AC system FORD MUSTANG 2003 Workshop Manual

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
22003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2308/S3B~us~en~ ...

SPECIFICATIONS
SECTION 309-
00: Exhaust System 2003 Mustang Workshop Manual Torque Specifications
Description Nm lb-
ft Dual converter-
to-exhaust manifold nuts 40 30
Sleeve U-
bolt nuts 55 41
Dual converter-
to-inlet pipe flange nuts 35 26 Klj . 1 ba
12003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2308/S3B~us~en~ ...

DESCRIPTION AND OPERATION
Exhaust System
WARNING: The normal operating temperature of the exhaust system is very high. Never
attempt to repair any part of the system until it has cooled. Be especially careful when working
around the three way catalytic converter. The temperature of the three way catalytic converter
rises to a high level after only a few minutes of engine operation.
CAUTION: When repairing exhaust system or removing exhaust components, disconnect
all heated oxygen sensors (HO2S) at the wiring connectors to prevent damage to the heated
oxygen sensors and wiring harness. For additional information, refer to Section 303 - 14 for
location of the heated oxygen sensors.
The exhaust system:
zcontains dual three- way catalytic converters.
z has a crossover pipe downstream of the three way catalytic converters (4.6L).
z has two upstream heated oxygen sensors mounted before the three- way catalytic converters.
z the production muffler and tailpipe assembly is a one- piece design exhaust system.
Exhaust System — 3.8L Exhaust System — 4.6L (2V) SECTION 309-
00: Exhaust System 2003 Mustang Workshop Manual Item Part Number Description
1 5F250 Dual converter assembly
2 5D255 Insulator bracket assembly
3 5A246 Insulator bracket, (tailpipe)
4 5D255 Insulator bracket assembly
5 5232 Muffler Klj . 1 ba
32003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2308/S3B~us~en~ ...

Exhaust System —
4.6L (4V) Item Part Number Description
1 5F250 Dual converter assembly
2 5230 Muffler, RH
3 5260 Insulator bracket assembly, RH
4 5260 Insulator bracket assembly, LH
5 5A246 Insulator bracket, tailpipe (2 req'd)
6 5230 Muffler, LH
Item Part Number Description
1 5F250 Dual converter assembly
2 5230 Muffler, RH
3 5260 Insulator bracket assembly, RH
4 5260 Insulator bracket assembly, LH
5 5230 Muffler, LH Klj . 2 ba
32003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2308/S3B~us~en~ ...

DIAGNOSIS AND TESTING
Exhaust System
Symptom Chart
SECTION 309-
00: Exhaust System 2003 Mustang Workshop Manual Symptom Chart
Condition
Possible Sources Action
z Noisy or
leaking
exhaust z
Broken or loose
clamps, hangers or
isolators.
z Punctures in the muffler
(5230).
z Broken, loose or
missing exhaust
manifold fasteners or
gaskets.
z Loose heated oxygen
or catalyst monitor
sensor. z
REPAIR as necessary.
z Exhaust system
misalignment. z
ALIGN exhaust system.
z Broken or loose
catalyst internal
components. z
LOOSEN all fasteners joining
the exhaust system and SHAKE
the system to isolate the
concern. REPAIR as necessary.
z Loss of
power z
Kinked or damaged
exhaust pipe.
z Clogged three- way
catalytic converter
(5F250).
z Foreign object in the
exhaust system. z
REPAIR as necessary. Klj . 1 ba
22003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2308/S3B~us~en~ ...

REMOVAL AND INSTALLATION
Muffler —
3.8L
Removal and Installation 1. Raise and support the vehicle. For additional information, refer to Section 100 - 02 .
2. Support the rear axle with a suitable jack.
3. Remove the upper arm- to-differential bolt.
4. Remove the nut and bolt and disconnect the rear shock absorbers (18124) from the axle housing.
zDiscard the nut.
5. Lower the rear axle.
6. Remove the dual converter assembly flange nuts.
SECTION 309-
00: Exhaust System 2003 Mustang Workshop Manual Klj . 1 ba
32003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2308/S3B~us~en~ ...

REMOVAL AND INSTALLATION
Muffler —
4.6L (2V)
Removal and Installation 1. Use a jack to support and lower the rear axle.
2. Remove the upper arm- to-differential bolt.
3. Remove the nut and bolt, and disconnect the rear shock absorbers (18124) from the axle housing.
zDiscard the nut.
4. Lower the rear axle.
5. Remove the dual converter assembly nuts. (RH shown, LH similar.)
6. Remove the RH intermediate exhaust hanger insulator.
SECTION 309-
00: Exhaust System 2003 Mustang Workshop Manual Klj . 1 ba
32003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2308/S3B~us~en~ ...

REMOVAL AND INSTALLATION
Muffler —
4.6L (4V)
Removal and Installation 1. Raise and support the vehicle. For additional information, refer to Section 100 - 02 .
2. NOTE: RH side shown, LH side similar.
Remove the dual converter assembly nuts.
3. Remove the RH exhaust hanger insulator (5260).
4. Remove the LH exhaust hanger insulator (5260). 5. Remove the RH intermediate exhaust pipe hanger insulator. SECTION 309-
00: Exhaust System 2003 Mustang Workshop Manual Klj . 1 ba
32003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2308/S3B~us~en~ ...

REMOVAL AND INSTALLATION
Dual Converter Y-
Pipe —3.8L
Removal
NOTE: The RH and LH catalytic converters are serviceable separately.
1. Raise and support the vehicle. For additional information, refer to Section 100 - 02 .
2. CAUTION: When repairing the exhaust system or removing exhaust components,
disconnect all heated oxygen sensors (HO2S) (9F472) and catalyst monitor sensors at
the wiring connectors to prevent damage to the sensors and wiring harnesses.
Disconnect the RH and LH HO2S connectors.
3. Disconnect the RH and LH catalyst monitor sensor connectors.
4. Remove the dual converter assembly nuts.
SECTION 309-
00: Exhaust System 2003 Mustang Workshop Manual Klj . 1 ba
52003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2308/S3B~us~en~ ...

REMOVAL AND INSTALLATION
Dual Converter H-
Pipe —4.6L (2V and 4V)
Removal
NOTE: The RH and LH catalytic converters are serviced separately.
1. Raise and support the vehicle. For additional information, refer to Section 100 - 02 .
2. CAUTION: When repairing exhaust system or removing the exhaust components,
disconnect all heated oxygen sensors (HO2S) (9F472) at the wiring connectors to prevent
damage to the heated oxygen sensors and wiring harness.
Disconnect the downstream RH and LH heated oxygen sensor connectors (9F472).
3. Disconnect the two upstream RH and LH catalyst monitor sensor connectors.
4. Remove the dual converter assembly nuts. (RH shown, LH similar.)
SECTION 309-
00: Exhaust System 2003 Mustang Workshop Manual Klj . 1 ba
42003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2308/S3B~us~en~ ...