transmission fluid FORD MUSTANG 2003 Workshop Manual

14.
NOTE: If not done so previously, soak the blocking ring in MERCON® Multi- Purpose ATF
Transmission Fluid XT -2-QDX or equivalent for ten minutes.
Install the fourth speed synchronizer blocking ring. zAlign the notches in the synchronizer blocking ring and the synchronizer hub inserts.
15. NOTE: Verify that the fourth speed synchronizer blocking ring is still in position.
Align the flat on the fourth gear clutching teeth with the countershaft cluster gear and install the
input shaft.
16. NOTE: Do not install the end play shims at this time.
NOTE: Do not apply sealant to the input shaft bearing retainer at this time.
Install the bearing race in the bearing retainer.
17. Install the input shaft bearing retainer with the notch facing upward. Klj . 6 ba
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21.
NOTE: If not done so previously, soak the blocking ring in transmission fluid for ten minutes.
Install the fifth speed cluster gear, the synchronizer blocking ring, the synchronizer assembly,
and the fifth gear shifter fork as an assembly.
22. CAUTION: To prevent component damage when installing the extension housing
(7A039), the alignment tab on the reverse brake ring (7M000) must engage the alignment
slot in the extension housing.
NOTE: If not done so previously, soak the blocking ring in transmission fluid for ten minutes.
Install the synchronizer blocking ring, the reverse brake ring, the thrust washer, and the fifth
speed synchronizer retaining snap ring.
23. Apply pipe sealant to the reversing lamp switch threads and install the switch.
24. Install the reverse gearshift lever retaining clip. Klj . 8 ba
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38. Apply a 3.2-
mm (1/8-inch) bead of silicone rubber to the sealing surface on the gearshift lever.
39. Install the gearshift lever.
40. Using the special tool, install the extension housing fluid seal.
41. Install the case plug.
42. NOTE: Before installing the transmission, the ball stud, clutch release lever and the input shaft
must be cleaned and lubricated with grease.
Install the clutch release hub and bearing and the clutch release lever. For additional
information, refer to Section 308 - 01 . Klj . 13 ba
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INSTALLATION
Transmission
1. NOTE: Before installing the transmission, the ball stud, clutch release lever and the input shaft
must be cleaned and lubricated. Use Motorcraft Premium Long-Life Grease XG-1- C or XG-1-K
or equivalent meeting Ford specification ESA- M1C75-B.
To install, reverse the removal procedure. Refer to Transmission in this section.
z Check, and as necessary, fill the transmission with MERCON® Multi- Purpose ATF
Transmission Fluid XT -2-QDX or equivalent. The total fill capacity is 2.6L (2.8 qt).
SECTION 308-
03A: Manual Transaxle/Transmission — T5OD 2003 Mustang Workshop Manual Klj . 1 ba
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SPECIFICATIONS
SECTION 308-
03B: Manual Transaxle/Transmission — TR3650 2003 Mustang Workshop Manual General Specifications
Item Specification
Lubricants and Sealants
Premium Long-
Life Grease
XG -1-C, K or T ESA-
M1C75- B Threadlock and Sealer
E0AZ-
19554- AA WSK-
M2G351- A5 Black Silicone Rubber
D6AZ-
19562- BA ESB-
M4G92- A Pipe Sealant with Teflon®
D8AZ-
19554- A ESR-
M18P7- A Motorcraft MERCON® Multi-Purpose (ATF)
Transmission Fluid
XT -2-QDX MERCON®
Synchronizer
Synchronizer blocking ring to conical face runout 0.5 mm (0.02 in)
End Play
Input shaft end play 0.02286 mm (0.0009 in) -
0.0508 mm
(0.002 in) Countershaft cluster gear end play 0.0 mm (0.0 in) -
0.076 mm (0.003 in) Output shaft end play 0.0012 mm (0.0005 in) -
0.100 mm (0.004
in)
Torque Specifications Description Nm lb-
ft lb-
in Gearshift lever to extension housing bolt 23 13 —
Gear shift lever to gear shift stub shaft bolt 37 27 —
OSS to case bolt 10 — 89
Reverse idler gear bolt 27 20 —
Fifth/reverse lockout bolt 20 15 —
Clutch housing to transmission main case bolt 31 23 —
Extension housing to transmission main case bolt 31 23 —
Drain plug 23 17 —
Reversing lamp switch 37 27 —
Fill plug 17 13 —
Transmission to engine bolt 75 55 —
Engine plate to transmission bolt 27 20 —
Crossmember to frame bolt 41 30 — Klj . 1 ba
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IN-
VEHICLE REPAIR
Seal
Removal 1. With the vehicle in NEUTRAL, raise and support the vehicle. For additional information, refer to Section 100 - 02 .
2. CAUTION: Index- mark the driveshaft flange and pinion flange, and the driveshaft
slip yoke and transmission output shaft.
Remove the driveshaft. For additional information, refer to Section 205 - 01 .
3. Using the special tools, remove the extension housing fluid seal.
Installation 1. Using the special tool, install the extension housing fluid seal.
SECTION 308-
03B: Manual Transaxle/Transmission — TR3650 2003 Mustang Workshop Manual Special Tool(s)
Installer, Transmission
Extension Housing Oil Seal
308-
227 (T94P-7657- A) Slide Hammer
100-
001 (T50T-100- A) Remover, Bushing
307-
001 (TOOL- 1175-AC) or
Equivalent Klj . 1 ba
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2.
CAUTION: Align the index marks.
Install the driveshaft. For additional information, refer to Section 205 - 01 .
3. Check the transmission fluid level, add fluid if necessary.
4. Lower the vehicle. Klj . 2 ba
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17. If transmission disassembly is necessary, drain the transmission fluid.
18. Position a transmission jack and support the transmission.
19. Remove the bolts and the transmission crossmember.
20. Remove the bolts. Klj . 4 ba
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4.
NOTE: Position a drain pan under the transmission.
Remove the case plug, then rotate the transmission to a horizontal position.
5. Using the special tools, remove the extension housing fluid seal.
6. NOTE: Rotate the transmission to a vertical position. NOTE: Position the gearshift lever in NEUTRAL. Klj . 2 ba
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16. Remove the snap ring, then using the special tool, press off the first/second gear synchronizer.
Assembly 1. Carry out the following before reassembling: zInspect the gears for broken or cracked teeth. Check for unusual wear patterns.
z Inspect the thrust washers for face wear, cracks, scoring and for signs of heat damage.
z Inspect the bearings, bearing cups and the synchronizers for wear or damage.
z Inspect the output shaft for scoring or worn or damaged splines. Install new components
as necessary.
2. Lubricate all components with the recommended transmission fluid when reassembling.
3. NOTE: Position the output shaft with the output end facing upward.
NOTE: Install the synchronizer assembly with the deeper center flange of the synchronizer hub
facing toward the rear of the output shaft.
Install the first/second synchronizer assembly on the output shaft, then install a new retaining
ring.
zIt may be necessary to press the hub into position on the shaft. Klj . 6 ba
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