transmission oil FORD MUSTANG 2003 Repair Manual

REMOVAL
Transmission
CAUTION: Whenever a transmission has been disassembled to install new parts the
transmission fluid cooler tubes must be cleaned and backflushed. Use a suitable torque
converter/fluid cooler cleaner. If equipped a new oil- to-air cooler must also be installed.
When internal wear or damage has occurred in the transmission, metal particles, clutch plate
material or band material may have been carried into the torque converter and fluid cooler.
These contaminants are a major cause of recurring transmission troubles and must be
removed from the system before the transmission is put back into use.
CAUTION: After transmission is removed for a major overhaul, it is important to
completely clean all transmission components, including torque converter, oil- to-air cooler if
equipped, cooler inlet tube, main control valve body, clutches and all coasting booster valve
shuttle balls after any transmission repair that generates contamination. These contaminants
are a major cause for recurring transmission concerns and must be removed from the system
before the transmission is returned to use.
The cleaning of foreign material from the direct clutch check ball is often omitted. This
omission can lead to repeat repair of the transmission.
If equipped a new oil- to-air cooler must be installed under the following conditions; for
installation refer to Section 307 - 02 .
z Evidence of transmission assembly or fluid contamination is found due to the following
transmission or converter failure modes:
„major metallic failure
„ multiple clutches or clutch plate failures
„ sufficient component wear which results in metallic contamination.
1. Place the transmission range selector lever in NEUTRAL.
2. Disconnect the battery ground cable. For additional information, refer to Section 414 - 01 .
3. Raise and support the vehicle. For additional information, refer to Section 100 - 02 .
4. Remove the dual converter Y pipe. For additional information, refer to Section 309 - 00 .
5. Disconnect the transmission harness electrical connector.
SECTION 307-
01: Automatic Transaxle/Transmission 2003 Mustang Workshop Manual Special Tool(s)
Retainer, Torque Converter
307-
346 (T97T-7902- A) Klj . 1 ba
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307-
077 (T80L-77110- A) Handle, Torque Converter
307-
091 (T81P-7902- C) Test Plate Screw Set,
Transmission
307-
126 (T82P-7006- C) Air Test Plate, Transmission
307-
246 (T92P-7006- A) Remover/Installer, Servo
Piston
307-
251 (T92P-70023- A) Retainer, Torque Converter
307-
346 (T97T-7902- A) Installer, Transmission
Extension Housing Oil Seal
308-
002 (T61L-7657- A) Gauge, Transmission Solenoid
Connectors
307-426
Material Item Specification
Multi-
Purpose Grease ESB-
M1C93- Klj . 2 ba
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DIAGNOSIS AND TESTING
Manual Transmission and Clutch
Inspection and Verification
It is important to get an accurate description of the concern before any diagnosis can be carried out.
Ask questions as to whether it occurs when hot or cold, during shifting, driving at a particular speed or
in a particular gear. If possible, have the customer demonstrate the concern.
zWith the vehicle at a complete stop, shift through all the gears and evaluate the noise at
different engine rpm. Check for any noises in NEUTRAL at different engine rpm.
Symptom Chart SECTION 308-
00: Manual Transaxle/Transmission and Clutch — General
Information 2003 Mustang Workshop
Manual Symptom Chart
Condition
Possible Sources Action
z Clutch slippage zClutch pedal
sticking.
z Pressure plate
diaphragm
spring damaged
or weakened.
z Clutch pressure
plate damaged.
z Clutch disc
facing damaged
or worn
excessively.
z Clutch disc
facing surface
hardened or oil-
coated.
z Clutch release
hub and bearing
binding.
z Flywheel glazed
or damaged.
z loose pressure
plate to flywheel
bolts z
Go To Pinpoint Test A .
z Clutch chatter or shudder zLoose or worn
engine mount.
z Loose pressure
plate to flywheel
bolts
z Oil on clutch
disc facing.
z Clutch pressure
plate damaged z
Go To Pinpoint Test B . Klj . 1 ba
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Pinpoint Tests
PINPOINT TEST A: CLUTCH SLIPPAGE
PINPOINT TEST B: CLUTCH CHATTER OR SHUDDER z
Shafts or bore.
z Overloading of
vehicle.
z Incorrect
preload.
z Input shaft oil
dam. z
Install new components
as necessary and verify
the oil dam installation is
correct. REFER to
Section 308 - 03A or
Section 308 - 03B .
CHECK for correct
installation of the snap
ring on the mainshaft
next to the oil dam.
z Oil baffle in the
input bearing
shim pack. z
INSTALL a new oil
baffle, making sure it is
not damaged during
assembly. REFER to
Section 308 - 03A or
Section 308 - 03B .
Test Step Result / Action to Take
A1 INSPECT THE CLUTCH LINKAGE
z
Key in OFF position.
z Block the wheels and apply the parking brake.
z Depress and slowly release the clutch pedal.
z Does the clutch pedal release without
binding? Yes
GO to
A2 .
No
INSPECT the clutch pedal. REFER to
Section 308 - 02 .
A2 CARRY OUT A STALL TEST
z
Key in START position.
z Block the wheels and apply the parking brake.
z Place the transmission in fourth gear.
z Increase the engine speed to 2000 rpm and
slowly release the clutch pedal.
z Does the engine stall within five seconds? Yes
The clutch is not slipping. VERIFY the
customer concern.
No
INSPECT the clutch components for
damage.
Test Step Result / Action to Take
B1 CHECK ENGINE OR TRANSMISSION MOUNTS
z
Inspect all the engine and transmission mounts
for looseness or damage. Refer to Section 303 -
01A or
Section 303 - 01B and
Section 308 - 03A or
Section 308 - 03B .
z Are any of the engine or transmission mounts Yes
TIGHTEN or INSTALL new engine
mounts or transmission mounts. TEST
the system for normal operation. Klj . 7 ba
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stopped and the measurement taken at the downstop is the
clutch reserve.
z Is the clutch reserve less than 19 mm (0.75 inch)? Item Pedal Position
1 Gear clash begins
2 Gear clash ends
3 Clutch pedal downstop
F5 INSPECT THE RELEASE LEVER AND PIVOT STUD
z
Remove the transmission.
z Inspect the release lever and the pivot stud for wear,
damage or misalignment.
z Is the release lever or pivot stud worn, damaged or
misaligned? Yes
INSTALL a new release
lever or pivot stud as
necessary. TEST the
system for normal
operation.
No
GO to
F6 .
F6 INSPECT THE RELEASE BEARING
z
Inspect the release bearing for wear or damage. Make sure
the release lever is seated in the release bearing pocket.
z Is the release bearing worn or damaged? Yes
INSTALL a new release
bearing. TEST the system
for normal operation.
No
GO to
F7 .
F7 INSPECT THE PILOT BEARING
z
Inspect the pilot bearing for wear or damage.
z Is the pilot bearing worn or damaged? Yes
INSTALL a new pilot
bearing. TEST the system
for normal operation.
No
GO to
F8 .
F8 INSPECT THE CLUTCH PRESSURE PLATE TO FLYWHEEL
BOLTS z
Measure the clutch pressure plate to flywheel bolts.
z Is the bolt torque greater than or equal to 65 Nm (48 lb-
ft)? Yes
INSTALL a new pressure
plate and clutch disc. Note
the condition of the
removed components
(wear, damage or oil
contamination). For oil Klj . 13 ba
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GENERAL PROCEDURES
Disc Check
WARNING: Dust and dirt present on wheel brake and clutch assemblies may contain
asbestos fibers that are hazardous to health when made airborne by cleaning with compressed
air or by dry brushing. Failure to follow these instructions may result in personal injury.
WARNING: Wheel brake assemblies and clutch facings should be cleaned using a vacuum
cleaner recommended for use with asbestos fibers such as the brake automobile brake drum
system with vacuum. Dust and dirt from the vacuum should be disposed of in a manner that
prevents dust exposure such as sealed bags. The bag must be labeled according to OSHA
instructions and the trash hauler notified as to the bag's contents. Failure to follow these
instructions may result in personal injury.
WARNING: If a vacuum suitable for asbestos is not available, cleaning should be done
wet. If dust generation is still possible, technicians should wear government- approved toxic
dust purifying respirators. Failure to follow these instructions may result in personal injury.
WARNING: Grinding or sanding on the brake linings, pads, rotors, drums or clutch
facings should be done only while using correct exhaust- ventilated equipment. Failure to
follow these instructions may result in personal injury.
WARNING: OSHA requires areas where asbestos dust generation is possible to be
isolated and posted with warning signs. Only technicians concerned with carrying out brake or
clutch service should be present in the area. Failure to follow these instructions may result in
personal injury.
1. Check the clutch disc lining surface for hardening or the presence of oil.
2. Check for a worn clutch disc lining. Measure the minimum allowable depth to the rivet heads with a slide caliper.
SECTION 308-
00: Manual Transaxle/Transmission and Clutch — General
Information 2003 Mustang Workshop
Manual Special Tool(s)
Brake/Automobile Brake Drum
System with Vacuum
164-
R3622 or equivalent Dial Indicator/Magnetic Base
100-
D002 (D78P-4201- B) or
equivalent Klj . 1 ba
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REMOVAL AND INSTALLATION
Disc and Pressure Plate —
3.8L and 4.6L (2V) Engines
1. Remove the transmission. For additional information, refer to Section 308 - 03A (T5OD) or
Section 308 - 03B (TR3650).
2. CAUTION: Loosen the bolts evenly to prevent clutch pressure plate damage.
NOTE: If the parts are to be reused, mark the clutch pressure plate and the flywheel.
Remove the bolts and remove the clutch pressure plate and the clutch disc.
Installation
NOTE: Clean the clutch pressure plate and flywheel with a commercial alcohol- based solvent so
surfaces are free from oil film.
Do not use cleaners with a petroleum base. Do not immerse the clutch pressure plate in the solvent.
1. Position the clutch disc on the flywheel. zUsing the special tool, align the clutch disc.
SECTION 308-
01: Clutch 2003 Mustang Workshop Manual Special Tool(s)
Clutch Aligner
308-
020 (T74P-7137- K)
Material Item Specification
Premium Long Life Grease
XG
-1-C ESA-
M1C75- B Klj . 1 ba
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Installation
1. NOTE: Clean the clutch pressure plate and flywheel with a commercial alcohol- based solvent
so surfaces are free from oil film. Do not use cleaners with a petroleum base.
NOTE: Before installing the transmission, the ball stud, the clutch release lever and the input
shaft must be cleaned and lubricated with grease.
To install, reverse the removal procedure.
zUsing the special tool, align the clutch disc and pressure plate to the flywheel.
2. Tighten the pressure plate bolts in two stages. zStage 1: Tighten the bolts to 45 Nm (33 lb- ft).
z Stage 2: Tighten the bolts an additional 60 degrees. Klj . 3 ba
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The clutch control system engages and disengages the clutch. The clutch control system disengages
the clutch when the clutch pedal is depressed and engages the clutch when the clutch pedal is
released. Clutch pedal motion is transmitted by the clutch release lever cable to the clutch release
lever. The clutch release hub and bearing engages the clutch pressure plate diaphragm spring,
releasing the pressure on the clutch disc which in turn disengages the transmission from the engine.
The clutch adjusts automatically to compensate for clutch disc wear. The clutch linkage is self-
adjusting.
The clutch pedal position (CPP) switch prevents the starter motor from engaging unless the clutch
pedal is depressed all the way to the floor. The switch plunger is contacted by the clutch pedal and
extends as the clutch pedal is pressed. The clutch pedal position switch is electrically connected in line
with the ignition switch and the starter motor relay coil. The CPP also turns off the speed control when
the clutch pedal is depressed. 4 7L583 Clutch pedal quadrant and pawl assembly Klj . 2 ba
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IN-
VEHICLE REPAIR
Seal
Removal 1. With the vehicle in NEUTRAL, raise and support the vehicle. For additional information, refer to Section 100 - 02 .
2. CAUTION: Index- mark the driveshaft flange and pinion flange, and the driveshaft
slip yoke and transmission output shaft.
Remove the driveshaft. For additional information, refer to Section 205 - 01 .
3. Using the special tools, remove the extension housing fluid seal.
Installation 1. Using the special tool, install the extension housing fluid seal.
SECTION 308-
03A: Manual Transaxle/Transmission — T5OD 2003 Mustang Workshop Manual Special Tool(s)
Installer, Transmission
Extension Housing Oil Seal
308-
227 (T94P-7657- A) Slide Hammer
100-
001 (T50T-100- A) Remover, Bushing
307-
001 (TOOL- 1175-AC) or
Equivalent Klj . 1 ba
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