FORD MUSTANG 2003 Workshop Manual

2. Assemble the gear shifter forks.
1. Install the gear shift plate into the gear shifter fork.
2. Install the gear shift fork inserts.
3. NOTE: Position the narrow side of the C- shaped gear selector interlock sleeve in the case
cover slot. Position the roll pin hole in the selector body toward the rear of the cover.
Install the gear selector interlock sleeve and the selector body as an assembly.
4. Lubricate the main shift control shaft with petroleum jelly.
5. NOTE: The 1-2 gear shifter fork is the larger shifter fork. The gear shifter fork offset lever must
face the cover. Position the gear shift plate attached to the 3- 4 gear shifter fork under the gear
shift plate attached to the 1- 2 gear shifter fork.
Position the gear shifter forks and the main shift control shaft in the cover. zSlide the shaft through the cover and shift the components until the shaft stops against
the cover.
6. CAUTION: Install the pin slightly below the selector body surface. Failure to
countersink the pin may result in interference between the pin and the gear selector interlock sleeve during shifts. Klj . 3 ba
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NOTE:
The flat on the main shift control shaft must face upward.
Install the pin. Klj . 4 ba
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DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES
Input Shaft and Bearing
Disassembly
1. Using the special tool and a press, remove the input bearing (7025).
2. Remove the bearing race and the end play selective shims.
3. Remove the input shaft seal (7052). Assembly SECTION 308-
03A: Manual Transaxle/Transmission — T5OD 2003 Mustang Workshop Manual Special Tool(s)
Input Shaft Seal Replacer
308-
220 (T94P-7025- AH) Pinion Bearing Cone Remover
205-
D002 (D79L-4621- A) or
Equivalent Klj . 1 ba
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1. Using the special tool, install the input shaft seal.
2.
NOTE: In installing a new input shaft seal as part of a transmission overhaul, do not install the
end play selective shims at this time.
Instal the end play selective shims and the bearing race.
3. Using a press and a capped length of pipe, install the input bearing. Klj . 2 ba
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Klj . 3 ba
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DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES
Output Shaft
Disassembly
1. Using the special tool and a press, remove the third/fourth gear synchronizer assembly (7124), the third speed synchronizer blocking ring (7107), and the third gear (7B340) as an assembly.
2. Remove the third speed bearing (7B369) and the third speed gear bearing spacer (7B320).
3. Remove the snap ring.
SECTION 308-
03A: Manual Transaxle/Transmission — T5OD 2003 Mustang Workshop Manual Special Tool(s)
Pinion Bearing Cone Remove
205-
D002 (D79L-4621- A) or
Equivalent Spiral Snap Ring Replacer
308-
096 (T85P-7025- A) Klj . 1 ba
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4. Using the special tool and a press, remove the fifth speed driven gear (7K316).
5. Remove the output shaft rear bearing (7065).
6. Remove the first gear (7100).
7.
NOTE: The first gear bearing spacer (7173) fits snugly on the output shaft assembly (7061).
Remove the first gear bearing (7127) and the spacer as an assembly. Klj . 2 ba
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8. Remove the first and second speed synchronizer hub ball (7K218).
9. Remove the first speed synchronizer inner cone (7175), the first speed synchronizer outer cone
(7174), and the first speed synchronizer blocking ring (7107) as an assembly.
10. Remove the snap ring and the thrust washer (7119).
11. Remove the second gear (7102), the second speed bearing (7B369), and the second speed gear bearing spacer (7728). Klj . 3 ba
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12. Remove the output shaft bearing snap ring and the second speed synchronizer thrust washer
(7117).
13. Remove the second speed synchronizer inner cone (7175), the second speed synchronizer outer cone (7174), and the second speed synchronizer blocking ring (7107) as an assembly.
14. Remove the first and second gear synchronizer sliding sleeve (7124).
15. CAUTION: Note the orientation of the synchronizer hub insert springs (7109) and
the synchronizer hub inserts (7A044) for assembly reference.
NOTE: The first and second gear synchronizer sliding sleeve, the hub, and the output shaft are
an assembly. Do not attempt to separate the hub from the output shaft. Only the synchronizer
hub insert springs and the synchronizer hub inserts are available separately. Remove the synchronizer hub insert springs and the hub inserts. Klj . 4 ba
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Assembly
1. Soak the blocking rings in transmission fluid for ten minutes. zUse MERCON® Multi- Purpose ATF Transmission Fluid XT -2-QDX or equivalent.
2. Assemble the first and second synchronizer. 1. Install the synchronizer hub insert springs and the synchronizer inserts into the synchronizer hub.
2. Install the sliding sleeve onto the hub.
3. 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.
NOTE: Align the slots in the synchronizer blocking ring with the tabs in the first and second
speed synchronizer.
Install the second speed synchronizer blocking ring and the inner and outer cones as an
assembly.
4. Install the second speed synchronizer thrust washer.
5. Using the special tool, install the output shaft bearing snap ring. Klj . 5 ba
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