2003 FORD MUSTANG engine

DESCRIPTION AND OPERATION
Clutch
The primary function of the clutch is to couple and uncouple engine power to the transmission upon
driver command. For additional information, refer to
Section 308 - 02 .
z The clutch is a single plate, dry friction clutch disc. The clutch disc has a splined hub (with
integral torsional dampening springs) which attaches the clutch disc to the input shaft.
z Engine output is coupled to the input shaft by the friction existing between the clutch disc
facings and the flywheel/clutch pressure plate assembly. The extent of this friction is directly
related to the composition of the facing material and the magnitude of the clamping force
exerted by the clutch pressure plate. These factors limit the amount of torque that can be
transmitted without slippage.
z The clamping force is obtained from a diaphragm spring contained within the clutch pressure
plate assembly. This force is developed during the attachment of the clutch pressure plate to
the flywheel.
z The clutch system is disengaged when the clutch pedal is depressed and engaged when the
clutch pedal is released. This displacement removes the spring load from the clutch pressure
plate and eliminates the coupling friction between the engine and the transmission.
z When the clutch pedal is depressed, a cable connected to the clutch release lever, hub and
bearing actuates the clutch pressure plate diaphragm spring, releasing pressure on the clutch
disc. This eliminates the engagement between the transmission and the engine.
SECTION 308-
01: Clutch 2003 Mustang Workshop Manual Klj . 1 ba
12003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2308/S3B~us~en~ ...

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
32003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2308/S3B~us~en~ ...

REMOVAL AND INSTALLATION
Disc and Pressure Plate —
4.6L (4V) Engine
1. Disconnect the battery ground cable. For additional information, refer to Section 414 - 01 .
2. Remove the transmission. For additional information, refer to Section 308 - 03C .
3. Remove the starter. 1. Remove the terminal cap.
2. Remove the nuts.
3. Remove the wires and position them aside.
4. Remove the two bolts and the starter.
4. Remove the clutch cable clip, then pull the cable through the clutch housing.
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
42003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2308/S3B~us~en~ ...

REMOVAL AND INSTALLATION
Pilot Bearing
1. Remove the clutch disc and the clutch pressure plate. For additional information, refer to Disc and Pressure Plate — 3.8L and 4.6L (2V) Engines or
Disc and Pressure Plate — 4.6L (4V) Engine
in this section.
2. Using the special tool, remove the pilot bearing from the flywheel.
Installation 1. Insert the pilot bearing into the crankshaft.
2. Install the clutch disc and the clutch pressure plate. For additional information, refer to Disc and Pressure Plate — 3.8L and 4.6L (2V) Engines or
Disc and Pressure Plate — 4.6L (4V) Engine in
this section.
SECTION 308-
01: Clutch 2003 Mustang Workshop Manual Special Tool(s)
Puller with Slide Hammer
308-
001 (T58L-101- B) Klj . 1 ba
22003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2308/S3B~us~en~ ...

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
22003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2308/S3B~us~en~ ...

REMOVAL AND INSTALLATION
Clutch Pedal —
Quadrant and Pawl Assembly
Removal 1. Disconnect the battery ground cable (14301). For additional information, refer to Section 414 -
01 .
2. Loosen the nut from inside the engine compartment.
3. Loosen the nuts from inside the vehicle.
4. Loosen the screw.
5. Disconnect the brake pedal position (BPP) switch electrical connector.
SECTION 308-
02: Clutch Controls 2003 Mustang Workshop Manual Klj . 1 ba
62003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2308/S3B~us~en~ ...

13. Remove the self-
adjusting mechanism.
14. Remove the self- adjusting mechanism shaft bushings.
Installation 1. NOTE: Before the installation of the clutch pedal shaft or clutch pedal, remove and inspect the
brake and clutch pedal bushings. Clean and lubricate with a light film of engine oil meeting Ford
specification WSS- M2C153-G and replace the brake and clutch pedal bushing if excessive wear
is evident.
To install, reverse the removal procedure. Klj . 4 ba
62003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2308/S3B~us~en~ ...

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
22003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2308/S3B~us~en~ ...