key FORD MUSTANG 2003 Workshop Manual

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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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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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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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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SPECIFICATIONS
SECTION 310-
00: Fuel System — General Information 2003 Mustang Workshop Manual General Specifications
Item Specification
Fuel tank capacity 59.42 liters (15.7 gallons)
Key on, engine off fuel pressure 207-
345 kPa
(30-50 psi) Engine running fuel pressure (idle) 152-
255 kPa
(27-37 psi) Lubricants
SAE 5W-
20 Super Premium Synthetic Blend Motor Oil XO-5W20- QSP WSS-
M2C153- H Klj . 1 ba
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Pinpoint Tests
PINPOINT TEST A: THE SPEED CONTROL IS INOPERATIVE
Test Step Result / Action to Take
A1 CHECK THE SPEED CONTROL SERVO VOLTAGE AND
GROUND z
Key in OFF position.
z Disconnect: Speed Control Servo C122.
z Key in ON position.
z Measure the voltage between speed control servo C122 Pin 7,
Circuit 294 (WH/LB), harness side and speed control servo
C122 Pin 10, Circuit 1205 (BK), harness side.
z Is voltage greater than 10 volts? Yes
GO to
A3 .
No
GO to A2 .
A2 CHECK THE CIRCUIT 1205 (BK) FOR AN OPEN
z
Key in OFF position.
z Measure the resistance between speed control servo C122 Pin
10, Circuit 1205 (BK), harness side and ground.
z Is the resistance less than 5 ohms? Yes
REPAIR Circuit 294
(WH/LB). TEST the
system for normal
operation.
No
REPAIR Circuit 1205
(BK). TEST the system
for normal operation.
A3 CHECK DEACTIVATOR SWITCH CIRCUITRY
z
Measure the voltage between speed control servo C122 Pin 9,
Circuit 636 (OG), harness side and speed control servo C122
Pin 10, Circuit 1205 (BK), harness side. Yes
GO to
A6 .
No
GO to A4 . Klj . 4 ba
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z
Is the voltage greater than 10 volts? A7 CHECK CIRCUIT 151 (LB/BK) FOR AN OPEN
z
Disconnect: Air Bag Sliding Contact C218a.
z Measure the resistance between speed control servo C122 Pin
5, Circuit 151 (LB/BK), harness side and air bag sliding contact
C218a Pin 4, Circuit 151 (LB/BK), harness side.
z Is the resistance less than 5 ohms? Yes
GO to
A8 .
No
REPAIR the circuit.
TEST the system for
normal operation. A8 CHECK THE AIR BAG SLIDING CONTACT
z
Remove the air bag; REFER to Section 501 - 20B .
z Disconnect: Speed Control Actuator Switch.
z Measure the resistance between bottom of air bag sliding
contact Pin 1 (component side) and top of air bag sliding
contact Pin 3 (component side).
z Is the resistance less than 5 ohms? Yes
INSTALL a new speed
control actuator switch;
REFER to
Switch —
Speed Control
Actuator . TEST the
system for normal
operation.
No
INSTALL a new air bag
sliding contact; REFER
to Section 501 - 20B .
TEST the system for
normal operation. A9 CHECK THE SPEED CONTROL ACTUATOR SWITCH ON
CIRCUITRY FOR SHORT TO POWER z
Key in ON position.
z Measure the voltage between speed control servo C122 Pin 5,
Circuit 151 (LB/BK), harness side and speed control servo C122
Pin 10, Circuit 1205 (BK), harness side. Yes
GO to
A10 .
No
GO to A12 . Klj . 6 ba
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z
Is any voltage present? A10 CHECK CIRCUIT 151 (LB/BK) FOR SHORT TO POWER
z
Key in OFF position.
z Disconnect: Air Bag Sliding Contact C218a.
z Key in ON position.
z Measure the voltage between speed control servo C122 Pin 5,
Circuit 151 (LB/BK), harness side and speed control servo C122
Pin 10, Circuit 1205 (BK), harness side.
z Is any voltage present? Yes
REPAIR the circuit.
TEST the system for
normal operation.
No
GO to
A11 .
A11 CHECK THE AIR BAG SLIDING CONTACT
z
Key in OFF position.
z Remove the air bag; REFER to Section 501 - 20B .
z Disconnect: Speed Control Actuator Switch.
z Key in ON position.
z Measure the voltage between bottom of air bag sliding contact
Pin 1 (component side) and ground.
z Is any voltage present? Yes
INSTALL a new air bag
sliding contact; REFER
to Section 501
- 20B .
TEST the system for
normal operation.
No
INSTALL a new speed
control actuator switch;
REFER to Switch —
Speed Control
Actuator . TEST the
system for normal
operation. A12 CHECK THE SPEED CONTROL ACTUATOR SET/ACCEL
CIRCUITRY z
Key in OFF position.
z Measure the resistance between speed control servo C122 Pin
5, Circuit 151 (LB/BK), harness side and speed control servo
C122 Pin 6, Circuit 848 (DG/OG), harness side, while the speed
control actuator switch SET/ACCEL is depressed. Yes
GO to
A13 .
No
INSTALL a new speed
control actuator switch; Klj . 7 ba
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PINPOINT TEST C: THE SPEED CONTROL DOES NOT DISENGAGE
WHEN THE BRAKES ARE APPLIED
PINPOINT TEST D: THE SPEED CONTROL DOES NOT DISENGAGE
WHEN THE CLUTCH IS APPLIED B2 CHECK THE SPEED CONTROL
ACTUATOR CABLE z
NOTE: The speed control actuator cable
must be disconnected at both ends while
carrying out this test.
z Check the speed control actuator cable
for sticking or binding at the speed
control servo and throttle body.
z Is the speed control actuator cable
OK? Yes
GO to
B3 .
No
INSTALL a new speed control actuator cable;
REFER to Actuator Cable — Speed Control .
TEST the system for normal operation. B3 CHECK THE SPEED CONTROL SERVO
z
INSTALL a known good speed control
servo.
z Test drive the vehicle for correct
operation.
z Does the speed control operate
correctly? Yes
INSTALL a new speed control servo; REFER
to
Actuator — Speed Control Servo . TEST the
system for normal operation.
No
INSTALL a new PCM; REFER to Section 303 -
14 . TEST the system for normal operation.
Test Step Result / Action to Take
C1 CHECK THE BPP SWITCH CIRCUITRY
z
Key in OFF position.
z Disconnect: Speed Control Servo C122 .
z Measure the voltage between speed control servo C122 Pin 4,
Circuit 511 (LG), harness side and speed control servo C122
Pin 10, Circuit 1205 (BK), harness side, while depressing the
brake pedal.
z Is the voltage greater than 10 volts? Yes
INSTALL a new speed
control servo; REFER to
Actuator
— Speed
Control Servo . TEST
the system for normal
operation.
No
REPAIR Circuit 810
(RD/LG) and Circuit 511
(LG) as necessary.
TEST the system for
normal operation. Test Step Result / Action to Take
D1 CHECK THE CLUTCH PEDAL POSITION (CPP) SWITCH
z
Key in OFF position.
z Disconnect: CPP Switch C2072.
z Measure the resistance between CPP switch pin 2
(component side) and CPP switch pin 1 (component side), Yes
INSTALL a new speed
control servo; REFER to
Actuator
— Speed Control Klj . 10 ba
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