transmission fluid FORD MUSTANG 2003 Workshop Manual

ASSEMBLY
Transmission
1. Lubricate all components with transmission fluid during assembly.
2. Attach the clutch housing to the special tool.
SECTION 308-
03B: Manual Transaxle/Transmission — TR3650 2003 Mustang Workshop Manual Special Tool(s)
Dial Indicator Gauge with
Holding Fixture
100-
002 (TOOL- 4201-C) or
equivalent Holding Fixture, Transmission
307-
003 (T57L- 500-B) Remover/Installer, Bearing
Tube
308-
024 (T75L-7025- B) Replacer/Adapter
308-
239 (T96P-7025- A) Installer, Transmission
Extension Housing Oil Seal
308-
227 (T94P-7657- A)
Material Item Specification
Motorcraft MERCON® Multi-
Purpose (ATF) Transmission
Fluid
XT
-2-QDX MERCON
Premium Long Life Grease
XG
-1-C, K or T ESA-
M1C75-
B Klj . 1 ba
192003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2308/S3B~us~en~ ...

52. Install the shift spring and bracket.
53. Install a new split pin in the gear shift off-
set lever.
z The split pin should be flush in the gear shift off- set lever.
54. Seat the extension housing and tighten the bolts to specification. zFill the gear shift off- set lever with petroleum jelly.
55. Using the special tool, install a new extension housing seal. zLubricate the seal with transmission fluid. Klj . 17 ba
192003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2308/S3B~us~en~ ...

shaft guide tube must be cleaned and lubricated.
Install the clutch release hub and bearing and the clutch release lever. For additional
information, refer to Section 308-
01.
61. Fill the transmission with transmission fluid to the specified level. zTransmission capacity is 3.6 liters (7.5 pints). Klj . 19 ba
192003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2308/S3B~us~en~ ...

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. For additional information, refer to Transmission in
this section.
zCheck, and as necessary, fill the transmission with transmission fluid. The total fill
capacity is 3.6L (7.5 pt).
2. Apply sealant to the fill plug threads and install the fill plug. zUse pipe sealant with Teflon® .
SECTION 308-
03B: Manual Transaxle/Transmission — TR3650 2003 Mustang Workshop Manual Material
Item Specification
Motorcraft MERCON® Multi-
Purpose (ATF) Transmission
Fluid
XT
-2-QDX MERCON
Pipe Sealant with Teflon®
D8AZ-
19554- A or equivalent WSK-
M2G350-
A2 Premium Long Life Grease
XG
-1-C, K or T or equivalent ESA-
M1C75- B Klj . 1 ba
12003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2308/S3B~us~en~ ...

SPECIFICATIONS
SECTION 308-
03C: Manual Transaxle/Transmission — T56 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 Non-
Acid Cure Silicone Rubber
E7TZ- 19562- A ESL-
M4G273- A Pipe Sealant with Teflon®
D8AZ-
19554- A ESR-
M18P7-A Preload
Input/output shaft preload 0.0 mm (in) -
0.05 mm (0.002 in) Countershaft cluster gear preload 0.0 mm (in) -
0.05 mm (0.002 in) Countershaft extension preload 0.05 mm (in) -
0.13 mm (0.005 in) Fluid
DEXRON III® (
ATF) Transmission Fluid
XT -2-QDX DEXRON III®
Capacity 3.9 L (4.1 qt.)
Synchronizer
Synchronizer blocking ring to conical face runout
1st, 2nd, 3rd, 4th, 5th & 6th gear 0.38 mm (0.01 in)
Synchronizer blocking ring to conical face runout
Reverse gear 0.75 mm (0.03 in)
Torque Specifications Description Nm lb-
ft lb-
in Transmission-to-
clutch adapter housing bolts 35 26 —
Crossmember-
to-frame bolts 41 30 —
Crossmember-
to-
transmission support bolts 58 43 —
OSS sensor bolt 10 — 7
Gearshift lever boot bolts 10 — 89
Lower gearshift lever bolts 20 15 —
Upper gearshift lever bolts 37 27 —
Shift dent 40 30 —
Shift lever guide bolts 27 20 — Klj . 1 ba
22003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2308/S3B~us~en~ ...

GENERAL PROCEDURES
Transmission Draining and Filling
1. Remove the drain plug and drain the transmission. zPosition a suitable drain pan under the transmission.
2. Clean and install the drain plug.
3. NOTE: Before removing, clean the area around the filler plug.
Remove the filler plug.
4. Using a suitable oil suction gun, fill the transmission to the correct level with the specified fluid. zTransmission capacity is 3.9 liters (4.1 quarts).
SECTION 308-
03C: Manual Transaxle/Transmission — T56 2003 Mustang Workshop Manual Material
Item Specification
DEXRON III® (
ATF)
Transmission Fluid
XT -2-QDX DEXRON III® Klj . 1 ba
22003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2308/S3B~us~en~ ...

5. Remove the bolts and the lower gearshift lever.
6. Disconnect the reverse lockout solenoid electrical connector.
7. With the vehicle in NEUTRAL, raise and support the vehicle. For additional information, refer to
Section 100 - 02 .
8. Drain the transmission fluid.
9. CAUTION: Index- mark the driveshaft flange and pinion flange, and the driveshaft Klj . 2 ba
52003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2308/S3B~us~en~ ...

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
122003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2308/S3B~us~en~ ...

ASSEMBLY
Transmission
SECTION 308-
03C: Manual Transaxle/Transmission — T56 2003 Mustang Workshop Manual Special Tool(s)
Dial Indicator Gauge with
Holding Fixture
100-
002 (TOOL- 4201-C) or
equivalent Holding Fixture, Transmission
307-
003 (T57L- 500-B) Remover/Installer, Bearing
Tube
308-
025 (T75L-7025- C) Installer, Bearing Cup
204-
039 (T77F-1217- B) Adapter for 303-
224 (Handle)
205- 153 (T80T-4000- W) Installer, Axle Shaft Oil Seal
205-
123 (T78P-1177- A)
Material Item Specification
DEXRON III® (
ATF)
Transmission Fluid
XT -2-QDX or equivalent DEXRON III®
Premium Long Life Grease ESA-
M1C75- B Klj . 1 ba
182003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2308/S3B~us~en~ ...

1. Lubricate all components with transmission fluid during assembly.
2. Attach the transmission adapter plate to the special tool.
3.
NOTE: If a new front input shaft bearing or front countershaft bearing was installed, install new
bearing cups.
Install the input shaft bearing cup and the countershaft bearing cup. Do not install the shims at
this time.
4. Install the input shaft.
5. Install the mainshaft onto the input shaft. XG
-1-C, K or T Threadlock and Sealer
E0AZ-
19554- AA WSK-
M2G351- A5
(type II) Black Non-
Acid Cure
Silicone Rubber
E7TZ- 19562- A ESL-
M4G273- A Klj . 2 ba
182003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2308/S3B~us~en~ ...