manual transmission FORD MUSTANG 2003 Workshop Manual

7.
NOTE: Position the gearshift lever in third/fourth neutral position.
Using a 5/32- inch drift and a hammer, drive the roll pin downward, then remove the rear offset
shift lever.
zInspect the rear offset shift lever for wear or damage. Install a new lever as necessary.
z Discard the roll pin.
8. Remove the eight bolts and carefully separate the extension housing from the transmission. Klj . 3 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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blocking ring.
26. Using the special tools, remove the fifth/sixth driven gear.
27. Remove the fifth/sixth shift fork snap ring.
28. Rotate the transmission to the horizontal position, then remove the countershaft extension as an assembly.
29. Remove the shift detent cover. Klj . 8 ba
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30. Remove the shift detent assembly.
31. Using a 5/32-
inch drift and a hammer, drive the roll pin downward.
32. Remove nine of the adapter- to-transmission case bolts.
33. NOTE: Rotate the transmission to a vertical position.
Remove the shift lever guide bolts. Klj . 9 ba
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34. Remove the two remaining adapter-
to-transmission case bolts, then remove the transmission
case and the front offset lever.
zSlide the transmission case upward, off the mainshaft and shift rails. Hold the offset lever
against the guide plate to prevent the release of the dent ball and spring.
35. Remove the dent ball, spring and roll pin from the front offset lever.
36. Rotate the fifth/sixth and reverse shift levers from the shift interlock plate, then remove the fifth/sixth and reverse shift rail assembly. Klj . 10 ba
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37. Lift up the mainshaft, then remove the countershaft.
38. Remove the mainshaft and shift rail as an assembly. Separate the shift rail assembly from the
mainshaft on the work bench.
39. Remove the input shaft and fourth gear synchronizer blocking ring.
40. Remove the countershaft bearing cup and the countershaft shim. zInspect the cup for wear or damage. Install a new cup and bearing as necessary.
z Inspect the cup bore for wear, scratches or grooves. Install a new transmission adapter
plate as necessary. Klj . 11 ba
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41. Remove the input shaft bearing cup and input shaft shim.
zInspect the cup for wear or damage. Install a new cup and bearing as necessary.
z Inspect the cup bore for wear, scratches or grooves. Install a new transmission adapter
plate as necessary.
42. Remove and discard the input shaft seal.
43. WARNING: Make sure protective eye wear is in place.
Clean the transmission adapter plate with solvent and dry with compressed air. Inspect the
adapter plate for cracks. Clean and check the sealing surface for nicks or scratches. zIf the adapter plate is cracked, install a new plate. If the sealing surface has nicks or
scratches, use a soft stone or crocus cloth to remove. Klj . 12 ba
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DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES
Input Shaft and Bearing
Disassembly and Assembly
SECTION 308-
03C: Manual Transaxle/Transmission — T56 2003 Mustang Workshop Manual Special Tool(s)
Plate, Bearing/Oil Seal
205-
090 (T75L-1165- B) Puller, Bearing
205-
D064 (D84L-1123- A) Installer, Drive Pinion Bearing
Cone
205-
004 (T53T-4621- B) Adapter Set, Step Plate
205-
DS011 (D80L-630- A) Universal Puller Set
303-
DS005 (D80L-100- A) Klj . 1 ba
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DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES
Output Shaft
Disassembly
SECTION 308-
03C: Manual Transaxle/Transmission — T56 2003 Mustang Workshop Manual Special Tool(s)
Puller, Bearing
205-
D064 (D84L-1123- A) Adapter for 303-
224 (Handle)
205- 153 (T80T-4000- W) Installer, Output Shaft Rear
Bearing
308-401
Remover/Installer, Bearing
Tube
308-
025 (T75L-7025- C) Item Part Number Description
1 7025 Output shaft front bearing Klj . 1 ba
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13. Inspect the output shaft for scoring or worn or damaged splines. Install a new output shaft as
necessary.
Assembly
1. Lubricate all components with the recommended transmission fluid when reassembling.
2. Using the special tools, press the output shaft front bearing on the output shaft.
3. Install the third gear bearing. zApply petroleum jelly to the bearing.
4. Install third gear, the third gear synchronizer blocking ring and the third/fourth gear synchronizer assembly. Position the output shaft with the output end facing upward. Using the special tool,
press the third/fourth gear synchronizer assembly into place.
zInstall the synchronizer body with the groove facing third gear.
z Stop press operation before keys engage the blocking ring slots. Lift and rotate the third
gear and the blocking ring until the keys are seated in the blocking ring. Klj . 7 ba
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