clutch FORD MUSTANG 2003 Workshop Manual

12. Remove the starter motor.
13. Disconnect the OSS sensor electrical connector. Disconnect the wiring harness from the
transmission.
14. Remove the bolt and the clutch release lever cover.
15. CAUTION: To prevent component damage, do not depress the clutch pedal with the
transmission removed.
Disengage the clutch release cable from the clutch release fork.
16. Remove the clutch cable retainer and remove the clutch cable from the transmission. Klj . 3 ba
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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.
1. Remove the clutch release hub and bearing and the clutch release lever. For additional information, refer to Section 308 - 01 .
2. WARNING: Make sure protective eye wear is in place.
Clean the transmission exterior with solvent and dry with compressed air. During disassembly,
clean all components with solvent and dry with compressed air.
3. Attach the transmission to the special tool.
SECTION 308-
03B: Manual Transaxle/Transmission — TR3650 2003 Mustang Workshop Manual Special Tool(s)
Remover, Mainshaft Bearing
308-
058 (T77J-7025- H) Screw, Bearing Removal tube
308-
092 (T84T-7025- B) Holding Fixture, Transmission
307-
003 (T57L- 500-B) Remover, Bushing
307-
001 (TOOL- 1175-AC) Remover/Installer, Bearing
Tube
308-
024 (T75L-7025- B) Klj . 1 ba
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18. Remove and discard the fifth gear synchronizer retaining ring.
19. Using a 5/32-
inch drift and a hammer, remove and discard the pin from the fifth gear shift fork.
20. Remove the fifth gear shift fork, synchronizer assembly, synchronizer cone and the fifth gear as an assembly. 21. Remove the fifth gear clutch cone. Klj . 6 ba
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33.
CAUTION: Do not remove all the bolts while in the horizontal position.
Remove the bolts. zRotate the transmission to a horizontal position. Remove 12 bolts, leaving two opposing
bolts in. Rotate the transmission to a vertical position, then remove the remaining two
bolts.
34. Carefully pry the clutch housing from the transmission main case. 35. Remove the transmission main case from the clutch housing. Klj . 10 ba
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41. Remove the reverse idler gear assembly.
42. Remove the reverse idler gear from the shaft.
zInspect the gear for wear or damage. Install a new gear as necessary.
43. Remove the reverse idler gear bearing. zThe reverse idler gear is three separate pieces: bearing, spacer, bearing.
z Inspect the bearing for wear or damage. Install new bearings as necessary.
44. Disassemble the clutch housing. 1. Remove the countershaft bearing cup and shim.
2. Remove the input shaft bearing cup and shim.
3. Remove the input shaft seal.
„Carefully pry out from the inside of the case. Klj . 13 ba
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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
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10. Install the input shaft.
11. Install the shift rails and shift forks on the mainshaft.
12. Install the mainshaft onto the clutch housing.
zThe notches on the shift rail should be pointing upward.
z Align the shift rails in the bores. Klj . 4 ba
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28. Install the countershaft.
29. Clean the mating surfaces of the transmission main case and the clutch housing. Apply a bead
of silicone rubber to the sealing surface on the clutch housing then install the transmission main
case. Tighten the bolts in a star pattern. Klj . 10 ba
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56. Install the shipping seal.
57. Rotate the transmission to a horizontal position.
58. Clean the mating surfaces of the shift cover opening surface and the shift cover. Apply a bead
of silicone rubber to the shift cover opening surface.
59. Install the gear shift lever.
60. NOTE: Before installing the transmission, the ball stud, the clutch release lever and the input Klj . 18 ba
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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
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