clock FORD MUSTANG 2003 Repair Manual

DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES
Torque Converter One-
Way Clutch Check
1. Install the special tool in one of the grooves in the stator thrust washer.
2. Install the special tool in the converter pump drive.
3. Use a torque wrench to turn the special tool counterclockwise while holding the special tool stationary.
zThe converter should lock up and hold torque.
z The torque converter one- way clutch should rotate freely in the clockwise direction.
z Try the clutch for lockup and hold in at least five positions.
SECTION 307-
01: Automatic Transaxle/Transmission 2003 Mustang Workshop Manual Special Tool(s)
Holding Tool, One-
Way Clutch
307- 062 (T76L-7902- C) or
equivalent Holding Tool, Torque
Converter Clutch
307-
067 (T77L-7902- R) or
equivalent Klj . 1 ba
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8.
NOTE: Make sure the band is seated on the anchor pins.
Install the reverse band.
9. NOTE: The planetary assembly and planetary gear support cannot be installed unless the notch
cut in the planetary gear support is aligned with the overdrive band anchor pin.
NOTE: The top of the planetary gear support must be below the snap ring groove.
Install the planetary assembly and planetary gear support as a unit. zRotate the output shaft to fully seat the planetary assembly.
10. NOTE: The planet support spring must be compressed and installed below the snap ring
groove. When the planet support spring is installed correctly both ends of the spring will be
visible.
Install the case to the planet support spring located at the 1 o'clock position.
11. Install the center support retaining ring. zReference the retaining ring tabs to the band anchor pin location. Klj . 5 ba
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18. Remove the reversing lamp switch (15520).
19. Remove the reverse gear shift rail.
1. Rotate the reverse gear shift rail clockwise to disengage the ball stud from the reverse gearshift lever.
2. Pull the reverse gear shift rail rearward slightly.
3. Rotate the reverse gear shift rail counterclockwise to align the ball stud with the slot in the case and remove the reverse gear shift rail.
20. Remove the snap ring and the output shaft speed wheel (7H150). Klj . 6 ba
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DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES
Selector Plate
Disassembly
1. NOTE: Mark the position of each gear shifter fork (7230).
Place the gear shift plates (7N232) and the gear selector interlock sleeve (7K201) in the neutral
position to center the gear shift plates and the selector body (7302).
2. Rotate the main shift control shaft (7358) counterclockwise and pull it rearward to access the pin. Remove the pin.
3. Using a twisting motion, remove the main shift control shaft.
4. Remove the gear shifter forks, the gear shift plates, the pin, the gear selector interlock sleeve, and the selector body.
SECTION 308-
03A: Manual Transaxle/Transmission — T5OD 2003 Mustang Workshop Manual Klj . 1 ba
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8. Install the pin.
9. Align the reverse gearshift lever, the reverse shift fork, and the reverse positioning spring.
10. NOTE: Observe the reverse positioning spring rotation. The spring must rotate
counterclockwise into its installed position.
Install the reverse shift fork.
zPlace the reverse idler gear and bushing into the NEUTRAL position. Align the reverse
shift fork and the reverse idler gear and bushing. Push downward on the reverse shift fork until fully engaged into the reverse idler gear and bushing. Klj . 4 ba
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18. Install the bolts.
19. Install the output shaft rear bearing cup.
20. Install the reverse gear shift rail.
zAlign the ball stud with the slot in the case and align the reverse gear shift rail with the
reverse shift fork. Once the ball stud enters the case, rotate the reverse gear shift rail
until the ball aligns with the reverse gearshift lever. Rotate the reverse gear shift rail
counterclockwise until the ball stud fully engages the reverse gearshift lever. Klj . 7 ba
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12.
WARNING: Make sure protective eye wear is in place.
Clean the housing with solvent and dry with compressed air. Clean and check the sealing
surface for nicks or scratches. Inspect the housing for cracks. zIf the housing is cracked, install a new housing. If the sealing surface has nicks or
scratches, use a soft stone or crocus cloth to remove.
13. Using the special tools, install the mainshaft bearing cup.
14. Using a suitable driver, install the extension housing seal. zInstall the seal with the drain hole at the six o'clock position.
15. To assemble, reverse the disassembly procedure. Klj . 6 ba
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SPECIFICATIONS
a
Manifold gauge set pressures may vary slightly depending on the distance between the service
SECTION 412-
00: Climate Control System - General Information 2003 Mustang Workshop Manual General Specifications
Item Specification
A/C Compressor
Type FS-
10 swashplate, 5 double- acting pistons Displacement 170 cc (10.4 cu in)
Rotation Clockwise
A/C Pressure Relief Valve
a Open pressures 3,792-
4,137 kPa (550- 600 psi) A/C Pressure Sensor Refer to the Powertrain Control/Emissions
Diagnosis (PC/ED) manual.
Coolant Hose Lubricant
MERPOL® ESE-
M99B144- B Evaporator Core Orifice
Color Orange
Diameter 1.45 mm (0.057 in)
Magnetic Clutch
Air gap clearance 0.35-
0.75 mm (0.014- 0.030 in) Dual Function Pressure Switch (V8)
a Fan on/open 2,137-
2,344 kPa (310- 340 psi) Fan off/close 1,655-
2,137 kPa (240- 310 psi) Clutch off/open 2,999-
3,275 kPa (435- 475 psi) Clutch on/closed 1,517-
1,931 kPa (220- 280 psi) Pressure Cutoff Switch (V6)
a Open 2,999-
3,275 kPa (435- 475 psi) Close 1,586-
1,999 kPa (230- 290 psi) A/C Cycling Switch Open and Closed Pressures
a Open pressure 145-
159 kPa (21- 23 psi) Close pressure 290 kPa (42 psi)
Refrigerant Lubricant and Capacity
PAG Refrigerant Compressor Oil (R-134a Systems)
F7AZ- 19589- DA (Motorcraft YN-12- C) WSH-
M1C231- B Capacity 254 ml (8.6 oz)
Refrigerant and Capacity
R134a Refrigerant YN-
19 WSH-
M17B19- A Capacity .96 kg (34 oz)
Refrigerant System Cleaner
A/C Systems Flushing Solvent F4AZ-19579-
A — Klj . 1 ba
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GENERAL PROCEDURES
Manifold Gauge Set Connection
1. Turn both valves on the R- 134a Manifold Gauge Set clockwise to close the low- and high-
pressure hoses to the center manifold and center hose.
2. Remove the A/C charging valve cap (19D702) from the low- pressure service gauge port valve.
3. Remove the A/C charging valve cap from the high- pressure service gauge port valve.
SECTION 412-
00: Climate Control System - General Information 2003 Mustang Workshop Manual Special Tool(s)
R-
134a Manifold Gauge Set
176- R032A or equivalent Klj . 1 ba
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10. Turn the tool handle clockwise to expand the tool tip inside the shaft seal.
11. Pull the seal from the A/C compressor.
Installation 1. CAUTION: To prevent refrigerant system contamination, do not allow dirt or other
foreign materials to enter the A/C compressor.
Clean the A/C compressor nose area.
2. Place the shaft seal on the special tool. Lubricate the shaft seal and the special tool with PAG oil or equivalent.
3. Position the shaft seal and the special tool over the A/C compressor shaft. Klj . 4 ba
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