manual transmission FORD MUSTANG 2003 Workshop Manual

33.
CAUTION: Do not remove all the bolts while in the horizontal position.
Remove the bolts. zRotate the transmission to a horizontal position. Remove 12 bolts, leaving two opposing
bolts in. Rotate the transmission to a vertical position, then remove the remaining two
bolts.
34. Carefully pry the clutch housing from the transmission main case. 35. Remove the transmission main case from the clutch housing. Klj . 10 ba
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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
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DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES
Output Shaft
Disassembly
1. Remove the retaining ring above fifth gear.
2. CAUTION: Hand tighten the special tool to prevent gear damage.
CAUTION: Support the output shaft while using the press to prevent damage to the
shaft or gears.
Using the special tool, press fifth gear, the spacer, the output shaft bearing and reverse gear
from the output shaft.
zDiscard the output shaft bearing.
SECTION 308-
03B: Manual Transaxle/Transmission — TR3650 2003 Mustang Workshop Manual Special Tool(s)
Remover, Drive Pinion Bearing
Cone
205-
D002 (D79L-4621- A) or
equivalent Installer, Drive Pinion Bearing
Cone
205-
011 (T57L-4621- B) Klj . 1 ba
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16. Remove the snap ring, then using the special tool, press off the first/second gear synchronizer.
Assembly 1. Carry out the following before reassembling: zInspect the gears for broken or cracked teeth. Check for unusual wear patterns.
z Inspect the thrust washers for face wear, cracks, scoring and for signs of heat damage.
z Inspect the bearings, bearing cups and the synchronizers for wear or damage.
z Inspect the output shaft for scoring or worn or damaged splines. Install new components
as necessary.
2. Lubricate all components with the recommended transmission fluid when reassembling.
3. NOTE: Position the output shaft with the output end facing upward.
NOTE: Install the synchronizer assembly with the deeper center flange of the synchronizer hub
facing toward the rear of the output shaft.
Install the first/second synchronizer assembly on the output shaft, then install a new retaining
ring.
zIt may be necessary to press the hub into position on the shaft. Klj . 6 ba
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DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES
Countershaft Bearing
Disassembly and Assembly
1. Cut the outer cage, then remove the outer cage and rollers.
2. Using the special tool and a press, remove the inner bearing.
3. Using the special tools, install the new countershaft bearing.
SECTION 308-
03B: Manual Transaxle/Transmission — TR3650 2003 Mustang Workshop Manual Special Tool(s)
Remover, Drive Pinion Bearing
Cone
205-
D002 (D79L-4621- A) or
equivalent Installer, Drive Pinion Bearing
Cone
205-
011 (T57L-4621- B) Klj . 1 ba
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DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES
Synchronizers
Disassembly and Assembly
NOTE:
This procedure applies to all synchronizer assemblies.
1. Scribe an alignment mark on the sliding sleeve and the hub for assembly reference.
2. Remove the sliding sleeve, then remove the synchronizer struts and the springs.
3. Install the synchronizer struts and the springs.
4. CAUTION: Match the alignment marks made during disassembly. The sleeve and
the hub have an extremely close fit. Hold the sleeve and hub square to prevent jamming.
Do not force the sleeve onto the hub.
Install the sliding sleeve.
SECTION 308-
03B: Manual Transaxle/Transmission — TR3650 2003 Mustang Workshop Manual Klj . 1 ba
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DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES
Gearshift Rail Bushing
Disassembly and Assembly
1. Using the special tools, remove the gearshift rail bearing from the transmission case. Discard the bearing.
2. Using the special tool, install the main shift rail bearing.
SECTION 308-
03B: Manual Transaxle/Transmission — TR3650 2003 Mustang Workshop Manual Special Tool(s)
Universal Puller Set
303-
DS005 (D80L-100- A) or
equivalent Installer, Shift Rail Bushing
308-
244 (T96P-7025- F) Slide Hammer
100-
001 (T50T-100- A) Klj . 1 ba
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DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES
Gearshift Rail and Fork
Disassembly and Assembly
1. Using a 5/32- inch drift and a hammer, remove and discard the split pin. Slide the shift fork from
the shift rail.
2. Remove the gearshift fork inserts.
3. CAUTION: Support the shift rail to prevent damage to the parts.
Position the gearshift fork on the shift rail. Align the split pin hole and install a new split pin.
4. Install the gear shift fork inserts.
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03B: Manual Transaxle/Transmission — TR3650 2003 Mustang Workshop Manual Klj . 1 ba
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ASSEMBLY
Transmission
1. Lubricate all components with transmission fluid during assembly.
2. Attach the clutch housing to the special tool.
SECTION 308-
03B: Manual Transaxle/Transmission — TR3650 2003 Mustang Workshop Manual Special Tool(s)
Dial Indicator Gauge with
Holding Fixture
100-
002 (TOOL- 4201-C) or
equivalent Holding Fixture, Transmission
307-
003 (T57L- 500-B) Remover/Installer, Bearing
Tube
308-
024 (T75L-7025- B) Replacer/Adapter
308-
239 (T96P-7025- A) Installer, Transmission
Extension Housing Oil Seal
308-
227 (T94P-7657- A)
Material Item Specification
Motorcraft MERCON® Multi-
Purpose (ATF) Transmission
Fluid
XT
-2-QDX MERCON
Premium Long Life Grease
XG
-1-C, K or T ESA-
M1C75-
B Klj . 1 ba
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6. Install the reverse idler gear on the shaft.
7. Install the reverse idler gear into the case.
8. Install a new seal on the reverse idler bolt, then install the bolt in the transmission case.
9.
NOTE: If a new front input shaft bearing or front countershaft bearing was installed, install new
bearing cups.
Install the front input shaft bearing cup and the front countershaft bearing cup. Do not install the
shims at this time.
zInstall the transmission main case. Klj . 3 ba
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