manual transmission FORD MUSTANG 2003 Workshop Manual

DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES
Countershaft
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) Remover/Installer, Bearing
Tube
308-
025 (T75L-7025- C) Installer, Output Shaft Rear
Bearing
308-401
Adapter for 303-
224 (Handle)
205- 153 (T80T-4000- W) 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. NOTE: Synchronizer components are not interchangeable. During disassembly, mark each
individual synchronizer for assembly. Synchronizer hubs and sleeves are a selected assembly
and should be kept together as originally assembled. Blocking rings are not interchangeable, do
not mix.
Scribe an alignment mark on the sliding sleeve and the hub for assembly reference.
2. Using a screwdriver, remove the spring. Turn the synchronizer over and remove the second spring. Remove the sliding sleeve and the synchronizer struts from the hub.
3. 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.
Assemble the synchronizer as follows:
zPosition the synchronizer sleeve on the hub. Make sure to align key openings in the hub
with the synchronizer sleeve.
z Install the keys with the slots facing the hub.
z Install the spring. Locate the tang to one of the key slots and position into place. Install
the second spring. Locate the spring tang on the same key but position in the opposite
direction.
SECTION 308-
03C: Manual Transaxle/Transmission — T56 2003 Mustang Workshop Manual Klj . 1 ba
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DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES
Gearshift Rail and Fork
Disassembly and Assembly
1. Disassemble the first/second and third/fourth shift rail as follows: zRotate the interlock plate until it is opposite of the shift links.
z Slide off the third/fourth shift fork and shift link. Separate the link from the fork.
z Slide off the first/second shift fork and shift link. Separate the link from the fork.
SECTION 308-
03C: Manual Transaxle/Transmission — T56 2003 Mustang Workshop Manual Item Part Number Description
1 — First/second shift fork pad
2 — First/second shift fork
3 — Interlock plate
4 — Shift link
5 — First/second, third/fourth shift rail
6 — Gear select solenoid lever
7 — Roll pin
8 — Selector pin
9 — Roll pin
10 — Shift link
11 — Third/fourth shift fork pad
12 — Third/fourth shift fork
13 — Shift rail collar
14 — Roll pin
15 — Fifth/sixth shift rail
16 — Roll pin
17 — Fifth/sixth shift rail lever
18 — Reverse shift rail lever Klj . 1 ba
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DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES
Extension Housing
Disassembly and Assembly
SECTION 308-
03C: Manual Transaxle/Transmission — T56 2003 Mustang Workshop Manual Special Tool(s)
Installer, Bearing Cup
204-
039 (T77F-1217- B) Adapter for 303-
224 (Handle)
205- 153 (T80T-4000- W) Klj . 1 ba
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DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES
Transmission Case
Disassembly and Assembly
1. Remove the bolts and the guide plate. zInspect the plate for wear or damage. Install a new plate as necessary. 2. Remove the case magnets. SECTION 308-
03C: Manual Transaxle/Transmission — T56 2003 Mustang Workshop Manual Special Tool(s)
Handle
205-
D055 (D81L-4000- A) Installer, Bearing Cup
204-
039 (T77F-1217- B) Installer, Drive Pinion Bearing
Cup
205-
054 (T71P-4616- A) Installer, Rear Axle Oil Seal
205-
155 (T80T-4000- Y) Klj . 1 ba
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ASSEMBLY
Transmission
SECTION 308-
03C: Manual Transaxle/Transmission — T56 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-
025 (T75L-7025- C) Installer, Bearing Cup
204-
039 (T77F-1217- B) Adapter for 303-
224 (Handle)
205- 153 (T80T-4000- W) Installer, Axle Shaft Oil Seal
205-
123 (T78P-1177- A)
Material Item Specification
DEXRON III® (
ATF)
Transmission Fluid
XT -2-QDX or equivalent DEXRON III®
Premium Long Life Grease ESA-
M1C75- B Klj . 1 ba
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1. Lubricate all components with transmission fluid during assembly.
2. Attach the transmission adapter plate to the special tool.
3.
NOTE: If a new front input shaft bearing or front countershaft bearing was installed, install new
bearing cups.
Install the input shaft bearing cup and the countershaft bearing cup. Do not install the shims at
this time.
4. Install the input shaft.
5. Install the mainshaft onto the input shaft. XG
-1-C, K or T Threadlock and Sealer
E0AZ-
19554- AA WSK-
M2G351- A5
(type II) Black Non-
Acid Cure
Silicone Rubber
E7TZ- 19562- A ESL-
M4G273- A Klj . 2 ba
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6. Install the countershaft.
zLift the mainshaft upward, tilt the countershaft and install.
7. Install the transmission case and tighten the bolts. Klj . 3 ba
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8.
NOTE: Rotate the transmission so that the input shaft is pointing downward.
NOTE: Rotate the input shaft/mainshaft to seat the bearings.
Using the special tools, measure the input shaft/mainshaft end play by applying an upward load
on the input shaft. Record the measurement.
9. Reposition the special tool on the countershaft. Place the tip of the dial between the fingers on the countershaft.
10. NOTE: Rotate the countershaft to seat the bearings.
Using the special tools, measure the countershaft gear end play by pushing upward on the
countershaft. Record the measurement. zUnscrew the installer from the handle. Insert the handle into the adapter plate plug hole. Klj . 4 ba
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11. Remove the bolts and the transmission case.
12. Remove the countershaft. Klj . 5 ba
182003 Mustang Workshop Manual
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