2003 FORD MUSTANG clutch

15.
NOTE: The seals are solid seals, however, when installing new seals use scarf- cut seals.
Remove the forward clutch input shaft seals.
16. Make sure the check ball in the clutch cylinder is free and clean. Check for correct seating.
Assembly 1. Inspect the clutch cylinder thrust surfaces, piston bore and clutch plate serrations for scores or burrs. Minor scores or burrs may be removed with crocus cloth. Install a new clutch cylinder if
badly scored or damaged.
2. Check the fluid passage in the clutch cylinder for obstructions. Clean out all fluid passages. Inspect the clutch piston for scores and install a new piston if necessary. Inspect check balls for
freedom of movement and correct seating.
3. Check the clutch release spring for distortion and cracks. Install a new spring (including the wave spring) if distorted or cracked.
4. Inspect composition clutch plates, steel clutch plates and clutch pressure plate for worn or scored bearing surfaces. Install new parts if they are deeply scored or burred.
5. Check the clutch plates for flatness and fit on the clutch hub serrations. Discard any plate that does not slide freely on serrations or that is not flat.
6. Check the clutch hub thrust surfaces for scores and the clutch hub splines for wear.
7. NOTE: To aid handling, the forward clutch assembly may be set in the extension housing or a
hole in the work bench.
Install the inner and outer forward clutch piston seals. Note the direction of the sealing rings
before installation. Klj . 5 ba
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8.
NOTE: Coat the piston seals and clutch drum sealing area with petroleum jelly.
Position the special tools on the clutch piston.
9. Using the special tools, install the forward clutch piston into the clutch drum. zPush the piston to the bottom of the drum using even pressure.
10. Using the special tool, compress the piston return spring and install the retaining ring.
11. Slowly release the press pressure and remove the forward clutch. Klj . 6 ba
92003 Mustang Workshop Manual
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12.
NOTE: Before assembly, soak the new clutch discs in clean automatic transmission fluid for 15
minutes.
Install the clutch pack assembly. 1. Install the pressure ring.
2. Install the clutch pack.
3. Install the pressure plate.
13. Install the clutch pack retaining ring.
14. Install the special tool on the forward clutch pack. zPush downward on the clutch pack.
z Release pressure and zero the dial indicator.
15. Using the special tool, check the clutch pack clearance. 1. Lift up on the clutch pack until it fully seats against the clutch pressure plate retainer.
2. Read the dial indicator.
„If the clearance is not within specifications, install the correct size retaining ring. Selective Retaining Ring
Specification Klj . 7 ba
92003 Mustang Workshop Manual
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16.
NOTE: Make sure the scarf-cut seals are mated correctly.
Slide the two scarf-cut seals on the input shaft.
17. Install the two scarf- cut seals on the input shaft.
18. Install the No. 3 forward clutch hub front bearing and the forward clutch hub. 1.52-
1.62 mm (0.060- 0.064 inch) 1.87-
1.98 mm (0.074- 0.078 inch) 2.24-
2.34 mm (0.088- 0.092 inch) 2.59-
2.69 mm (0.102- 0.106 inch) Klj . 8 ba
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DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES
Planetary Gear Support Assembly and Planetary One-
Way
Clutch
Disassembly and Assembly
1. NOTE: Inspect the outer and inner races for scores or damaged surface areas where rollers
contact the races. Inspect the rollers and springs for excessive wear or damage. Inspect the
spring and cage for bent or damaged spring retainers.
Rotate the center support counterclockwise and lift to remove the planetary gear support.
2. Remove the planetary one- way clutch.
SECTION 307-
01: Automatic Transaxle/Transmission 2003 Mustang Workshop Manual Item Part Number Description
1 7A130 Planetary gear support
2 7A089 Planetary one-
way clutch 3 7A398 Planetary assembly Klj . 1 ba
22003 Mustang Workshop Manual
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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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1. The forward clutch sun gear and reverse sun gear assembly are assembled as part of the
transmission assembly procedure. Klj . 2 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
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