FORD MUSTANG 2003 Workshop Manual

Klj . 2 ba
22003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2308/S3B~us~en~ ...

DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES
Gearshift Rail and Fork
Disassembly and Assembly
1. Using a 5/32- inch drift and a hammer, remove and discard the split pin. Slide the shift fork from
the shift rail.
2. Remove the gearshift fork inserts.
3. CAUTION: Support the shift rail to prevent damage to the parts.
Position the gearshift fork on the shift rail. Align the split pin hole and install a new split pin.
4. Install the gear shift fork inserts.
SECTION 308-
03B: Manual Transaxle/Transmission — TR3650 2003 Mustang Workshop Manual Klj . 1 ba
22003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2308/S3B~us~en~ ...

Klj . 2 ba
22003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2308/S3B~us~en~ ...

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~ ...

3.
NOTE: If a new rear output shaft bearing was installed or a new rear countershaft bearing is
being used, install new bearing cups.
Install the rear countershaft bearing cup and the rear output shaft bearing cup.
zLubricate the bearing cups and the shift rail bearing with petroleum jelly.
4. Install the rear countershaft bearing.
5. Install the reverse idler gear bearings and spacer on the shaft. Klj . 2 ba
192003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2308/S3B~us~en~ ...

6. Install the reverse idler gear on the shaft.
7. Install the reverse idler gear into the case.
8. Install a new seal on the reverse idler bolt, then install the bolt in the transmission case.
9.
NOTE: If a new front input shaft bearing or front countershaft bearing was installed, install new
bearing cups.
Install the front input shaft bearing cup and the front countershaft bearing cup. Do not install the
shims at this time.
zInstall the transmission main case. Klj . 3 ba
192003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2308/S3B~us~en~ ...

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
192003 Mustang Workshop Manual
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13. Install the countershaft.
zLift the mainshaft upward, tilt the countershaft and install.
14. Install the case with two opposing bolts.
15. NOTE: Rotate the transmission so that the input shaft is pointing upward.
NOTE: Rotate the input shaft to seat the bearings.
Using the special tools, measure the input shaft end play by applying an upward load on the Klj . 5 ba
192003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2308/S3B~us~en~ ...

output shaft. Record the measurement.
16. Rotate the transmission so that the input shaft is pointing downward.
17. NOTE: Rotate the countershaft to seat the bearings.
Using the special tools, measure the countershaft gear end play by pulling upward on the
countershaft. Record the measurement.
18. Remove the two bolts and lift the transmission main case off. Klj . 6 ba
192003 Mustang Workshop Manual
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19. Remove the countershaft.
20. Remove the mainshaft. Klj . 7 ba
192003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2308/S3B~us~en~ ...