2003 FORD MUSTANG torque

Release bearing rub will
disappear when the
clutch is engaged. In the
event that a bearing is
damaged, the noise is
more pronounced while
engaged in gear under
load or coast than in
NEUTRAL.
Noisy in forward gears
zComponents
grounding out
on the
transmission. z
CHECK for screws,
bolts, etc., of body or
other components
grounding out.
CORRECT as
necessary.
z Components
housing bolts. z
CHECK the torque on
the transmission-to-
flywheel housing bolts
and the flywheel
housing- to-engine block
bolts. TIGHTEN the
bolts to specification.
REFER to Section 308 -
01 .
z Bearings or
gears. z
INSPECT the bearings.
INSPECT the gears and
gear teeth for wear or
damage. INSTALL new
components as
necessary. REFER to
Section 308 - 01 .
z Gears clash when
shifting from one forward
gear to another z
Pilot bearing. zCHECK for a binding
condition between the
input shaft and the
engine crankshaft pilot
bearing. INSTALL new
components as
necessary. REFER to
Section 308 - 01 .
z Gear teeth
and/or
synchronizer. z
REPAIR or INSTALL
new components as
necessary. REFER to
Section 308 - 03A or
Section 308 - 03B .
z Engine idle
speed too high. z
REFER to the
Powertrain
Control/Emissions
Diagnosis (PC/ED)
manual.
z Transmission jumps out
of gear z
Transmission
range selector
lever boot. z
INSTALL a new boot if
exceptionally stiff.
REFER to Section 308 -
03A or
Section 308 -
03B .
z Transmission-to-
engine mounting
bolts. z
TIGHTEN the bolts to
specification. Klj . 4 ba
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z
Other
component
leaking. z
IDENTIFY leaking fluid
as engine, power
steering, or transmission
fluid. REPAIR as
necessary.
z False report. zREMOVE all traces of
lube on the exposed
transmission surfaces.
CHECK the vent for free
breathing. OPERATE
the transmission and
INSPECT for new
leakage. REPAIR as
necessary. REFER to
Section 308 - 03A or
Section 308 - 03B .
z Internal
components. z
INSPECT for leaks at
the input shaft bearing
retainer seal and the
shift rail expansion plug.
REFER to Section 308 -
03A or
Section 308 -
03B . INSPECT for leaks
at the top cover gasket.
INSPECT the case for
sand holes or cracks.
REPAIR or INSTALL a
new case as necessary.
REFER to Section 308 -
03A or
Section 308 -
03B .
z Fill and drain
plugs. z
CHECK fill and drain
plugs and bore threads.
REPAIR as necessary.
TIGHTEN plugs to
specified torque value.
REFER to Section 308 -
03A or
Section 308 -
03B .
z Bearing failure zOther part
failure.
z Raceways or
rollers.
z Lubricant.
z Towing vehicle
further than 80
km (50 miles)
with driveshaft
installed.
Mainshaft
tapered bearing
and needle
caged bearings
are especially
susceptible to
damage. z
REMOVE,
DISASSEMBLE and
CLEAN the
transmission. Inspect for
damaged parts and
install new components
as necessary. (Note:
RESET the bearing
preload if any new
tapered bearings are
installed). REFER to
Section 308 - 03A or
Section 308 - 03B .
z Vibration break-
up of retainer
and brinelling of
races.
z Bearing(s). z
DETERMINE the cause
of vibration and
CORRECT. Otherwise
PROCEED as above. Klj . 6 ba
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stopped and the measurement taken at the downstop is the
clutch reserve.
z Is the clutch reserve less than 19 mm (0.75 inch)? Item Pedal Position
1 Gear clash begins
2 Gear clash ends
3 Clutch pedal downstop
F5 INSPECT THE RELEASE LEVER AND PIVOT STUD
z
Remove the transmission.
z Inspect the release lever and the pivot stud for wear,
damage or misalignment.
z Is the release lever or pivot stud worn, damaged or
misaligned? Yes
INSTALL a new release
lever or pivot stud as
necessary. TEST the
system for normal
operation.
No
GO to
F6 .
F6 INSPECT THE RELEASE BEARING
z
Inspect the release bearing for wear or damage. Make sure
the release lever is seated in the release bearing pocket.
z Is the release bearing worn or damaged? Yes
INSTALL a new release
bearing. TEST the system
for normal operation.
No
GO to
F7 .
F7 INSPECT THE PILOT BEARING
z
Inspect the pilot bearing for wear or damage.
z Is the pilot bearing worn or damaged? Yes
INSTALL a new pilot
bearing. TEST the system
for normal operation.
No
GO to
F8 .
F8 INSPECT THE CLUTCH PRESSURE PLATE TO FLYWHEEL
BOLTS z
Measure the clutch pressure plate to flywheel bolts.
z Is the bolt torque greater than or equal to 65 Nm (48 lb-
ft)? Yes
INSTALL a new pressure
plate and clutch disc. Note
the condition of the
removed components
(wear, damage or oil
contamination). For oil Klj . 13 ba
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SPECIFICATIONS
SECTION 308-
01: Clutch 2003 Mustang Workshop Manual General Specifications
Item Specification
Pressure Plate
Pressure plate diameter (3.8L) 280 mm (11.0 in)
Pressure plate diameter 4.6L (2V) 280 mm (11.0 in)
Pressure plate diameter 4.6L (4V) 280 mm (11.0 in)
Clutch Disc
Clutch diameter (3.8L)
280 mm (11.0 in) Number of springs:
5 plain
Color identification:
none Clutch diameter (4.6L 2V)
280 mm (11.0 in) Number of springs:
4 plain
Color identification:
none Clutch diameter (4.6L 4V)
280 mm (11.0 in) Number of springs:
5 plain
Color identification:
no paint daub Fluid and Lubricants
Motorcraft Premium Long-
Life Grease
XG -1-C or equivalent ESA-
M1C75- B
Torque Specifications Description Nm lb-
ft Pressure plate to flywheel bolt (3.8L) 33 24
Pressure plate to flywheel bolts 4.6L (2V) 45 + 60° 33 + 60°
Pressure plate-
to-flywheel bolts 4.6L (4V) 45 + 60° 33 + 60° Klj . 1 ba
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DESCRIPTION AND OPERATION
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 - 02 .
z The clutch is a single plate, dry friction clutch disc. The clutch disc has a splined hub (with
integral torsional dampening springs) which attaches the clutch disc to the input shaft.
z Engine output is coupled to the input shaft by the 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 force
exerted by the clutch pressure plate. 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 to
the flywheel.
z The clutch system is disengaged when the clutch pedal is depressed and engaged when the
clutch pedal is released. 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.
SECTION 308-
01: Clutch 2003 Mustang Workshop Manual Klj . 1 ba
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SPECIFICATIONS
SECTION 308-
02: Clutch Controls 2003 Mustang Workshop Manual General Specifications
Item Specification
Clutch System
System adjustment Self adjusting
Fluid and Lubricant
Super Premium SAE 10W-30
XO- 10W-30- BSP WSS-
M2C153- G
Torque Specifications Description Nm lb-
ft lb-
in Brake booster nuts 25 18 —
Brake pedal support bracket to cowl bolt 25 18 —
Clutch pedal retaining nut 40 30 —
Clutch release lever cable bracket screw (3.8L) 10 — 89
Clutch release lever cable to bulkhead screws 4 — 35
Clutch release lever cable to crossmember retaining screw 8 — 71
Clutch release lever cable to master cylinder retaining screw (4.6L) 8 — 71
Instrument panel reinforcement screws 9 — 80
Instrument panel steering column cover screws 9 — 80 Klj . 1 ba
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SPECIFICATIONS
SECTION 308-
03A: Manual Transaxle/Transmission — T5OD 2003 Mustang Workshop Manual General Specifications
Item Specification
Lubricants and Sealants
Multi-
Purpose Grease
D0AZ- 19584- AA ESB-
M1C93- B Threadlock and Sealer
E0AZ-
19554- AA WSK-
M2G351- A5 Clear Silicone Rubber
D6AZ-
19562- AA ESB-
M4G92- A Pipe Sealant with Teflon®
D8AZ-
19554- A ESR-
M18P7-A MERCON® Multi-
Purpose ATF Transmission Fluid
XT -2-QDX Mercon®
Preload
Output shaft preload 0.0127 mm ( 0.0005 in) - 0.1016 mm ( 0.004 in)
Synchronizer
Synchronizer blocking ring to conical face runout 0.5 mm (0.02 in)
End Play
Countershaft cluster gear end play 0.0254 mm ( 0.001 in) -
0.127 mm ( 0.005 in) Output shaft end play 0.0127 mm ( 0.0005 in) - 0.1016 mm ( 0.004 in)
Torque Specifications Description Nm lb-
ft lb-
in Bolt retaining gearshift lever to extension housing 18 13 —
Screw retaining inner shift boot to floor pan 10 — 89
Bolt retaining gear shift lever to gear shift stub shaft 37 27 —
Bolt retaining OSS to case 10 — 89
Bolt retaining countershaft rear bearing retainer to case 21 15 —
Shift lever reverse pin 40 30 —
Reversing lamp switch 37 27 —
Bolt retaining case cover to case 12 9 —
Bolt retaining extension housing to case 54 40 —
Bolt retaining input shaft bearing retainer to case 21 15 —
Drain plug 23 17 —
Bolt retaining transmission to block 75 55 —
Bolt retaining engine plate to transmission 27 20 — Klj . 1 ba
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SPECIFICATIONS
SECTION 308-
03B: Manual Transaxle/Transmission — TR3650 2003 Mustang Workshop Manual General Specifications
Item Specification
Lubricants and Sealants
Premium Long-
Life Grease
XG -1-C, K or T ESA-
M1C75- B Threadlock and Sealer
E0AZ-
19554- AA WSK-
M2G351- A5 Black Silicone Rubber
D6AZ-
19562- BA ESB-
M4G92- A Pipe Sealant with Teflon®
D8AZ-
19554- A ESR-
M18P7- A Motorcraft MERCON® Multi-Purpose (ATF)
Transmission Fluid
XT -2-QDX MERCON®
Synchronizer
Synchronizer blocking ring to conical face runout 0.5 mm (0.02 in)
End Play
Input shaft end play 0.02286 mm (0.0009 in) -
0.0508 mm
(0.002 in) Countershaft cluster gear end play 0.0 mm (0.0 in) -
0.076 mm (0.003 in) Output shaft end play 0.0012 mm (0.0005 in) -
0.100 mm (0.004
in)
Torque Specifications Description Nm lb-
ft lb-
in Gearshift lever to extension housing bolt 23 13 —
Gear shift lever to gear shift stub shaft bolt 37 27 —
OSS to case bolt 10 — 89
Reverse idler gear bolt 27 20 —
Fifth/reverse lockout bolt 20 15 —
Clutch housing to transmission main case bolt 31 23 —
Extension housing to transmission main case bolt 31 23 —
Drain plug 23 17 —
Reversing lamp switch 37 27 —
Fill plug 17 13 —
Transmission to engine bolt 75 55 —
Engine plate to transmission bolt 27 20 —
Crossmember to frame bolt 41 30 — Klj . 1 ba
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