automatic transmission fluid FORD MUSTANG 2003 Service Manual

2. Install the clutch piston outer seal so that when the piston is installed the sealing lip points
toward the bottom of the cylinder.
3. NOTE: Coat the inner and outer direct clutch piston seals, clutch cylinder sealing area and
piston inner sealing area with petroleum jelly.
Using the special tool, install the direct clutch piston.
4. Install the piston return spring and retainer assembly.
5. Using the special tool, compress the piston return spring and install the retaining ring.
6. NOTE: Before assembly, soak new clutch discs in clean automatic transmission fluid for 15
minutes.
Install the clutch pack retaining ring. 1. Alternate external spline (steel) plates and internal spline (friction) plates, starting with a steel plate and ending with the friction plate.
2. Install the clutch pack retaining ring. Klj . 7 ba
112003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2748/S3B~us~en~ ...

DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES
Torque Converter
1. A new or remanufactured torque converter must be installed if one or more of the following statements is true:
zA torque converter malfunction has been determined based on complete diagnostic
procedures.
z Converter stud or studs, impeller hub or bushing are damaged.
z Discoloration (due to overheating).
z The torque converter is found to be out of specification when carrying out one of the
following torque converter checks:
„One- Way Clutch Check
„ End Play Check
„ Stator to Turbine Interference Check
„ Stator to Impeller Interference Check
„ Torque Converter Leak Check
z Evidence of transmission assembly or fluid contamination due to the following
transmission or converter failure modes:
„Major metallic failure.
„ Multiple clutches or clutch plate failures.
„ Sufficient component wear which results in metallic contamination.
SECTION 307-
01: Automatic Transaxle/Transmission 2003 Mustang Workshop Manual Klj . 1 ba
12003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2748/S3B~us~en~ ...

DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES
Torque Converter Cleaning And Inspection
1. If a new torque converter is being installed, continue with Substep 2 of Step 2.
2. If a new torque converter is not being installed, the following procedures must be performed: 1. The torque converter must be thoroughly cleaned.
„Torque converters with drain plugs can be cleaned by using a suitable torque
converter/fluid cooler cleaner.
„ Torque converters without drain plugs can be cleaned by hand. Partially fill the
torque converter using only recommended transmission fluid for the applicable
transmission. Hand agitate the torque converter and then thoroughly drain the
fluid. Refill the torque converter with clean automatic transmission fluid specified
for transmission, and reinstall.
2. All in- tank and auxiliary coolers must be thoroughly cleaned by forward and backward
flushing. For additional information, refer to Transmission Fluid Cooler — Backflushing
and Cleaning in this section.
3. All cooler lines must be thoroughly cleaned by backward and forward flushing. For additional information, refer to Transmission Fluid Cooler — Backflushing and Cleaning
in this section.
4. All Cooler Bypass Valves (CBV), if equipped, must be thoroughly cleaned.
5. Carry out the Transmission Fluid Cooler Flow Test. For additional information, refer to
Transmission Fluid Cooler — Backflushing and Cleaning in this section.
6. If the transmission cooling system fails the Transmission Fluid Cooler Flow Test, a new fluid cooler, cooler bypass valve, and/or cooler lines must be installed. For additional
information, refer to Section 307 - 02 .
7. If new coolers are to be installed, use only factory approved service parts.
SECTION 307-
01: Automatic Transaxle/Transmission 2003 Mustang Workshop Manual Material
Item Specification
MERCON® V Automatic
Transmission Fluid
XT
-5-QM, XT -5-DM MERCON® V Klj . 1 ba
22003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2748/S3B~us~en~ ...

DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES
Torque Converter Flushing
NOTE:
When the transmission has been repaired for internal damage the torque converter must be
cleaned using a mechanically agitated cleaner.
1. Using a suitable torque converter/fluid cooler cleaner, clean and flush the torque converter.
2. After flushing, drain the remainder of the solvent.
3. Add 1.9 liter (2 qt.) of clean transmission fluid to the converter and agitate by hand.
4. Thoroughly drain the solution.
SECTION 307-
01: Automatic Transaxle/Transmission 2003 Mustang Workshop Manual Material
Item Specification
MERCON® V Automatic
Transmission Fluid
XT
-5-QM, XT -5-DM MERCON® V Klj . 1 ba
12003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2748/S3B~us~en~ ...

ASSEMBLY
Transmission
SECTION 307-
01: Automatic Transaxle/Transmission 2003 Mustang Workshop Manual Special Tool(s)
Dial Indicator Gauge with
Holding Fixture
100-
002 (TOOL- 4201-C) Rubber Tip Air Nozzle
100-
D009 (D93L-7000- A) Alignment Gauge, TR Sensor
307-
351 (T97L-70010- A) Slide Hammer
100-
001 (T50T-100- A) Installer, Shift Shaft Fluid Seal
307-
050 (T74P-77498- A) Shim Selection Gauge
307-
072 (T80L-77003- A) Installer, Servo Piston
307-
073 (T80L-77030- A) Remover/Installer,
Transmission Extension
Housing Klj . 1 ba
252003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2748/S3B~us~en~ ...

CAUTION: Before beginning assembly, carry out and inspect the following:
When building up subassemblies and assembling the transmission, ALWAYS use new gaskets
and seals.
All fasteners must be tightened to the torque specification indicated. In addition to appearing in
the section, the necessary torques can be found in the General Specifications Chart.
When building up subassemblies, each component part should be lubricated with clean
transmission fluid. It is also good practice to lubricate the subassemblies as they are installed
in the case.
Needle bearings, thrust washers and seals should be lightly coated with petroleum jelly during
subassembly buildup or transmission assembly.
Many components and surfaces in the transmission are precision machined. Careful handling
during disassembly, cleaning, inspection and assembly can prevent unnecessary damage to
machined surfaces.
1. Use the special tools to install the rear case bushing if removed. 1. Position the rear case bushing and the special tool inside the case.
2. Assemble the special tools through the back of the case.
2. Place the transmission in the vertical position.
3. Coat the No. 9 case rear bearing with petroleum jelly and install on the case boss.
4. CAUTION: Be sure the No. 7 needle bearing and direct clutch hub are installed as
shown in the Subassembly section. Internal damage and shift problems may occur. D0AZ-
19584- AA B
MERCON® V Automatic
Transmission Fluid
XT
-5-QM, XT -5-DM MERCON® V Klj . 3 ba
252003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2748/S3B~us~en~ ...

23.
NOTE: Before assembly, soak the new clutch discs in clean automatic transmission fluid for 15
minutes.
Install the intermediate clutch pack and selective steel plate.
24. Using the special tool, check the intermediate clutch clearance. 1. Position the special tool on the pump case mounting surface.
2. Maintaining downward pressure, use a depth micrometer to measure and verify intermediate clutch clearance is within specification.
If the intermediate clutch is not within specification, install a correct selective plate.
25. Install the intermediate anti- rattle clip, if equipped. Selective Steel Plates
Specification
1.80-
1.70 mm (0.071- 0.067 inch) 2.05-
1.95 mm (0.081- 0.077 inch) 2.31-
2.20 mm (0.091- 0.087 inch) 2.56-
2.46 mm (0.101- 0.097 inch) Klj . 9 ba
252003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2748/S3B~us~en~ ...

36. Install the output shaft speed (OSS) sensor.
1. Position the OSS sensor.
2. Install the bolt.
37. Using the special tool, install the manual control lever seal.
38. NOTE: Lubricate the electronic pressure control (EPC) solenoid O- rings with clean automatic
transmission fluid.
Install the EPC solenoid.
1. Install the EPC solenoid.
2. Install the EPC solenoid bracket and bolt. Klj . 13 ba
252003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2748/S3B~us~en~ ...

68. Lightly lubricate the converter hub with clean automatic transmission fluid.
69.
WARNING: The torque converter can fall out if the transmission is tipped.
CAUTION: Make sure the converter hub is fully engaged in the front pump support
and gear and rotates freely. Do not damage the hub seal.
CAUTION: If the torque converter slides out, the hub seal may be damaged.
Using the special tools, install the torque converter.
70. Lubricate the torque converter pilot hub with multi- purpose grease. Klj . 24 ba
252003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2748/S3B~us~en~ ...

INSTALLATION
Transmission
1. CAUTION: During this move, to avoid damage, do not allow the transmission to get
into a nose- down position as this will cause the torque converter to move forward and
disengage from the pump gear. The converter housing is piloted into position by dowels
in the rear of the engine block. The torque converter must rest squarely against the
flexplate. This indicates that the converter pilot is not binding in the engine crankshaft.
Position and secure the transmission on the high- lift transmission jack.
2. CAUTION: Make sure the torque converter is fully seated in the transmission before
positioning the transmission to the engine.
Using the special tool, install the transmission to the engine.
zAlign the orange balancing marks on the converter stud and the flexplate bolt hole. 3. Reconnect the harness. SECTION 307-
01: Automatic Transaxle/Transmission 2003 Mustang Workshop Manual Special Tool(s)
Retainer, Torque Converter
307-
346 (T97T-7902- A)
Material Item Specification
Multi-
Purpose Grease
D0AZ- 19584- AA ESB-
M1C93-
B MERCON® V Automatic
Transmission Fluid
XT
-5-QM, XT -5-DM MERCON® V Klj . 1 ba
72003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2748/S3B~us~en~ ...