lock FORD MUSTANG 2003 Workshop Manual

1. Soak the blocking rings in transmission fluid for ten minutes.
2. Position the countershaft cluster gear in the case.
3.
CAUTION: Failure to correctly support the case during bearing installation will
result in permanent distortion of the case.
Using a the special tools and a press, install the rear countershaft bearing assembly. 1. Position two 6.35 mm (0.25 in) pieces of bar stock between the countershaft and the
case.
2. Using a the special tools and a press, install the rear countershaft bearing assembly. D8AZ-
19554- A A
Multi-
Purpose Grease
D0AZ- 19554- AA ESB-
M1C93-
B Clear Silicone Rubber
D6AZ-
19562- AA ESB-
M4G92-
A Motorcraft Premium Long Life
Grease
XG
-1-C ESA-
M1C75-
B Klj . 2 ba
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8. Install the pin.
9. Align the reverse gearshift lever, the reverse shift fork, and the reverse positioning spring.
10. NOTE: Observe the reverse positioning spring rotation. The spring must rotate
counterclockwise into its installed position.
Install the reverse shift fork.
zPlace the reverse idler gear and bushing into the NEUTRAL position. Align the reverse
shift fork and the reverse idler gear and bushing. Push downward on the reverse shift fork until fully engaged into the reverse idler gear and bushing. Klj . 4 ba
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14.
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.
Install the fourth speed synchronizer blocking ring. zAlign the notches in the synchronizer blocking ring and the synchronizer hub inserts.
15. NOTE: Verify that the fourth speed synchronizer blocking ring is still in position.
Align the flat on the fourth gear clutching teeth with the countershaft cluster gear and install the
input shaft.
16. NOTE: Do not install the end play shims at this time.
NOTE: Do not apply sealant to the input shaft bearing retainer at this time.
Install the bearing race in the bearing retainer.
17. Install the input shaft bearing retainer with the notch facing upward. Klj . 6 ba
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18. Install the bolts.
19. Install the output shaft rear bearing cup.
20. Install the reverse gear shift rail.
zAlign the ball stud with the slot in the case and align the reverse gear shift rail with the
reverse shift fork. Once the ball stud enters the case, rotate the reverse gear shift rail
until the ball aligns with the reverse gearshift lever. Rotate the reverse gear shift rail
counterclockwise until the ball stud fully engages the reverse gearshift lever. Klj . 7 ba
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21.
NOTE: If not done so previously, soak the blocking ring in transmission fluid for ten minutes.
Install the fifth speed cluster gear, the synchronizer blocking ring, the synchronizer assembly,
and the fifth gear shifter fork as an assembly.
22. CAUTION: To prevent component damage when installing the extension housing
(7A039), the alignment tab on the reverse brake ring (7M000) must engage the alignment
slot in the extension housing.
NOTE: If not done so previously, soak the blocking ring in transmission fluid for ten minutes.
Install the synchronizer blocking ring, the reverse brake ring, the thrust washer, and the fifth
speed synchronizer retaining snap ring.
23. Apply pipe sealant to the reversing lamp switch threads and install the switch.
24. Install the reverse gearshift lever retaining clip. Klj . 8 ba
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29. Apply a 3.2-
mm (1/8-in) bead of silicone rubber to the sealing surface on the extension housing.
30. Install the detent ball, the shifter detent spring, and the gearshift offset lever. 1. Coat the shifter detent spring with petroleum jelly and install it in the gearshift offset lever.
2. Lubricate the detent plate and install the detent ball in the neutral position on the plate.
3. Position the gearshift offset lever in the extension housing with the gear shift interlock
spring over the detent ball.
31. CAUTION: To prevent component damage, the alignment tab on the reverse brake
ring must align with the alignment slot in the extension housing.
NOTE: Verify that the oil pick- up funnel engages the fifth gear synchronizer.
Slide the gearshift offset lever and the extension housing into place as an assembly. Press
downward on the gearshift offset lever to compress the shifter interlock spring and push the
gearshift offset lever and extension housing into place. Klj . 10 ba
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SPECIFICATIONS
SECTION 308-
03B: Manual Transaxle/Transmission — TR3650 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 Silicone Rubber
D6AZ-
19562- BA ESB-
M4G92- A Pipe Sealant with Teflon®
D8AZ-
19554- A ESR-
M18P7- A Motorcraft MERCON® Multi-Purpose (ATF)
Transmission Fluid
XT -2-QDX MERCON®
Synchronizer
Synchronizer blocking ring to conical face runout 0.5 mm (0.02 in)
End Play
Input shaft end play 0.02286 mm (0.0009 in) -
0.0508 mm
(0.002 in) Countershaft cluster gear end play 0.0 mm (0.0 in) -
0.076 mm (0.003 in) Output shaft end play 0.0012 mm (0.0005 in) -
0.100 mm (0.004
in)
Torque Specifications Description Nm lb-
ft lb-
in Gearshift lever to extension housing bolt 23 13 —
Gear shift lever to gear shift stub shaft bolt 37 27 —
OSS to case bolt 10 — 89
Reverse idler gear bolt 27 20 —
Fifth/reverse lockout bolt 20 15 —
Clutch housing to transmission main case bolt 31 23 —
Extension housing to transmission main case bolt 31 23 —
Drain plug 23 17 —
Reversing lamp switch 37 27 —
Fill plug 17 13 —
Transmission to engine bolt 75 55 —
Engine plate to transmission bolt 27 20 —
Crossmember to frame bolt 41 30 — Klj . 1 ba
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DESCRIPTION AND OPERATION
Manual Transmission
The TR3650 five-
speed manual transmission features the following:
z The fifth speed gear functions as an overdrive gear.
z The forward gears are synchronized and helical cut.
z The reverse gear operates through a constant- mesh, fully synchronized system.
z The shift interlock system prevents the engagement of more than one gear.
z The countershaft is serviced as an assembly.
z An aluminum main case, extension housing and bell housing. Transmission Internal Components — Disassembled View SECTION 308-
03B: Manual Transaxle/Transmission — TR3650 2003 Mustang Workshop Manual Klj . 1 ba
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8 7064 Retaining ring
9 7124 Third/fourth gear synchronizer assembly
10 7107 Third/fourth gear synchronizer blocking ring
11 — Third/fourth gear synchronizer spring (part of
7124)
12 — Third/fourth gear synchronizer insert (part of
7124)
13 — Third/fourth gear synchronizer hub (part of 7124)
14 — Third/fourth gear synchronizer sleeve (part of
7124)
15 7B340 Third gear
16 7B369 Third gear needle bearing
17 — Third gear bushing
18 — Check ball
19 — Thrust washer
20 — Second gear needle bearing
21 7102 Second gear
22 7175 First/second gear synchronizer inner cone
23 7174 First/second gear synchronizer outer cone
24 7061 Output shaft
25 — Retaining ring
26 7124 First/second gear synchronizer assembly
27 7107 First/second gear synchronizer blocking ring
28 — First/second gear synchronizer spring (part of
7124)
29 — First/second gear synchronizer hub (part of 7124)
30 — First/second gear synchronizer insert (part of
7124)
31 — First/second gear synchronizer sleeve (part of
7124)
32 7127 First gear needle bearing
33 7100 First gear
34 — Reverse clutch cone
35 7124 Reverse gear synchronizer assembly
36 7107 Reverse gear synchronizer blocking ring
37 — Reverse gear synchronizer spring (part of 7124)
38 — Reverse gear synchronizer hub (part of 7124)
39 — Reverse gear synchronizer insert (part of 7124)
40 — Reverse gear synchronizer sleeve (part of 7124)
41 — Retaining ring
42 7N168 Reverse needle bearing
43 7C238 Reverse driven gear
44 — Reverse gear bushing Klj . 3 ba
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Transmission Case and Shift Components — Disassembled View 45 — Selector gate
46 7025 Mainshaft rear bearing and cup
47 7K316 Mainshaft fifth gear
48 — Retaining ring
49 7H150 Output shaft speed (OSS) sensor
50 — Retaining ring
51 7L172 Shim
52 7025 Countershaft front bearing and cup
53 7113 Countershaft
54 7025 Countershaft rear bearing and cup
55 — Thrust bearing
56 7144 Countershaft fifth gear
57 — Countershaft fifth gear needle bearing
58 — Countershaft fifth gear bearing spacer
59 — Retaining ring
60 7124 Fifth gear synchronizer assembly
61 7107 Fifth gear synchronizer blocking ring
62 — Fifth gear synchronizer spring (part of 7124)
63 — Fifth gear synchronizer hub (part of 7124)
64 — Fifth gear synchronizer insert (part of 7124)
65 — Fifth gear synchronizer sleeve (part of 7124)
66 — Fifth gear clutch cone
67 — Retaining ring
68 — Reverse idler gear support
69 7140 Reverse idler gear shaft
70 7141 Reverse idler gear
71 7E169 Reverse idler gear needle bearing
72 — Reverse idler gear bearing spacer Klj . 4 ba
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