers and shift links for wear or damage. Install new
components as necessary.
z Check the shift fork pads for wear. Install new pads as necessary.
4. To assemble, reverse the disassembly procedure. zInstall new roll pins. Klj . 2 ba
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Item Part Number Description
1 — Countershaft extension bearing cup
2 — Countershaft extension bearing shim
3 — Fluid funnel
4 — Case plug
5 — Reverse idler shaft bracket
6 — Reverse idler gear thrust washer
7 7141 Reverse idler gear
8 — Reverse idler gear needle bearing
9 7140 Reverse idler gear shaft
10 7052 Extension housing seal
11 — Snap ring
12 — Mainshaft bearing cup
13 — Output shaft speed (OSS) sensor
14 — Reverse lockout solenoid
15 — O-
ring Klj . 2 ba
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1. Remove the bolt and the output shaft speed (OSS) sensor.
2. Remove the bolt and the reverse lockout solenoid.
3. Remove the bolts and the reverse idler shaft bracket.
4. Remove the reverse idler gear thrust washer. 16 7A039 Extension housing Klj . 3 ba
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12.
WARNING: Make sure protective eye wear is in place.
Clean the housing with solvent and dry with compressed air. Clean and check the sealing
surface for nicks or scratches. Inspect the housing for cracks. zIf the housing is cracked, install a new housing. If the sealing surface has nicks or
scratches, use a soft stone or crocus cloth to remove.
13. Using the special tools, install the mainshaft bearing cup.
14. Using a suitable driver, install the extension housing seal. zInstall the seal with the drain hole at the six o'clock position.
15. To assemble, reverse the disassembly procedure. Klj . 6 ba
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1. Lubricate all components with transmission fluid during assembly.
2. Attach the transmission adapter plate to the special tool.
3.
NOTE: If a new front input shaft bearing or front countershaft bearing was installed, install new
bearing cups.
Install the input shaft bearing cup and the countershaft bearing cup. Do not install the shims at
this time.
4. Install the input shaft.
5. Install the mainshaft onto the input shaft. XG
-1-C, K or T Threadlock and Sealer
E0AZ-
19554- AA WSK-
M2G351- A5
(type II) Black Non-
Acid Cure
Silicone Rubber
E7TZ- 19562- A ESL-
M4G273- A Klj . 2 ba
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18. Install the input shaft and fourth gear synchronizer blocking ring.
19. Assemble the shift rail assembly to the mainshaft, then install the mainshaft and shift rail as an
assembly.
zRotate the mainshaft to engage the fourth gear synchronizer blocking ring with the
synchronizer keys.
20. Lift up the mainshaft, then install the countershaft. Klj . 8 ba
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21. Install the fifth/sixth and reverse shift rail assembly and align the slots of the shift levers with the
shift interlock plate.
22. Clean the mating surfaces of the transmission main case and the transmission adapter plate. Apply a bead of silicone rubber to the sealing surface on the transmission adapter plate. Install
the spring and detent ball into the front offset lever, then install the transmission case and the
front offset lever.
zMake sure the transmission is in neutral to keep the third/fourth gear shift rail from
engaging.
z Compress the front offset lever against the guide plate when installing.
z Tighten the bolts in a star pattern. Klj . 9 ba
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23. Apply threadlock and sealer to the threads of the shift lever guide bolts, then install the bolts.
zPull up on the fifth/sixth shift rail to align the slot of the interlock plate with the guide bolt
hole.
24. Install a new front offset lever roll pin. zInstall the pin until it is flush with the lever.
25. Apply threadlock and sealer to the threads of the shift dent, then install the shift detent assembly. Klj . 10 ba
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34. Install the reverse shift fork, the reverse synchronizer and the thrust washer as an assembly.
zAlign the pockets in the blocking ring with the struts in the synchronizer.
35. Install the reverse shift fork snap ring.
36. Install a new reverse gear synchronizer snap ring. 37. Install the reverse gear needle bearing and the reverse gear synchronizer blocking ring. Klj . 13 ba
182003 Mustang Workshop Manual
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