2003 FORD MUSTANG light

68. Lightly lubricate the converter hub with clean automatic transmission fluid.
69.
WARNING: The torque converter can fall out if the transmission is tipped.
CAUTION: Make sure the converter hub is fully engaged in the front pump support
and gear and rotates freely. Do not damage the hub seal.
CAUTION: If the torque converter slides out, the hub seal may be damaged.
Using the special tools, install the torque converter.
70. Lubricate the torque converter pilot hub with multi- purpose grease. Klj . 24 ba
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Pinpoint Tests
PINPOINT TEST A: THE SHIFT INTERLOCK SYSTEM DOES NOT
RELEASE/LOCK CORRECTLY z
The shift control is
out of correct gear
relationship z
Transmission shift
cable and bracket.
z Retainer bracket.
z Shift control linkage
out of adjustment. z
Go To Pinpoint Test B .
z Transmission range
indicator does not
correspond to the
gear z
Transmission shift
cable bracket. z
TIGHTEN the bolts
holding transmission
shift cable bracket.
z Transmission shift
cable loose from the
transmission
retainer bracket. z
TIGHTEN the bolts.
z Shift linkage. zVERIFY digital
transmission range
(DTR) sensor range for
correct adjustment.
REFER to Section 307 -
01 .
z The Transmission
Control Switch (TCS)
Is Inoperative z
CJB Fuse 28 (15A).
z TCS.
z TCS not cycled
during self- test.
z Powertrain control
module (PCM).
z Circuitry. z
Go To Pinpoint Test C .
z The Transmission
Control Indicator
Lamp (TCIL) Is Not
Operating Correctly z
Bulb.
z Instrument cluster.
z Powertrain control
module. z
REFER to Section 413 -
01 .
z Excessive Shift Effort zTransmission shift
cable. z
INSTALL a new
transmission shift cable.
z Cable bracket. zADJUST the cable.
TIGHTEN the screws.
z Transmission Range
Selector Lever Will
Not Shift z
Transmission shift
cable. z
INSTALL a new
transmission shift cable.
z Broken transmission
shift cable. z
INSTALL a new
transmission shift cable. Test Step Result / Action to Take
A1 TEST THE BRAKE LIGHTS
z
Key in ON position.
z Apply the brake pedal and observe the stoplamps.
z Do the stoplamps illuminate? Yes
GO to
A2 .
No
REFER to Section 417 -Klj . 2 ba
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PINPOINT TEST D: CLUTCH PEDAL PULSATION clutch disengaged and engine idling, move
the shift lever to a position halfway between
REVERSE and NEUTRAL.
z Slowly engage clutch. The transmission will
behave as if it is in NEUTRAL.
z Gear clash can now be heard if an attempt
is made to shift into REVERSE with the
clutch engaged. Reserve can now be
measured.
z While maintaining light pressure on the shift
selector, slowly press the clutch pedal to the
floor. The gear clash will stop and the shift
selector will slide into the REVERSE
position.
z Is there a minimum 19.05 mm (0.750 inch)
clutch pedal reserve? CHECK the clutch pressure plate and clutch
disc. INSTALL a new clutch pressure plate
or clutch disc if necessary. REFER to
Section 308
- 01 . TEST the system for
normal operation. Test Step Result / Action to Take
D1 CHECK THE CLUTCH PEDAL
PULSATION z
Key in START position.
z With the transmission in NEUTRAL,
slowly press the clutch pedal.
z Does the clutch pedal pulsate while
being pressed? Yes
GO to
D2 .
No
VERIFY customer concern. GO to Symptom Chart if necessary.
D2 INSPECT PRESSURE PLATE BOLTS
z
Inspect the pressure plate- to-flywheel
bolts.
z Are any of the pressure plate- to-
flywheel bolts loose? Yes
TIGHTEN or INSTALL new bolts. REFER to
Section 308
- 01 . TEST the system for normal
operation.
No
GO to D3 .
D3 INSPECT THE CLUTCH PRESSURE
PLATE z
Remove the clutch pressure plate.
Refer to Section 308 - 01 .
z INSPECT the clutch pressure plate for
damage. Refer to Pressure Plate Check .
z Are there any signs of damage
present on the clutch pressure plate? Yes
INSTALL a new clutch pressure plate. REFER
to
Section 308 - 01 . TEST the system for normal
operation.
No
GO to D4 .
D4 INSPECT THE CLUTCH DISC
z
Carry out the clutch disc inspection
procedure. Refer to Disc Check .
z Is the clutch disc OK? Yes
GO to
D5 .
No
INSTALL a new clutch disc. REFER to Section 308 - 01 . TEST the system for normal operation.
D5 INSPECT THE FLYWHEEL Klj . 9 ba
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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
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18. Remove the reversing lamp switch (15520).
19. Remove the reverse gear shift rail.
1. Rotate the reverse gear shift rail clockwise to disengage the ball stud from the reverse gearshift lever.
2. Pull the reverse gear shift rail rearward slightly.
3. Rotate the reverse gear shift rail counterclockwise to align the ball stud with the slot in the case and remove the reverse gear shift rail.
20. Remove the snap ring and the output shaft speed wheel (7H150). Klj . 6 ba
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2. Assemble the gear shifter forks.
1. Install the gear shift plate into the gear shifter fork.
2. Install the gear shift fork inserts.
3. NOTE: Position the narrow side of the C- shaped gear selector interlock sleeve in the case
cover slot. Position the roll pin hole in the selector body toward the rear of the cover.
Install the gear selector interlock sleeve and the selector body as an assembly.
4. Lubricate the main shift control shaft with petroleum jelly.
5. NOTE: The 1-2 gear shifter fork is the larger shifter fork. The gear shifter fork offset lever must
face the cover. Position the gear shift plate attached to the 3- 4 gear shifter fork under the gear
shift plate attached to the 1- 2 gear shifter fork.
Position the gear shifter forks and the main shift control shaft in the cover. zSlide the shaft through the cover and shift the components until the shaft stops against
the cover.
6. CAUTION: Install the pin slightly below the selector body surface. Failure to
countersink the pin may result in interference between the pin and the gear selector interlock sleeve during shifts. Klj . 3 ba
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DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES
Synchronizers
Disassembly
NOTE:
This procedure applies to all synchronizer assemblies (7124). The synchronizers are slightly
different in design. Notation is made where procedural differences occur.
1. On the third/fourth speed synchronizer and the fifth speed synchronizer, scribe an alignment mark on the sliding sleeve and the hub for assembly reference.
2. NOTE: Only the synchronizer hub insert springs (7109) and the synchronizer hub inserts
(7A044) are available separately.
Remove the synchronizer hub inserts and the hub insert springs.
3. The first/second speed synchronizer sliding sleeve, the hub, and the output shaft are an assembly. Do not attempt to separate the hub from the output shaft. Discard the entire
assembly if wear or damage to the synchronizer or output shaft is evident.
4. On the third/fourth speed synchronizer and the fifth speed synchronizer, remove the sliding sleeve.
Assembly 1. NOTE: Both synchronizer hub insert springs engage the same synchronizer hub insert but
rotate in the opposite direction.
NOTE: The third/fourth speed synchronizer uses the winged synchronizer hub inserts.
Install the synchronizer hub inserts and the hub insert springs. Verify that the spring tabs are
SECTION 308-
03A: Manual Transaxle/Transmission — T5OD 2003 Mustang Workshop Manual Klj . 1 ba
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REMOVAL
Transmission
1. Remove the gearshift lever knob.
2. Remove the console panel gearshift plate. Disconnect the cigar lighter electrical connector, then lift the gearshift lever boot over the gearshift lever.
3. Remove the bolts and the upper gearshift lever.
4. Remove the bolts and the lower gearshift lever boot.
SECTION 308-
03C: Manual Transaxle/Transmission — T56 2003 Mustang Workshop Manual Klj . 1 ba
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