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1. Using the special tool and a press, remove the countershaft bearing assembly (7F431).
2.
CAUTION: Failure to correctly support the case (7005) during bearing race removal
will result in permanent distortion of the case.
NOTE: Remove the front countershaft bearing race only if damaged or worn.
Using the special tools and a press, remove the bearing race and the countershaft front bearing
seal (7693).
Assembly
NOTE: Position the countershaft in the transmission case before installing the rear countershaft
bearing.
1. Install the countershaft front bearing seal on the bearing race.
2. Coat the outside diameter of the bearing race with sealer. zUse Threadlock and Sealer E0AZ-19554- AA or equivalent meeting Ford specification WSK - M2G351 - 5A. Klj . 2 ba
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3.
CAUTION: Failure to correctly support the case during bearing race installation will
result in permanent distortion of the case.
Using the special tools and a press, install the bearing race.
4. Using the special tool and a press, install the front countershaft bearing. 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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positioned over the hub inserts.
2. CAUTION: Match the alignment marks made during disassembly. The sleeve and
the hub have an extremely close fit. Hold the sleeve and hub square to prevent jamming.
Do not force the sleeve onto the hub.
On the third/fourth speed synchronizer and the fifth speed synchronizer, install the sliding
sleeve. Klj . 2 ba
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ASSEMBLY
Transmission
SECTION 308-
03A: Manual Transaxle/Transmission — T5OD 2003 Mustang Workshop Manual Special Tool(s)
Dial Indicator with Bracketry
100-
002 (TOOL- 4201-C) or
Equivalent Gauge, Clutch Housing
308-
021 (T75L-4201- A) Extension Housing Seal
Replacer
308-
227 (T94P-7657- A) Holding Fixture
307-
003 (T57L- 500-B) Remover and Replacer Tube
308-
052 (T77J-7025- B) Torrington Bearing Installer
308-
083 (T83P-7025- AH)
Material Item Specification
Motorcraft MERCON® Multi-
Purpose (ATF) Transmission
Fluid
XT
-2-QDX MERCON®
Pipe Sealant with Teflon® ESR-M18P7- Klj . 1 ba
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1. Soak the blocking rings in transmission fluid for ten minutes.
2. Position the countershaft cluster gear in the case.
3.
CAUTION: Failure to correctly support the case during bearing installation will
result in permanent distortion of the case.
Using a the special tools and a press, install the rear countershaft bearing assembly. 1. Position two 6.35 mm (0.25 in) pieces of bar stock between the countershaft and the
case.
2. Using a the special tools and a press, install the rear countershaft bearing assembly. D8AZ-
19554- A A
Multi-
Purpose Grease
D0AZ- 19554- AA ESB-
M1C93-
B Clear Silicone Rubber
D6AZ-
19562- AA ESB-
M4G92-
A Motorcraft Premium Long Life
Grease
XG
-1-C ESA-
M1C75-
B Klj . 2 ba
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4. Install the rear countershaft bearing race.
5.
NOTE: Do not install the shims at this time.
Install the countershaft rear bearing retainer.
6. Using the special tool, measure the countershaft cluster gear end play. zIf the end play is not within the specifications, remove the countershaft rear bearing
retainer, and install the necessary thickness shim(s). Reinstall the countershaft rear
bearing retainer, and recheck the end play.
z Bend the tabs of the countershaft rear bearing retainer over the bolts when the end play
adjustment is complete.
7. Position the reverse idler gear and bushing in the case with the shift lever groove facing the rear of the case. Install the reverse idler gear shaft and the reverse gear overtravel stop. Klj . 3 ba
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8. Install the pin.
9. Align the reverse gearshift lever, the reverse shift fork, and the reverse positioning spring.
10. NOTE: Observe the reverse positioning spring rotation. The spring must rotate
counterclockwise into its installed position.
Install the reverse shift fork.
zPlace the reverse idler gear and bushing into the NEUTRAL position. Align the reverse
shift fork and the reverse idler gear and bushing. Push downward on the reverse shift fork until fully engaged into the reverse idler gear and bushing. Klj . 4 ba
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