2003 FORD MUSTANG clutch

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 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
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DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES
Torque Converter One-
Way Clutch Check
1. Install the special tool in one of the grooves in the stator thrust washer.
2. Install the special tool in the converter pump drive.
3. Use a torque wrench to turn the special tool counterclockwise while holding the special tool stationary.
zThe converter should lock up and hold torque.
z The torque converter one- way clutch should rotate freely in the clockwise direction.
z Try the clutch for lockup and hold in at least five positions.
SECTION 307-
01: Automatic Transaxle/Transmission 2003 Mustang Workshop Manual Special Tool(s)
Holding Tool, One-
Way Clutch
307- 062 (T76L-7902- C) or
equivalent Holding Tool, Torque
Converter Clutch
307-
067 (T77L-7902- R) or
equivalent Klj . 1 ba
22003 Mustang Workshop Manual
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DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES
Torque Converter Turbine to Pump Stator Interference
Check
1. NOTE: Front pump support may remain in front pump support and gear during this test.
Position the torque converter with the pump drive up.
2. Install the front pump support to engage the mating splines of the front pump support shaft on the torque converter.
3. Install the forward clutch cylinder and shaft, engaging the splines with the rear clutch hub.
4. Check for stator to turbine interference. 1. Hold the front pump support stationary.
2. Attempt to rotate the forward clutch cylinder and shaft.
„The turbine and torque converter clutch assemblies should rotate in both
directions, not exceeding maximum torque of 9.5 Nm (7 lb- ft), without any signs of
metallic interference or scraping noise.
5. If interference exists, the stator front thrust washer may be worn, allowing the stator to hit the turbine. In such cases, a new or remanufactured torque converter must be installed.
zThe converter crankshaft pilot should be checked for nicks or damaged surfaces that
could cause interference when installing the torque converter into the crankshaft. Check
the converter front impeller hub for nicks or sharp edges that would damage the pump
seal.
SECTION 307-
01: Automatic Transaxle/Transmission 2003 Mustang Workshop Manual Klj . 1 ba
22003 Mustang Workshop Manual
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CAUTION: Before beginning assembly, carry out and inspect the following:
When building up subassemblies and assembling the transmission, ALWAYS use new gaskets
and seals.
All fasteners must be tightened to the torque specification indicated. In addition to appearing in
the section, the necessary torques can be found in the General Specifications Chart.
When building up subassemblies, each component part should be lubricated with clean
transmission fluid. It is also good practice to lubricate the subassemblies as they are installed
in the case.
Needle bearings, thrust washers and seals should be lightly coated with petroleum jelly during
subassembly buildup or transmission assembly.
Many components and surfaces in the transmission are precision machined. Careful handling
during disassembly, cleaning, inspection and assembly can prevent unnecessary damage to
machined surfaces.
1. Use the special tools to install the rear case bushing if removed. 1. Position the rear case bushing and the special tool inside the case.
2. Assemble the special tools through the back of the case.
2. Place the transmission in the vertical position.
3. Coat the No. 9 case rear bearing with petroleum jelly and install on the case boss.
4. CAUTION: Be sure the No. 7 needle bearing and direct clutch hub are installed as
shown in the Subassembly section. Internal damage and shift problems may occur. D0AZ-
19584- AA B
MERCON® V Automatic
Transmission Fluid
XT
-5-QM, XT -5-DM MERCON® V Klj . 3 ba
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Install the output shaft and output shaft ring gear.
5. Install the No. 8 bearing.
6. Install the direct clutch.
7. NOTE: The reverse band support retaining ring is used for assembly purposes during
production. The reverse band support retaining ring is not required during assembly and it will
not affect the operation of the transmission.
Install the reverse band support retaining ring. Klj . 4 ba
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12. Install the forward clutch sun gear, the No. 5 forward clutch sun gear bearing and the reverse
sun gear.
13. Install the No. 4 forward clutch hub bearing.
14. Install the intermediate stub shaft. 15. Install the forward clutch hub and the No. 3 forward clutch hub front bearing. Klj . 6 ba
252003 Mustang Workshop Manual
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16. Install the forward clutch assembly.
17.
NOTE: Make sure the reverse clutch cylinder lugs are completely seated in the notches of the
reverse sun gear.
Install the reverse clutch cylinder assembly. 1. Install the reverse clutch cylinder.
2. Install the No. 2 forward clutch bearing.
18. Install the overdrive band. zPosition the overdrive band pocket onto the anchor pin. Klj . 7 ba
252003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2748/S3B~us~en~ ...