warning FORD MUSTANG 2003 Workshop Manual

DISASSEMBLY
Transmission
Disassembly
NOTE:
During disassembly, if any roll pins, retaining rings or bearings are removed, install new
components. Install bearings and bearing cups as a set only.
1. WARNING: Make sure protective eye wear is in place. SECTION 308-
03C: Manual Transaxle/Transmission — T56 2003 Mustang Workshop Manual Special Tool(s)
Holding Fixture, Transmission
307-
003 (T57L- 500-B) Puller, Bearing
205-
D064 (D84L-1123- A) 2 or 3 Jaw Puller
205-
D027 (D80L-1013- A) Remover, Mainshaft Bearing
308-
058 (T77J-7025- H) Remover/Installer, Bearing
Tube
308-
025 (T75L-7025- C) Removal Screw, Bearing Tube
308-
092 (T84T-7025- B) Klj . 1 ba
132003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2308/S3B~us~en~ ...

41. Remove the input shaft bearing cup and input shaft shim.
zInspect the cup for wear or damage. Install a new cup and bearing as necessary.
z Inspect the cup bore for wear, scratches or grooves. Install a new transmission adapter
plate as necessary.
42. Remove and discard the input shaft seal.
43. WARNING: Make sure protective eye wear is in place.
Clean the transmission adapter plate with solvent and dry with compressed air. Inspect the
adapter plate for cracks. Clean and check the sealing surface for nicks or scratches. zIf the adapter plate is cracked, install a new plate. If the sealing surface has nicks or
scratches, use a soft stone or crocus cloth to remove. Klj . 12 ba
132003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2308/S3B~us~en~ ...

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
62003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2308/S3B~us~en~ ...

7.
WARNING: Make sure protective eye wear is in place.
Clean the case with solvent and dry with compressed air. Clean and check the sealing surface
for nicks or scratches. Inspect the case for cracks. zIf the case is cracked, install a new case. If the sealing surface has nicks or scratches,
use a soft stone or crocus cloth to remove.
8. NOTE: If a new countershaft bearing is being installed, install a new bearing cup. Always install
new bearings and cups in a set.
Using the special tools, install the countershaft bearing cup.
9. NOTE: If a new mainshaft bearing is being installed, install a new bearing cup. Always install
new bearings and cups in a set.
Using the special tools, install the mainshaft bearing cup.
10. To assemble, reverse the disassembly procedure. Klj . 3 ba
42003 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~ ...

DESCRIPTION AND OPERATION
Fuel System
Component Location
WARNING: Do not smoke or carry lighted tobacco or open flame of any type when
working on or near any fuel- related components. Highly flammable mixtures are always present and may be ignited, resulting in possible personal injury. SECTION 310-
00: Fuel System — General Information 2003 Mustang Workshop Manual Item Part Number Description
1 9341 Inertia fuel shutoff switch
2 9F593 Fuel injector
3 9155 Fuel filter
4 9002 Fuel tank
5 9H307 Fuel pump module and flange assembly Klj . 1 ba
22003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2308/S3B~us~en~ ...

GENERAL PROCEDURES
Pressure Relief
WARNING: Do not smoke or carry lighted tobacco or open flame of any type when
working on or near any fuel- related components. Highly flammable mixtures are always present
and may be ignited, resulting in possible personal injury.
WARNING: Fuel in the fuel system remains under high pressure even when the engine is
not running. Before servicing or disconnecting any of the fuel lines or fuel system components,
the fuel system pressure must be relieved to prevent accidental spraying of fuel, causing
personal injury or a fire hazard.
1. Remove the Schrader valve cap and install the Fuel Pressure Gauge.
2. CAUTION: Open the manual valve slowly on the Fuel Pressure Gauge.
Relieve the fuel pressure. zPlace the fuel in a suitable container.
SECTION 310-
00: Fuel System — General Information 2003 Mustang Workshop Manual Special Tool(s)
Fuel Pressure Gauge
310-
012 (T80L-9974- B) Klj . 1 ba
22003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2308/S3B~us~en~ ...

GENERAL PROCEDURES
Fuel Tank Draining
WARNING: Do not smoke or carry lighted tobacco or an open flame of any type when
working on or near any fuel- related components. Highly flammable mixtures are always present
and may be ignited, resulting in possible personal injury.
1. Disconnect the battery ground cable. For additional information, refer to Section 414 - 01 .
2. Remove the fuel tank filler cap.
3. Insert the hose guide into the filler neck.
4. NOTE: Insert the hose until the stop contacts the guide tube. If the stop does not contact the
guide tube, remove the hose and repeat the procedure.
Insert the chamfered end of the hose into the filler neck through the guide tube.
SECTION 310-
00: Fuel System — General Information 2003 Mustang Workshop Manual Special Tool(s)
Fuel Storage Tanker
164-R3202 or equivalent
Fuel Tank Drain Hose
310-
F013 Klj . 1 ba
22003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2308/S3B~us~en~ ...

GENERAL PROCEDURES
Spring Lock Couplings
Disconnect
WARNING: Do not smoke or carry lighted tobacco or open flame of any type when
working on or near any fuel- related components. Highly flammable mixtures are always present
and may be ignited, resulting in possible personal injury.
WARNING: Fuel in the fuel system remains under high pressure even when the engine is
not running. Before servicing or disconnecting any of the fuel lines or fuel system components,
the fuel system pressure must be relieved to prevent accidental spraying of fuel, causing
personal injury or a fire hazard.
1. Relieve the fuel system pressure. For additional information, refer to Pressure Relief in this
section.
2. Remove the fuel tube clip.
SECTION 310-
00: Fuel System — General Information 2003 Mustang Workshop Manual Special Tool(s)
Disconnect Tool, Spring Lock
Coupling (3/8 inch yellow)
310-
D004 (D87L-9280- A) or
equivalent Disconnect Tool, Spring Lock
Coupling (1/2 inch green)
310-
D005 (D87L-9280- B) or
equivalent
Material Item Specification
SAE 5W-
20 Super Premium
Synthetic Blend Motor Oil
XO- 5W20- QSP or equivalent WSS-
M2C153-
H Klj . 1 ba
32003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2308/S3B~us~en~ ...

GENERAL PROCEDURES
Fuel Line Fittings —
Push Connect
Disconnect WARNING: Do not smoke or carry lighted tobacco or open flame of any type when
working on or near any fuel- related components. Highly flammable mixtures are always present
and may be ignited, resulting in possible personal injury.
WARNING: Fuel in the fuel system remains under high pressure even when the engine is
not running. Before servicing or disconnecting any of the fuel lines or fuel system components,
the fuel system pressure must be relieved to prevent accidental spraying of fuel, causing
personal injury or a fire hazard.
1. Relieve the fuel system pressure. For additional information, refer to Pressure Relief in this
section.
2. Disconnect the safety clip from the male hose.
3. Install the Fuel Line Disconnect Set and push into the fitting.
SECTION 310-
00: Fuel System — General Information 2003 Mustang Workshop Manual Special Tool(s)
Disconnect Tool, Spring Lock
Coupling
310-
S039 (T90T-9550- S)
Material Item Specification
SAE 5W-
20 Super Premium
Blend Motor Oil
XO- 5W20-QSP or equivalent WSS-
M2C153-
H Klj . 1 ba
32003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2308/S3B~us~en~ ...