2003 FORD MUSTANG service

DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES
Torque Converter Cleaning And Inspection
1. If a new torque converter is being installed, continue with Substep 2 of Step 2.
2. If a new torque converter is not being installed, the following procedures must be performed: 1. The torque converter must be thoroughly cleaned.
„Torque converters with drain plugs can be cleaned by using a suitable torque
converter/fluid cooler cleaner.
„ Torque converters without drain plugs can be cleaned by hand. Partially fill the
torque converter using only recommended transmission fluid for the applicable
transmission. Hand agitate the torque converter and then thoroughly drain the
fluid. Refill the torque converter with clean automatic transmission fluid specified
for transmission, and reinstall.
2. All in- tank and auxiliary coolers must be thoroughly cleaned by forward and backward
flushing. For additional information, refer to Transmission Fluid Cooler — Backflushing
and Cleaning in this section.
3. All cooler lines must be thoroughly cleaned by backward and forward flushing. For additional information, refer to Transmission Fluid Cooler — Backflushing and Cleaning
in this section.
4. All Cooler Bypass Valves (CBV), if equipped, must be thoroughly cleaned.
5. Carry out the Transmission Fluid Cooler Flow Test. For additional information, refer to
Transmission Fluid Cooler — Backflushing and Cleaning in this section.
6. If the transmission cooling system fails the Transmission Fluid Cooler Flow Test, a new fluid cooler, cooler bypass valve, and/or cooler lines must be installed. For additional
information, refer to Section 307 - 02 .
7. If new coolers are to be installed, use only factory approved service parts.
SECTION 307-
01: Automatic Transaxle/Transmission 2003 Mustang Workshop Manual Material
Item Specification
MERCON® V Automatic
Transmission Fluid
XT
-5-QM, XT -5-DM MERCON® V Klj . 1 ba
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DESCRIPTION AND OPERATION
Transmission Cooling —
Integral
This vehicle with an automatic transmission is equipped with an integral transmission fluid cooler. The
cooler is contained inside of the radiator outlet tank and cannot be serviced separately. The cooler
transfers heat from the transmission fluid to the engine coolant.
For transmission fluid cooler flow test, refer to Section 307 - 01 .
For transmmission fluid cooler backflushing and cleaning, refer to Section 307 - 01 .
Transmission Fluid Cooler Tubes SECTION 307-
02: Transaxle/Transmission Cooling 2003 Mustang Workshop Manual Item Part Number Description
1 — Fluid cooler inlet tube
2 — Fluid cooler outlet tube
3 7005 Transmission case
4 — Transmission case fittings Klj . 1 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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DESCRIPTION AND OPERATION
Manual Transmission
The TR3650 five-
speed manual transmission features the following:
z The fifth speed gear functions as an overdrive gear.
z The forward gears are synchronized and helical cut.
z The reverse gear operates through a constant- mesh, fully synchronized system.
z The shift interlock system prevents the engagement of more than one gear.
z The countershaft is serviced as an assembly.
z An aluminum main case, extension housing and bell housing. Transmission Internal Components — Disassembled View SECTION 308-
03B: Manual Transaxle/Transmission — TR3650 2003 Mustang Workshop Manual Klj . 1 ba
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Item Number Description
1 — Transmission assembly number
2 — Build date code—
month 3 — Build date code—
day 4 — Build date code—
year 5 — Shift number
6 — Serial number
7 — Service repair code
8 — Identification number located on left lower side of
transmission case Klj . 7 ba
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DESCRIPTION AND OPERATION
Manual Transmission
The T56 six-
speed manual transmission features the following:
z six forward speeds and one reverse speed.
z forward gears are synchronized and helical cut.
z a reverse gear operates through a constant- mesh, fully synchronized system.
z a shift interlock system prevents the engagement of more than one gear.
z a countershaft with two sections, the countershaft cluster and the countershaft extension. The
countershaft cluster is serviced as an assembly, the countershaft extension components are
serviced.
z two tapered roller bearings on the output shaft.
z two tapered roller bearings on the countershaft cluster.
z a tapered roller bearing on the input shaft.
z a tapered roller bearing on the countershaft extension.
z countershaft cluster endplay controlled by shims located in the transmission adapter plate.
z countershaft extension endplay controlled by shims located in the extension housing.
z input/output shaft endplay is controlled by shims located in the transmission adapter plate.
z removable wear pads on the shift forks.
z an aluminum main case, extension housing, adapter plate and clutch housing.
Transmission Identification
The transmission identification tag is located under the lower bolt that retains the extension housing to
the main case.
The six speed (T56) transmission is available for the Mustang 4.6L (4V).
Transmission Identification SECTION 308-
03C: Manual Transaxle/Transmission — T56 2003 Mustang Workshop Manual Item Part
Number Description
1 — Transmission assembly number
2 — Build date code —
month Klj . 1 ba
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3 — Build date code —
day 4 — Build date code —
year 5 — Shift number
6 — Serial number
7 — Service repair code
8 — Identification number located on left lower side of
transmission case Klj . 2 ba
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REMOVAL AND INSTALLATION
Dual Converter Y-
Pipe —3.8L
Removal
NOTE: The RH and LH catalytic converters are serviceable separately.
1. Raise and support the vehicle. For additional information, refer to Section 100 - 02 .
2. CAUTION: When repairing the exhaust system or removing exhaust components,
disconnect all heated oxygen sensors (HO2S) (9F472) and catalyst monitor sensors at
the wiring connectors to prevent damage to the sensors and wiring harnesses.
Disconnect the RH and LH HO2S connectors.
3. Disconnect the RH and LH catalyst monitor sensor connectors.
4. Remove the dual converter assembly nuts.
SECTION 309-
00: Exhaust System 2003 Mustang Workshop Manual Klj . 1 ba
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