torque FORD MUSTANG 2003 Workshop Manual

REMOVAL
Transmission
CAUTION: Whenever a transmission has been disassembled to install new parts the
transmission fluid cooler tubes must be cleaned and backflushed. Use a suitable torque
converter/fluid cooler cleaner. If equipped a new oil- to-air cooler must also be installed.
When internal wear or damage has occurred in the transmission, metal particles, clutch plate
material or band material may have been carried into the torque converter and fluid cooler.
These contaminants are a major cause of recurring transmission troubles and must be
removed from the system before the transmission is put back into use.
CAUTION: After transmission is removed for a major overhaul, it is important to
completely clean all transmission components, including torque converter, oil- to-air cooler if
equipped, cooler inlet tube, main control valve body, clutches and all coasting booster valve
shuttle balls after any transmission repair that generates contamination. These contaminants
are a major cause for recurring transmission concerns and must be removed from the system
before the transmission is returned to use.
The cleaning of foreign material from the direct clutch check ball is often omitted. This
omission can lead to repeat repair of the transmission.
If equipped a new oil- to-air cooler must be installed under the following conditions; for
installation refer to Section 307 - 02 .
z Evidence of transmission assembly or fluid contamination is found due to the following
transmission or converter failure modes:
„major metallic failure
„ multiple clutches or clutch plate failures
„ sufficient component wear which results in metallic contamination.
1. Place the transmission range selector lever in NEUTRAL.
2. Disconnect the battery ground cable. For additional information, refer to Section 414 - 01 .
3. Raise and support the vehicle. For additional information, refer to Section 100 - 02 .
4. Remove the dual converter Y pipe. For additional information, refer to Section 309 - 00 .
5. Disconnect the transmission harness electrical connector.
SECTION 307-
01: Automatic Transaxle/Transmission 2003 Mustang Workshop Manual Special Tool(s)
Retainer, Torque Converter
307-
346 (T97T-7902- A) Klj . 1 ba
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24. Unclip the harness.
25.
WARNING: The torque converter is heavy and may result in injury if it falls out of
the transmission. Secure the torque converter in the transmission.
Using the special tool, secure the torque converter in the transmission then lower the
transmission from the vehicle.
26. Carry out the transmission fluid cooler backflushing and cleaning. For additional information, refer to Transmission Fluid Cooler — Backflushing and Cleaning . Klj . 6 ba
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DISASSEMBLY
Transmission
SECTION 307-
01: Automatic Transaxle/Transmission 2003 Mustang Workshop Manual Special Tool(s)
Slide Hammer
100-
001 (T50T-100- A) Holding Fixture, Transmission
307-
003 (T57L- 500-B) Slide Hammer
307-
005 (T59L- 100-B) Remover, Transmission Fluid
Seal
307-
048 (T74P-77248- A) Handle, Torque Converter
307-
091 (T81P-7902- C) Remover, Transmission Fluid
Pump
307-
221 (T89T-70010- A) Remover/Installer, Servo
Piston
307-
251 (T92P-70023- A) Remover, Torque Converter
Fluid Seal Klj . 1 ba
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1. Remove the special tool.
2. Using the special tools, remove torque converter.
3. Using the special tool, mount the transmission to the bench. 307-
309 (T94P-77001- BH) Retainer, Torque Converter
307-
346 (T97T-7902- A) Remover, Bearing Cup
308-
047 (T77F-1102- A) Klj . 2 ba
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7.
CAUTION: Do not pull on the molded lead frame. This may cause damage to the
connector ends. Carefully pry up on the locking tabs to disconnect the solenoids.
Disconnect the molded lead frame from the solenoids.
Disconnect the molded lead frame from the solenoids. 1. Disconnect the shift solenoid SSA and SSB.
2. Disconnect the torque converter clutch (TCC).
3. Disconnect the electronic pressure control (EPC) solenoid.
4. Disconnect the bulkhead inter- connector.
8. Remove the output shaft speed (OSS) sensor. 1. Remove the bolt.
2. Remove the OSS sensor. Klj . 4 ba
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26. Using the special tools, remove the extension housing seal.
27.
NOTE: These bolts have been coated with a sealant. High break torque may be required to
remove these bolts.
Remove the extension housing.
1. Remove the four bolts and two nuts.
2. Remove the extension housing and the extension housing gasket.
28. Remove the parking pawl. 1. Remove the parking pawl shaft.
2. Remove the parking pawl return spring.
3. Remove the parking pawl.
29. Rotate the transmission to the vertical position with the output shaft towards the floor.
30. CAUTION: Extreme care must be taken during transmission connector removal. Do
not use a hammer on the connector body.
Place a screwdriver on the flat portion of the connector and push the connector out through the
bottom of the case. Klj . 10 ba
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31. Using the special tools, remove the front pump seal.
32.
NOTE: These bolts have been coated with sealant. High break torque may be required to
remove the bolts.
Remove the bolts.
33. Using the special tools, remove the front pump support.
34. Remove and discard the pump gasket. Klj . 11 ba
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1. Remove the torque converter clutch (TCC) solenoid and the shift solenoid.
1. Remove the bolt.
2. Remove the shift solenoid.
3. Remove the TCC solenoid.
2. Remove the two reinforcement plates. 1. Remove the bolts.
2. Remove the plates.
3. Remove the separator plate and discard the gaskets.
4. NOTE: Note the location of the eight coasting booster valve shuttle balls for assembly. Remove the eight coasting booster valve shuttle balls. 45 — Control valve plate (part of 7A100) Klj . 3 ba
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Assembly
1. CAUTION: Before beginning assembly, carry out and inspect the following:
When building up subassemblies and assembling the transmission, ALWAYS use new
gaskets and seals.
All fasteners must be tightened to the torque specification indicated. In addition to
appearing in the section, the necessary torques can be found in the General
Specifications Chart.
When building up subassemblies, each component part should be lubricated with clean
transmission fluid. It is also good practice to lubricate the subassemblies as they are
installed in the case.
Needle bearings, thrust washers and seals should be lightly coated with petroleum jelly
during subassembly buildup or transmission assembly.
Many components and surfaces in the transmission are precision machined. Careful
handling during disassembly, cleaning, inspection and assembly can prevent
unnecessary damage to machined surfaces.
Install the valve body cover plate. 1. Position the valve body cover plate gasket and cover plate.
2. Install the two guide pin bolts.
3. Install the bolts.
2. Tighten the bolts in the sequence shown. Klj . 5 ba
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DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES
Pump and Intermediate Clutch Piston
Pump and Intermediate Clutch Piston —
Disassembled View
SECTION 307-
01: Automatic Transaxle/Transmission 2003 Mustang Workshop Manual Special Tool(s)
Installer, Front Pump Fluid
Seal
307-
014 (T63L-77837- A) Protector, Piston Seal
307-
339 (T95L-77005- A) Item Part Number Description
1 7902 Torque converter
2 7A248 Front pump O-
ring 3 N605789-S101 Bolt
4 — Pump body assembly
5 N605787-S1000 Front pump support bolt
6 7D014 No. 1 pump support thrust washer
7 7D020 Reverse clutch cylinder seal
8 7D019 Forward clutch cylinder seal
9 7E005 Intermediate clutch piston
10 7F224 Intermediate clutch piston outer seal Klj . 1 ba
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