sensor 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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14. Remove the shipping seal.
15. Remove the OSS sensor tone wheel retaining ring.
16. Using the special tools, remove the OSS sensor tone wheel.
17. Remove the OSS sensor tone wheel check ball. Klj . 5 ba
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44. Install the control rail and the plastic spacer, then install the first/second shift finger. Install a
new split pin.
zInstall the split pin until it is flush with the shift finger.
45. Install the OSS sensor tone wheel check ball. zUse petroleum jelly to hold the check ball in place.
46. Place the OSS sensor tone wheel on the output shaft, aligning the slot in the OSS wheel with the check ball. Using the special tool, install the OSS sensor tone wheel. Klj . 15 ba
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47. Install a new OSS sensor tone wheel retaining ring.
48. Install the fifth/reverse gear lockout.
49. Install the bolt.
50. Clean the mating surfaces of the transmission main case and the extension housing. Apply a
bead of silicone rubber to the sealing surface of the transmission case.
51. Install the extension housing and at the same time install the gear shift off- set lever. Klj . 16 ba
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SPECIFICATIONS
SECTION 308-
03C: Manual Transaxle/Transmission — T56 2003 Mustang Workshop Manual General Specifications
Item Specification
Lubricants and Sealants
Premium Long-
Life Grease
XG -1-C, K or T ESA-
M1C75- B Threadlock and Sealer
E0AZ-
19554- AA WSK-
M2G351- A5 Black Non-
Acid Cure Silicone Rubber
E7TZ- 19562- A ESL-
M4G273- A Pipe Sealant with Teflon®
D8AZ-
19554- A ESR-
M18P7-A Preload
Input/output shaft preload 0.0 mm (in) -
0.05 mm (0.002 in) Countershaft cluster gear preload 0.0 mm (in) -
0.05 mm (0.002 in) Countershaft extension preload 0.05 mm (in) -
0.13 mm (0.005 in) Fluid
DEXRON III® (
ATF) Transmission Fluid
XT -2-QDX DEXRON III®
Capacity 3.9 L (4.1 qt.)
Synchronizer
Synchronizer blocking ring to conical face runout
1st, 2nd, 3rd, 4th, 5th & 6th gear 0.38 mm (0.01 in)
Synchronizer blocking ring to conical face runout
Reverse gear 0.75 mm (0.03 in)
Torque Specifications Description Nm lb-
ft lb-
in Transmission-to-
clutch adapter housing bolts 35 26 —
Crossmember-
to-frame bolts 41 30 —
Crossmember-
to-
transmission support bolts 58 43 —
OSS sensor bolt 10 — 7
Gearshift lever boot bolts 10 — 89
Lower gearshift lever bolts 20 15 —
Upper gearshift lever bolts 37 27 —
Shift dent 40 30 —
Shift lever guide bolts 27 20 — Klj . 1 ba
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slip yoke and transmission output shaft.
Remove the driveshaft. For additional information, refer to
Section 205 - 01 .
10. Disconnect the heated oxygen sensor (HO2S) electrical connectors from the crossmember.
11. Position a transmission jack and support the transmission.
12. Remove the bolts and the transmission crossmember.
13. Remove the bolt and the clutch release lever cover. Klj . 3 ba
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14. Disengage the clutch release cable from the clutch release fork.
15. Disconnect the wiring harness from the transmission.
16. Disconnect the output shaft speed (OSS) sensor electrical connector.
17. Disconnect the reverse lamp electrical connector. Klj . 4 ba
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9. Remove the plug from the transmission adapter plate.
10. NOTE: Rotate the transmission to a vertical position.
Remove the shipping seal.
11. Remove the output shaft speed (OSS) sensor tone wheel retaining ring.
12. Using the special tools, remove the OSS sensor tone wheel. Klj . 4 ba
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13. Remove and discard the OSS sensor tone wheel lower retaining ring.
14. Remove and discard the rear mainshaft roller bearing snap ring.
15. Remove the upper spacer, the rear mainshaft roller bearing and the lower spacer.
zInspect the rear mainshaft roller bearing for wear or damage. Install a new bearing as
necessary.
16. Remove and discard the reverse gear snap ring. Klj . 5 ba
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Item Part Number Description
1 — Countershaft extension bearing cup
2 — Countershaft extension bearing shim
3 — Fluid funnel
4 — Case plug
5 — Reverse idler shaft bracket
6 — Reverse idler gear thrust washer
7 7141 Reverse idler gear
8 — Reverse idler gear needle bearing
9 7140 Reverse idler gear shaft
10 7052 Extension housing seal
11 — Snap ring
12 — Mainshaft bearing cup
13 — Output shaft speed (OSS) sensor
14 — Reverse lockout solenoid
15 — O-
ring Klj . 2 ba
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