manual transmission FORD MUSTANG 2003 Workshop Manual

21. Install the fifth/sixth and reverse shift rail assembly and align the slots of the shift levers with the
shift interlock plate.
22. Clean the mating surfaces of the transmission main case and the transmission adapter plate. Apply a bead of silicone rubber to the sealing surface on the transmission adapter plate. Install
the spring and detent ball into the front offset lever, then install the transmission case and the
front offset lever.
zMake sure the transmission is in neutral to keep the third/fourth gear shift rail from
engaging.
z Compress the front offset lever against the guide plate when installing.
z Tighten the bolts in a star pattern. Klj . 9 ba
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26. Clean the mating surfaces of the transmission main case and the shift detent cover. Apply a
bead of silicone rubber to the sealing surface on the transmission case. Install the cover and
tighten the bolts.
27. Rotate the transmission to a horizontal position. Install the countershaft extension assembly and the fifth/sixth gear shift fork. Make sure the splines are fully engaged.
28. NOTE: Remove the countershaft extension shim from the extension housing.
Install the extension housing and tighten the bolts.
29. NOTE: Rotate the transmission to the vertical position.
Using the special tools, measure the countershaft extension end play by pushing upward on the
countershaft extension. Record the measurement. zInsert a suitable bar into the adapter plate plug hole until it engages the countershaft
extension. Klj . 11 ba
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46. Install a new OSS sensor tone wheel retaining ring.
47. Install the shipping seal.
48. Apply threadlock and sealer to the threads of the plug, then install the plug into the transmission
adapter plate.
49. Clean the mating surfaces of the transmission main case and the extension housing. Apply a bead of silicone rubber to the sealing surface on the transmission case. Install the extension
housing and tighten the bolts. Klj . 16 ba
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50. Install the rear offset shift lever, then install a new roll pin.
zInstall the pin until it is flush with the lever.
51. Install the vent hose.
52. NOTE: Before installing the transmission, the ball stud, the clutch release lever and the input
shaft guide tube must be cleaned and lubricated.
Install the clutch release lever and the clutch release hub and bearing. Klj . 17 ba
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INSTALLATION
Transmission
1. NOTE: Before installing the transmission, the ball stud, clutch release lever and the input shaft
must be cleaned and lubricated with grease.
Position the transmission to the clutch adapter housing. Install the eight transmission- to-clutch
adapter housing bolts.
2. Connect the output shaft speed (OSS) sensor electrical connector.
3. Connect the reverse lamp electrical connector.
SECTION 308-
03C: Manual Transaxle/Transmission — T56 2003 Mustang Workshop Manual Material
Item Specification
DEXRON III® (
ATF)
Transmission Fluid
XT -2-QDX or equivalent DEXRON III®
Pipe Sealant with Teflon®
D8AZ-
19554- A or equivalent WSK-
M2G350-
A2 Premium Long Life Grease
XG
-1-C, K or T or equivalent ESA-
M1C75- B Klj . 1 ba
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4. Connect the wiring harness to the transmission.
5. Connect the clutch release cable to the clutch release fork.
6. Install the clutch release lever cover and bolt.
7. Install the transmission crossmember and the bolts. Klj . 2 ba
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8. Remove the transmission jack from the transmission.
9. Connect the heated oxygen sensor (HO2S) electrical connectors to the crossmember.
10. CAUTION: Align the index marks on the driveshaft flange and pinion flange, and the
driveshaft slip yoke and transmission output shaft.
Install the driveshaft. For additional information, refer to Section 205 - 01 .
11. Fill the transmission to capacity with the specified transmission fluid. Apply sealant to the fill plug threads and install the fill plug.
zThe total fill capacity is 3.9L (4.1 qt).
12. Lower the vehicle.
13. Connect the reverse lockout solenoid electrical connector. Klj . 3 ba
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DESCRIPTION AND OPERATION
Speed Control
The speed control system consists of the following components:
zspeed control actuator cable (9A825)
z deactivator switch
z output shaft sensor (OSS)
z speed control actuator switches (9C888)
z brake pedal position (BPP) switch (13480)
z speed control servo (9C735)
z clutch pedal position switch (manual transmission only)
SECTION 310-
03: Speed Control 2003 Mustang Workshop Manual Klj . 1 ba
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z
Is the resistance between 612 and 748 ohms? REFER to
Switch —
Speed Control
Actuator . TEST the
system for normal
operation. A13 CHECK THE BPP SWITCH CIRCUITRY
z
Measure the resistance between speed control servo C122 Pin
4, Circuit 511 (LG), harness side, and speed control servo C122
Pin 10, Circuit 1205 (BK), harness side.
z Is the resistance less than 20 ohms? Yes
GO to
A16 .
No
If automatic
transmission, REPAIR
Circuit 511 (LG) and
Circuit 810 (LG/RD) as
necessary. TEST the
system for normal
operation.
If manual transmission,
GO to A14 .
A14 CHECK CIRCUIT 511 (LG) AND CIRCUIT 810 (RD/LG) FOR
AN OPEN z
Disconnect: CPP Switch C2072.
z Measure the resistance between CPP Switch C2072 Pin 1,
Circuit 511 (LG), harness side and ground.
z Is the resistance less than 20 ohms? Yes
GO to
A15 .
No
REPAIR Circuit 511
(LG) and Circuit 810
(LG/RD) as necessary.
TEST the system for
normal operation. A15 CHECK CIRCUIT 511 (LG) FOR AN OPEN
z
Measure the resistance between speed control servo C122 Pin
4, Circuit 511 (LG), harness side and CPP switch C2072 Pin 2,
Circuit 511 (LG), harness side. Yes
INSTALL a new CPP
switch. TEST the
system for normal
operation.
No
REPAIR the circuit.
TEST the system for
normal operation. Klj . 8 ba
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DESCRIPTION AND OPERATION
Instrument Cluster and Panel Illumination
The instrument cluster and panel illumination system illuminates the following components:
zinstrument cluster (10849)
z audio unit (18806)
z A/C- heater control
z fog lamp switch
z transmission range indicator
z traction control switch
z rear window defrost control switch
The instrument cluster is a hybrid electronic cluster (HEC), which uses both hardwired circuitry and the
standard corporate protocol (SCP) communication network to transmit and receive information. The
Mustang instrument cluster backlighting has illumination bulbs that are installed separately from the
instrument cluster. The Cobra instrument cluster has a laminated, electroluminescent applique to
backlight the cluster . The electroluminescent applique and instrument cluster must be installed as an
assembly. SECTION 413-
00: Instrument Cluster and Panel Illumination 2003 Mustang Workshop Manual Klj . 1 ba
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