2003 FORD MUSTANG clutch

19. Install the overdrive servo spring.
1. Install the overdrive servo piston return spring.
2. Install the overdrive servo piston.
20. Verify the tip of the piston assembly engages the pocket of the overdrive band.
21. Using the special tool, compress the overdrive servo assembly and install the overdrive servo retaining ring.
22. Install the intermediate clutch pressure plate. Klj . 8 ba
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23.
NOTE: Before assembly, soak the new clutch discs in clean automatic transmission fluid for 15
minutes.
Install the intermediate clutch pack and selective steel plate.
24. Using the special tool, check the intermediate clutch clearance. 1. Position the special tool on the pump case mounting surface.
2. Maintaining downward pressure, use a depth micrometer to measure and verify intermediate clutch clearance is within specification.
If the intermediate clutch is not within specification, install a correct selective plate.
25. Install the intermediate anti- rattle clip, if equipped. Selective Steel Plates
Specification
1.80-
1.70 mm (0.071- 0.067 inch) 2.05-
1.95 mm (0.081- 0.077 inch) 2.31-
2.20 mm (0.091- 0.087 inch) 2.56-
2.46 mm (0.101- 0.097 inch) Klj . 9 ba
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SPECIFICATIONS
SECTION 308-
00: Manual Transaxle/Transmission and Clutch — General
Information 2003 Mustang Workshop
Manual General Specifications
Item Specification
Pressure plate
Pressure spring Belleville
Sensor spring Belleville
Clutch Disc (3.8L)
Clutch diameter 280 mm (11.0 inches)
Number of springs 5
Color identification none
Clutch Disc (4.6L 2V)
Clutch diameter 280 mm (11.0 inches)
Number of springs 4
Color identification none
Lubricants (Spec and Capacity) Fluid
T50D-
MERCON® Multi- Purpose ATF Transmission Fluid XT -2-QDX 2.6L (2.8 qt)
TR3650-
Synthetic MERCON® ( ATF) Transmission Fluid E6AZ-19582- B 3.6L (7.5 pt) Klj . 1 ba
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DESCRIPTION AND OPERATION
Manual Transmission and Clutch
The primary function of the clutch is to couple and uncouple engine power to the transmission upon
driver command. For additional information, refer to
Section 308 - 01 .
Clutch Disc and Clutch Pressure Plate — 3.8L
SECTION 308-
00: Manual Transaxle/Transmission and Clutch — General
Information 2003 Mustang Workshop
Manual Item Part Number Description
1 6397 Flywheel housing to block dowel (2 req'd)
2 — Rear face of block and flywheel (part of 6010)
3 6397 Flywheel to clutch pressure plate dowel (3 req'd)
4 7600 Pilot bearing
5 7550 Clutch disc
6 7563 Clutch pressure plate Klj . 1 ba
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Clutch Disc and Clutch Pressure Plate —
4.6L (2V) 7 7548 Clutch release hub and bearing
8 7515 Clutch release lever
9 7B602 Clutch release lever stud
10 N606063-S2 Bolt (6 req'd)
11 6392 Flywheel housing
12 7050 Main drive gear bearing retainer
13 55981-
S36 M Bolt
14 7513 Clutch release lever dust shield
15 N807508-S2 Screw and washer assembly
Item Part Number Description
1 6375 Flywheel
2 6397 Flywheel to clutch pressure plate dowel (3
req'd)
3 7600 Pilot bearing
4 7550 Clutch disc
5 7563 Clutch pressure plate
6 7515 Clutch release lever
7 7B602 Clutch release lever stud
8 N606063-S2 Bolt (6 req'd)
9 6392 Flywheel housing
10 55981-
S36M Bolt
11 7513 Clutch release lever dust shield Klj . 2 ba
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Clutch Disc and Clutch Pressure Plate —
4.6L (4V)
z The clutch is a single plate, dry friction clutch disc. The clutch disc has a splined hub with
integral torsional springs. The clutch disc hub attaches to the input shaft.
z Engine output is coupled to the transmission input shaft by friction existing between the clutch
disc facings and the flywheel/clutch pressure plate assembly. The extent of this friction is directly related to the composition of the facing material and the magnitude of the clamping 12 7548 Clutch release hub and bearing
13 N808969-
S100 Bolt
14 N808969-
S100 Bolt (6 req'd)
15 — Rear face of block and flywheel (part of 6010)
16 — Bolt (3 req'd)
17 6397 Flywheel housing to block dowel (2 req'd)
Item Part Number Description
1 6375 Flywheel
2 7600 Pilot bearing
3 7550 Clutch disc
4 7563 Clutch pressure plate
5 7548 Clutch release hub and bearing
6 7515 Clutch release lever
7 7B602 Clutch release lever stud
8 6392 Flywheel housing
9 N808969-S100 Clutch pressure plate bolt (6 req'd) Klj . 3 ba
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forces exerted by the clutch pressure plate and the flywheel on the facings. These factors limit
the amount of torque that can be transmitted without slippage.
z The clamping force is obtained from a diaphragm spring contained within the clutch pressure
plate assembly. This force is developed during the attachment of the clutch pressure plate
assembly to the flywheel.
z The clutch system is disengaged when the clutch pedal is pressed and is accomplished when
the release fingers are fully displaced toward the flywheel. This displacement removes the
spring load from the clutch pressure plate and eliminates the coupling friction between the
engine and the transmission.
z When the clutch pedal is depressed a cable connected to the clutch release lever, hub and
bearing actuates the clutch pressure plate diaphragm spring, releasing pressure on the clutch
disc. This eliminates the engagement between the transmission and the engine. Klj . 4 ba
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DIAGNOSIS AND TESTING
Manual Transmission and Clutch
Inspection and Verification
It is important to get an accurate description of the concern before any diagnosis can be carried out.
Ask questions as to whether it occurs when hot or cold, during shifting, driving at a particular speed or
in a particular gear. If possible, have the customer demonstrate the concern.
zWith the vehicle at a complete stop, shift through all the gears and evaluate the noise at
different engine rpm. Check for any noises in NEUTRAL at different engine rpm.
Symptom Chart SECTION 308-
00: Manual Transaxle/Transmission and Clutch — General
Information 2003 Mustang Workshop
Manual Symptom Chart
Condition
Possible Sources Action
z Clutch slippage zClutch pedal
sticking.
z Pressure plate
diaphragm
spring damaged
or weakened.
z Clutch pressure
plate damaged.
z Clutch disc
facing damaged
or worn
excessively.
z Clutch disc
facing surface
hardened or oil-
coated.
z Clutch release
hub and bearing
binding.
z Flywheel glazed
or damaged.
z loose pressure
plate to flywheel
bolts z
Go To Pinpoint Test A .
z Clutch chatter or shudder zLoose or worn
engine mount.
z Loose pressure
plate to flywheel
bolts
z Oil on clutch
disc facing.
z Clutch pressure
plate damaged z
Go To Pinpoint Test B . Klj . 1 ba
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