drain bolt FORD MUSTANG 2003 Repair Manual

5. Remove the converter drain back valve and solenoid pressure supply screen.
6. Remove the main control valve body cover plate.
1. Remove the 13 bolts.
2. Remove the valve body cover plate and gasket. Klj . 4 ba
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Disassembly
1. Remove the No. 1 selective pump support thrust washer.
2. Remove the front pump support. 1. Remove the bolts.
2. Remove the front pump support.
3. Remove the seal rings. 11 7F225 Intermediate clutch piston inner seal
12 7A108 Pump support
13 — Pump outer gerotor gear
14 — Pump inner gerotor gear
15 7A136 Pump gasket
16 — Pump bushing
17 7A248 Pump inner seal
18 391855-S100 Converter drain plug Klj . 2 ba
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z
Excessive noise zPilot bearing
worn or
damaged.
z Excessive
crankshaft end
play. z
Go To Pinpoint Test G .
z Transmission difficult to
shift z
Lubricant. zADD or DRAIN AND
FILL with specified
lubricant.
z Internal shift
mechanism. z
CHECK the internal shift
mechanism for smooth
operation. REPAIR or
INSTALL a new
mechanism as
necessary.
z Sliding gears,
synchronizers. z
CHECK for free
movement of gears and
synchronizers. REPAIR
or INSTALL new
components as
necessary.
z Housings, shaft. zCHECK for binding
condition between the
input shaft and the
engine crankshaft pilot
bearing or bushing.
REPAIR or INSTALL
new components as
necessary. REFER to
Section 308 - 03A or
Section 308 - 03B .
z Loose pressure
plate to flywheel
bolts. z
CHECK for loose bolts
at the pressure plate.
INSTALL new
components as
necessary. REFER to
Section 308 - 01 .
z NOTE: While verifying
the condition, determine
whether the noise is gear
rollover noise, release
bearing rub or some
other transmission-
related noise. Gear
rollover noise, inherent in
manual transmissions, is
caused by the constant
mesh gears turning at the
engine idle speed while
the clutch is engaged and
the transmission is in
NEUTRAL. Release
bearing rub is sometimes
mistaken for mainshaft
bearing noise. Gear
rollover noise will
disappear when the
clutch is disengaged or
when the transmission is
engaged in gear. z
Lubricant. zADD or DRAIN AND
FILL with specified
lubricant. Klj . 3 ba
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SPECIFICATIONS
SECTION 308-
03A: Manual Transaxle/Transmission — T5OD 2003 Mustang Workshop Manual General Specifications
Item Specification
Lubricants and Sealants
Multi-
Purpose Grease
D0AZ- 19584- AA ESB-
M1C93- B Threadlock and Sealer
E0AZ-
19554- AA WSK-
M2G351- A5 Clear Silicone Rubber
D6AZ-
19562- AA ESB-
M4G92- A Pipe Sealant with Teflon®
D8AZ-
19554- A ESR-
M18P7-A MERCON® Multi-
Purpose ATF Transmission Fluid
XT -2-QDX Mercon®
Preload
Output shaft preload 0.0127 mm ( 0.0005 in) - 0.1016 mm ( 0.004 in)
Synchronizer
Synchronizer blocking ring to conical face runout 0.5 mm (0.02 in)
End Play
Countershaft cluster gear end play 0.0254 mm ( 0.001 in) -
0.127 mm ( 0.005 in) Output shaft end play 0.0127 mm ( 0.0005 in) - 0.1016 mm ( 0.004 in)
Torque Specifications Description Nm lb-
ft lb-
in Bolt retaining gearshift lever to extension housing 18 13 —
Screw retaining inner shift boot to floor pan 10 — 89
Bolt retaining gear shift lever to gear shift stub shaft 37 27 —
Bolt retaining OSS to case 10 — 89
Bolt retaining countershaft rear bearing retainer to case 21 15 —
Shift lever reverse pin 40 30 —
Reversing lamp switch 37 27 —
Bolt retaining case cover to case 12 9 —
Bolt retaining extension housing to case 54 40 —
Bolt retaining input shaft bearing retainer to case 21 15 —
Drain plug 23 17 —
Bolt retaining transmission to block 75 55 —
Bolt retaining engine plate to transmission 27 20 — Klj . 1 ba
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17.
CAUTION: To prevent damage, do not depress the clutch pedal with the
transmission removed.
Disengage the clutch release cable from the clutch release fork.
18. Remove the clutch cable retainer and remove the clutch cable from the transmission.
19. If transmission disassembly is necessary, drain the transmission fluid.
20. Position a transmission jack and support the transmission.
21. Remove the bolts and the transmission crossmember. Klj . 4 ba
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3. Attach the transmission to the special tool.
4.
NOTE: Position a drain pan under the transmission.
Remove the case plug.
5. NOTE: Position the gearshift lever in NEUTRAL.
Remove the bolts and the gearshift lever.
6. CAUTION: Do not attempt to remove the gearshift offset lever with the extension
housing bolted in place. A lug, located on the bottom of the gearshift offset lever,
meshes with the detent plate preventing enough rearward movement of the gearshift
offset lever to allow removal.
Remove the split pin and the gearshift shaft bushing. Klj . 2 ba
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SPECIFICATIONS
SECTION 308-
03B: Manual Transaxle/Transmission — TR3650 2003 Mustang Workshop Manual General Specifications
Item Specification
Lubricants and Sealants
Premium Long-
Life Grease
XG -1-C, K or T ESA-
M1C75- B Threadlock and Sealer
E0AZ-
19554- AA WSK-
M2G351- A5 Black Silicone Rubber
D6AZ-
19562- BA ESB-
M4G92- A Pipe Sealant with Teflon®
D8AZ-
19554- A ESR-
M18P7- A Motorcraft MERCON® Multi-Purpose (ATF)
Transmission Fluid
XT -2-QDX MERCON®
Synchronizer
Synchronizer blocking ring to conical face runout 0.5 mm (0.02 in)
End Play
Input shaft end play 0.02286 mm (0.0009 in) -
0.0508 mm
(0.002 in) Countershaft cluster gear end play 0.0 mm (0.0 in) -
0.076 mm (0.003 in) Output shaft end play 0.0012 mm (0.0005 in) -
0.100 mm (0.004
in)
Torque Specifications Description Nm lb-
ft lb-
in Gearshift lever to extension housing bolt 23 13 —
Gear shift lever to gear shift stub shaft bolt 37 27 —
OSS to case bolt 10 — 89
Reverse idler gear bolt 27 20 —
Fifth/reverse lockout bolt 20 15 —
Clutch housing to transmission main case bolt 31 23 —
Extension housing to transmission main case bolt 31 23 —
Drain plug 23 17 —
Reversing lamp switch 37 27 —
Fill plug 17 13 —
Transmission to engine bolt 75 55 —
Engine plate to transmission bolt 27 20 —
Crossmember to frame bolt 41 30 — Klj . 1 ba
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Transmission Identification
The transmission identification tag is located under the lower bolt that retains the extension housing to
the main case.
The five speed overdrive (TR3650) transmission is available for the Mustang 4.6L (2V).
Transmission Identification 16 7240 Main shift rail
17 7F018 Gearshift offset lever
18 — Spacer
19 — Bearing
20 7210 Gearshift lever
21 — Gearshift plate and spring
22 — Shipping seal
23 7052 Output shaft seal
24 — Extension housing bushing
25 7A039 Extension housing
26 7034 Vent
27 — Vehicle speed sensor (VSS)
28 — Fifth/reverse gear lockout
29 7L027 Magnet
30 7K201 Shift interlock plate
31 7005 Transmission main case
32 — Interlock pins
33 7A010 Drain plug
34 15520 Reverse lamp switch
35 — Detent plug
36 — Detent spring
37 — Detent
38 6392 Clutch housing
39 7B602 Ball stud
40 — Bearing
Part Klj . 6 ba
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17. If transmission disassembly is necessary, drain the transmission fluid.
18. Position a transmission jack and support the transmission.
19. Remove the bolts and the transmission crossmember.
20. Remove the bolts. Klj . 4 ba
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Guide plate bolts 22 16 —
Reverse lockout solenoid bolt 18 13 —
Drain plug 27 20 —
Reversing lamp switch 27 20 —
Fill plug 27 20 —
Reverse idler shaft bracket bolts 25 18 —
Extension housing bolts 35 26 —
Shift dent cover bolts 20 15 —
Adapter plate plug 27 20 — Klj . 2 ba
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