manual transmission FORD MUSTANG 2003 Workshop Manual

IN-
VEHICLE REPAIR
Gearshift Lever and Boot
Removal and Installation 1. Remove the gearshift lever knob.
2. Remove the console panel gearshift plate. Lift the gearshift lever boot over the gearshift lever.
3. Remove the bolts and the shift lever.
SECTION 308-
03B: Manual Transaxle/Transmission — TR3650 2003 Mustang Workshop Manual Material
Item Specification
Clear Silicone Rubber
D6AZ-
19562- AA or equivalent ESB-
M4G92- A Klj . 1 ba
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IN-
VEHICLE REPAIR
Output Shaft Speed (OSS) Sensor
Removal and Installation 1. With the vehicle in NEUTRAL, raise and support the vehicle. For additional information, refer to Section 100 - 02 .
2. Disconnect the electrical connector.
3. Remove the output shaft speed (OSS) sensor.
4. To install, reverse the removal procedure.
SECTION 308-
03B: Manual Transaxle/Transmission — TR3650 2003 Mustang Workshop Manual Klj . 1 ba
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REMOVAL
Transmission
1. Disconnect the battery ground cable. For additional information, refer to Section 414 - 01 .
2. Remove the gearshift lever knob.
3. Remove the console panel gearshift plate. Lift the gearshift lever boot over the gearshift lever.
4. Remove the bolts and the shift lever.
5. With the vehicle in NEUTRAL, raise and support the vehicle. For additional information, refer to Section 100 - 02 .
6. Remove the dual converter H- pipe. For additional information, refer to Section 309 - 00 .
7. CAUTION: Index- mark the driveshaft flange and pinion flange, and the driveshaft slip yoke and transmission output shaft. SECTION 308-
03B: Manual Transaxle/Transmission — TR3650 2003 Mustang Workshop Manual Klj . 1 ba
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Remove the driveshaft. For additional information, refer to
Section 205 - 01 .
8. Disconnect the reversing lamp switch electrical connector. Disconnect the wiring harness from the transmission.
9. Remove the starter motor. For additional information, refer to Section 303 - 06 .
10. Remove the bolts.
11. Remove the starter solenoid nuts and position the wires aside. Klj . 2 ba
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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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17. If transmission disassembly is necessary, drain the transmission fluid.
18. Position a transmission jack and support the transmission.
19. Remove the bolts and the transmission crossmember.
20. Remove the bolts. Klj . 4 ba
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21. Lower the transmission and remove the five bolts. Klj . 5 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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4.
NOTE: Position a drain pan under the transmission.
Remove the case plug, then rotate the transmission to a horizontal position.
5. Using the special tools, remove the extension housing fluid seal.
6. NOTE: Rotate the transmission to a vertical position. NOTE: Position the gearshift lever in NEUTRAL. Klj . 2 ba
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10. Remove the 12 bolts.
11. Using a flat-
blade screwdriver, separate the extension housing, then remove the gearshift offset
lever from the transmission case.
zRemove and discard the split pin from the gearshift offset lever during removal.
12. Remove the fifth/reverse gear lockout bolt.
13. Remove the fifth/reverse gear lockout. Klj . 4 ba
152003 Mustang Workshop Manual
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