2003 FORD MUSTANG automatic transmission

DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES
Reverse Sun Gear
Disassembly
1. Remove the reverse clutch sun gear assembly and the No. 4 forward clutch hub bearing and race.
2. Remove the forward clutch sun gear assembly and the No. 5 forward clutch sun gear bearing and race. Assembly SECTION 307-
01: Automatic Transaxle/Transmission 2003 Mustang Workshop Manual Item Part Number Description
1 7C096 Forward clutch hub bearing No. 4
2 7F244 Forward clutch sun gear bearing No. 5
3 7A399 Forward clutch sun gear
4 7A019 Reverse sun gear assembly Klj . 1 ba
22003 Mustang Workshop Manual
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DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES
Output Shaft and Direct Clutch Cylinder
Output Shaft, Direct Clutch Cylinder and Ring Gear Disassembled
View
SECTION 307-
01: Automatic Transaxle/Transmission 2003 Mustang Workshop Manual Special Tool(s)
Compressor, Clutch Spring
307-
015 (T65L-77515- A) Protector, Piston Seal
307-
080 (T80L-77234- A) Protector, Transmission Direct
Clutch Outer Fluid Seal
307-
422
Material Item Specification
MERCON® V Automatic
Transmission Fluid
XT
-5-QM, XT -5-DM MERCON® V Klj . 1 ba
112003 Mustang Workshop Manual
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2. Install the clutch piston outer seal so that when the piston is installed the sealing lip points
toward the bottom of the cylinder.
3. NOTE: Coat the inner and outer direct clutch piston seals, clutch cylinder sealing area and
piston inner sealing area with petroleum jelly.
Using the special tool, install the direct clutch piston.
4. Install the piston return spring and retainer assembly.
5. Using the special tool, compress the piston return spring and install the retaining ring.
6. NOTE: Before assembly, soak new clutch discs in clean automatic transmission fluid for 15
minutes.
Install the clutch pack retaining ring. 1. Alternate external spline (steel) plates and internal spline (friction) plates, starting with a steel plate and ending with the friction plate.
2. Install the clutch pack retaining ring. Klj . 7 ba
112003 Mustang Workshop Manual
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DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES
Torque Converter
1. A new or remanufactured torque converter must be installed if one or more of the following statements is true:
zA torque converter malfunction has been determined based on complete diagnostic
procedures.
z Converter stud or studs, impeller hub or bushing are damaged.
z Discoloration (due to overheating).
z The torque converter is found to be out of specification when carrying out one of the
following torque converter checks:
„One- Way Clutch Check
„ End Play Check
„ Stator to Turbine Interference Check
„ Stator to Impeller Interference Check
„ Torque Converter Leak Check
z Evidence of transmission assembly or fluid contamination 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.
SECTION 307-
01: Automatic Transaxle/Transmission 2003 Mustang Workshop Manual Klj . 1 ba
12003 Mustang Workshop Manual
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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
22003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2748/S3B~us~en~ ...

DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES
Torque Converter Flushing
NOTE:
When the transmission has been repaired for internal damage the torque converter must be
cleaned using a mechanically agitated cleaner.
1. Using a suitable torque converter/fluid cooler cleaner, clean and flush the torque converter.
2. After flushing, drain the remainder of the solvent.
3. Add 1.9 liter (2 qt.) of clean transmission fluid to the converter and agitate by hand.
4. Thoroughly drain the solution.
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
12003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2748/S3B~us~en~ ...

DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES
Torque Converter Leak Check
1. Clean the outside surface of the torque converter.
2. Install the special tool into the converter hub.
3. WARNING: Always follow correct safety procedures while using press. Failure to
follow these instructions may result in personal injury.
Install the torque converter with the installed special tool into the arbor press.
Secure the press, apply enough force to seal the tool into the torque converter.
4. NOTE: Use clean dry shop air.
Apply air pressure to the valve on the special tool.
SECTION 307-
01: Automatic Transaxle/Transmission 2003 Mustang Workshop Manual Special Tool(s)
Leak Tester, Torque Converter
307-
421 Klj . 1 ba
32003 Mustang Workshop Manual
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DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES
Torque Converter Impeller to Pump Stator Interference
Check
1. NOTE: Front pump support may remain in front pump support and gear during this test.
Position the front pump support with the splines up.
2. Mount the torque converter on the front pump support with the splines on the one- way clutch
inner race, engaging the mating splines of the front pump support.
3. Hold the front pump support stationary and rotate the torque converter counterclockwise. zThe torque converter should rotate freely with no signs of scraping.
z If there are signs of scraping, install a new or remanufactured torque converter.
SECTION 307-
01: Automatic Transaxle/Transmission 2003 Mustang Workshop Manual Klj . 1 ba
22003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2748/S3B~us~en~ ...