lock FORD MUSTANG 2003 Workshop Manual

Transmission Identification
The transmission identification tag is located under the lower bolt that retains the extension housing to
the main case.
The five speed overdrive (TR3650) transmission is available for the Mustang 4.6L (2V).
Transmission Identification 16 7240 Main shift rail
17 7F018 Gearshift offset lever
18 — Spacer
19 — Bearing
20 7210 Gearshift lever
21 — Gearshift plate and spring
22 — Shipping seal
23 7052 Output shaft seal
24 — Extension housing bushing
25 7A039 Extension housing
26 7034 Vent
27 — Vehicle speed sensor (VSS)
28 — Fifth/reverse gear lockout
29 7L027 Magnet
30 7K201 Shift interlock plate
31 7005 Transmission main case
32 — Interlock pins
33 7A010 Drain plug
34 15520 Reverse lamp switch
35 — Detent plug
36 — Detent spring
37 — Detent
38 6392 Clutch housing
39 7B602 Ball stud
40 — Bearing
Part Klj . 6 ba
72003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2308/S3B~us~en~ ...

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
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2308/S3B~us~en~ ...

22. Remove the fifth gear synchronizer blocking ring.
zInspect the blocking ring for wear or damage. Install new blocking rings as necessary.
23. Remove the fifth gear synchronizer sleeve from the synchronizer hub.
24. Remove the synchronizer inserts and the springs.
25. Remove the needle bearings and the thrust washer. zThe fifth gear needle bearing is three separate pieces: bearing, spacer, bearing Klj . 7 ba
152003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2308/S3B~us~en~ ...

29. Remove the main shift rail and the plastic spacer.
30. Remove the bolts and the shift interlock plate.
31. Using a magnet, remove the interlock pins.
zOne lock pin in the center rail, two between the rails.
32. Remove the three detent plugs, springs and the detents. Klj . 9 ba
152003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2308/S3B~us~en~ ...

DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES
Input Shaft and Bearing
Disassembly and Assembly
1. Disassemble the input shaft. 1. Remove the third/fourth synchronizer blocking ring.
2. Remove the input shaft thrust washer.
3. Remove the input shaft thrust bearing.
4. Remove the input shaft pocket bearing.
z Inspect all components for wear or damage. Install new components as necessary.
SECTION 308-
03B: Manual Transaxle/Transmission — TR3650 2003 Mustang Workshop Manual Special Tool(s)
Remover, Driver Pinion
Bearing Cone
205-
D002 (D79L-4621- A) or
equivalent Installer, Drive Pinion Bearing
Cone
205-
011 (T57L-4621- B) Remover/Installer, Bearing
Tube
308-
024 (T75L-7025- B) Klj . 1 ba
32003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2308/S3B~us~en~ ...

2. Using the special tool and a press, remove the input shaft front bearing assembly. Discard the
bearing.
3. Inspect the input shaft and bearings for wear or damage. Install new components as necessary.
4. Using the special tools and a press, install the new input shaft front bearing.
5. Install the input shaft pocket bearing, the washer, input shaft bearing and the third/fourth synchronizer blocking ring.
zLubricate the bearing and bearing race with petroleum jelly. Klj . 2 ba
32003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2308/S3B~us~en~ ...

3. Remove reverse gear needle bearing.
zInspect the needle bearing for wear or damage. Install a new needle bearing as
necessary.
4. Remove the check ball and the blocking ring. zInspect the blocking ring for wear or damage. Install new blocking rings as necessary.
5. NOTE: Install the special tool with the flat side facing first gear. Klj . 2 ba
172003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2308/S3B~us~en~ ...

Using the special tools, press the bearing spacer, the reverse gear synchronizer cone and first
gear from the output shaft.
6. Remove the first gear needle bearing. zInspect the needle bearing for wear or damage. Install a new needle bearing as
necessary.
7. Remove the first gear synchronizer inner cone, the first gear synchronizer outer cone and the first gear synchronizer blocking ring.
zInspect all components for wear or damage. Install new components as necessary. Klj . 3 ba
172003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2308/S3B~us~en~ ...

8.
NOTE: Reposition the output shaft on the press with the input shaft end facing upward.
Remove and discard the retaining ring.
9. Remove the third/fourth synchronizer hub.
10. Remove the third/fourth blocking ring.
11. Remove the third gear. zInspect the gear for wear or damage. Install a new gear as necessary. Klj . 4 ba
172003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2308/S3B~us~en~ ...

12. Remove the third gear needle bearing.
zInspect the needle bearing for wear or damage. Install a new needle bearing as
necessary.
13. NOTE: Install the special tool behind second gear with the flat side of the tool facing second
gear.
Using the special tool, remove the spacer, second gear thrust washer and second gear.
zInspect the gear for wear or damage. Install a new gear as necessary.
14. Remove the check ball and second gear needle bearing. zInspect the needle bearing for wear or damage. Install a new needle bearing as
necessary.
15. Remove the second gear synchronizer inner cone, second gear synchronizer outer cone and the second gear synchronizer blocking ring.
zInspect all components for wear or damage. Install new components as necessary. Klj . 5 ba
172003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2308/S3B~us~en~ ...