FORD MUSTANG 2003 Workshop Manual

8.
NOTE: Rotate the transmission so that the input shaft is pointing downward.
NOTE: Rotate the input shaft/mainshaft to seat the bearings.
Using the special tools, measure the input shaft/mainshaft end play by applying an upward load
on the input shaft. Record the measurement.
9. Reposition the special tool on the countershaft. Place the tip of the dial between the fingers on the countershaft.
10. NOTE: Rotate the countershaft to seat the bearings.
Using the special tools, measure the countershaft gear end play by pushing upward on the
countershaft. Record the measurement. zUnscrew the installer from the handle. Insert the handle into the adapter plate plug hole. Klj . 4 ba
182003 Mustang Workshop Manual
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11. Remove the bolts and the transmission case.
12. Remove the countershaft. Klj . 5 ba
182003 Mustang Workshop Manual
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13. Remove the mainshaft.
14. Remove the input shaft. Klj . 6 ba
182003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2308/S3B~us~en~ ...

15. Remove the input shaft bearing cup and the countershaft bearing cup.
16. Using the special tools, install the new input shaft seal.
17. Using the recorded end play measurements, select and install the appropriate shims to achieve
the proper end play. Install the front input shaft bearing cup and the front countershaft bearing
cup.
zLubricate the bearing cups with petroleum jelly. Klj . 7 ba
182003 Mustang Workshop Manual
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18. Install the input shaft and fourth gear synchronizer blocking ring.
19. Assemble the shift rail assembly to the mainshaft, then install the mainshaft and shift rail as an
assembly.
zRotate the mainshaft to engage the fourth gear synchronizer blocking ring with the
synchronizer keys.
20. Lift up the mainshaft, then install the countershaft. Klj . 8 ba
182003 Mustang Workshop Manual
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21. Install the fifth/sixth and reverse shift rail assembly and align the slots of the shift levers with the
shift interlock plate.
22. Clean the mating surfaces of the transmission main case and the transmission adapter plate. Apply a bead of silicone rubber to the sealing surface on the transmission adapter plate. Install
the spring and detent ball into the front offset lever, then install the transmission case and the
front offset lever.
zMake sure the transmission is in neutral to keep the third/fourth gear shift rail from
engaging.
z Compress the front offset lever against the guide plate when installing.
z Tighten the bolts in a star pattern. Klj . 9 ba
182003 Mustang Workshop Manual
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23. Apply threadlock and sealer to the threads of the shift lever guide bolts, then install the bolts.
zPull up on the fifth/sixth shift rail to align the slot of the interlock plate with the guide bolt
hole.
24. Install a new front offset lever roll pin. zInstall the pin until it is flush with the lever.
25. Apply threadlock and sealer to the threads of the shift dent, then install the shift detent assembly. Klj . 10 ba
182003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2308/S3B~us~en~ ...

26. Clean the mating surfaces of the transmission main case and the shift detent cover. Apply a
bead of silicone rubber to the sealing surface on the transmission case. Install the cover and
tighten the bolts.
27. Rotate the transmission to a horizontal position. Install the countershaft extension assembly and the fifth/sixth gear shift fork. Make sure the splines are fully engaged.
28. NOTE: Remove the countershaft extension shim from the extension housing.
Install the extension housing and tighten the bolts.
29. NOTE: Rotate the transmission to the vertical position.
Using the special tools, measure the countershaft extension end play by pushing upward on the
countershaft extension. Record the measurement. zInsert a suitable bar into the adapter plate plug hole until it engages the countershaft
extension. Klj . 11 ba
182003 Mustang Workshop Manual
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30. Remove the extension housing.
31.
NOTE: If a new countershaft extension bearing was installed, install a new bearing cup.
Using the recorded end play measurement, select and install the appropriate shims to achieve
the proper end play. Install the countershaft extension bearing cup. zLubricate the bearing cup with petroleum jelly.
32. Install the fifth/sixth shift fork snap ring.
33. Using the special tool, press the fifth/sixth driven gear. zAlign the splines of the fifth/sixth driven gear with the drive gear on the countershaft
extension. Klj . 12 ba
182003 Mustang Workshop Manual
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34. Install the reverse shift fork, the reverse synchronizer and the thrust washer as an assembly.
zAlign the pockets in the blocking ring with the struts in the synchronizer.
35. Install the reverse shift fork snap ring.
36. Install a new reverse gear synchronizer snap ring. 37. Install the reverse gear needle bearing and the reverse gear synchronizer blocking ring. Klj . 13 ba
182003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2308/S3B~us~en~ ...