2003 FORD MUSTANG clutch

INSTALLATION
Transmission
1. NOTE: Before installing the transmission, the ball stud, clutch release lever and the input shaft
must be cleaned and lubricated. Use Motorcraft Premium Long-Life Grease XG-1- C or XG-1-K
or equivalent meeting Ford specification ESA- M1C75-B.
To install, reverse the removal procedure. For additional information, refer to Transmission in
this section.
zCheck, and as necessary, fill the transmission with transmission fluid. The total fill
capacity is 3.6L (7.5 pt).
2. Apply sealant to the fill plug threads and install the fill plug. zUse pipe sealant with Teflon® .
SECTION 308-
03B: Manual Transaxle/Transmission — TR3650 2003 Mustang Workshop Manual Material
Item Specification
Motorcraft MERCON® Multi-
Purpose (ATF) Transmission
Fluid
XT
-2-QDX MERCON
Pipe Sealant with Teflon®
D8AZ-
19554- A or equivalent WSK-
M2G350-
A2 Premium Long Life Grease
XG
-1-C, K or T or equivalent ESA-
M1C75- B Klj . 1 ba
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SPECIFICATIONS
SECTION 308-
03C: Manual Transaxle/Transmission — T56 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 Non-
Acid Cure Silicone Rubber
E7TZ- 19562- A ESL-
M4G273- A Pipe Sealant with Teflon®
D8AZ-
19554- A ESR-
M18P7-A Preload
Input/output shaft preload 0.0 mm (in) -
0.05 mm (0.002 in) Countershaft cluster gear preload 0.0 mm (in) -
0.05 mm (0.002 in) Countershaft extension preload 0.05 mm (in) -
0.13 mm (0.005 in) Fluid
DEXRON III® (
ATF) Transmission Fluid
XT -2-QDX DEXRON III®
Capacity 3.9 L (4.1 qt.)
Synchronizer
Synchronizer blocking ring to conical face runout
1st, 2nd, 3rd, 4th, 5th & 6th gear 0.38 mm (0.01 in)
Synchronizer blocking ring to conical face runout
Reverse gear 0.75 mm (0.03 in)
Torque Specifications Description Nm lb-
ft lb-
in Transmission-to-
clutch adapter housing bolts 35 26 —
Crossmember-
to-frame bolts 41 30 —
Crossmember-
to-
transmission support bolts 58 43 —
OSS sensor bolt 10 — 7
Gearshift lever boot bolts 10 — 89
Lower gearshift lever bolts 20 15 —
Upper gearshift lever bolts 37 27 —
Shift dent 40 30 —
Shift lever guide bolts 27 20 — Klj . 1 ba
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DESCRIPTION AND OPERATION
Manual Transmission
The T56 six-
speed manual transmission features the following:
z six forward speeds and one reverse speed.
z forward gears are synchronized and helical cut.
z a reverse gear operates through a constant- mesh, fully synchronized system.
z a shift interlock system prevents the engagement of more than one gear.
z a countershaft with two sections, the countershaft cluster and the countershaft extension. The
countershaft cluster is serviced as an assembly, the countershaft extension components are
serviced.
z two tapered roller bearings on the output shaft.
z two tapered roller bearings on the countershaft cluster.
z a tapered roller bearing on the input shaft.
z a tapered roller bearing on the countershaft extension.
z countershaft cluster endplay controlled by shims located in the transmission adapter plate.
z countershaft extension endplay controlled by shims located in the extension housing.
z input/output shaft endplay is controlled by shims located in the transmission adapter plate.
z removable wear pads on the shift forks.
z an aluminum main case, extension housing, adapter plate and clutch housing.
Transmission Identification
The transmission identification tag is located under the lower bolt that retains the extension housing to
the main case.
The six speed (T56) transmission is available for the Mustang 4.6L (4V).
Transmission Identification SECTION 308-
03C: Manual Transaxle/Transmission — T56 2003 Mustang Workshop Manual Item Part
Number Description
1 — Transmission assembly number
2 — Build date code —
month Klj . 1 ba
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slip yoke and transmission output shaft.
Remove the driveshaft. For additional information, refer to
Section 205 - 01 .
10. Disconnect the heated oxygen sensor (HO2S) electrical connectors from the crossmember.
11. Position a transmission jack and support the transmission.
12. Remove the bolts and the transmission crossmember.
13. Remove the bolt and the clutch release lever cover. Klj . 3 ba
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14. Disengage the clutch release cable from the clutch release fork.
15. Disconnect the wiring harness from the transmission.
16. Disconnect the output shaft speed (OSS) sensor electrical connector.
17. Disconnect the reverse lamp electrical connector. Klj . 4 ba
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18. Remove the eight transmission-
to-clutch adapter housing bolts.
19. Move the transmission rearward until the input shaft is clear of the pressure plate, then lower the rear of the transmission while moving it forward to clear the exhaust pipe. Lower the
transmission from the vehicle. Klj . 5 ba
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Clean the transmission exterior with solvent and dry with compressed air. During disassembly,
clean all components with solvent and dry with compressed air.
2. Remove the clutch release hub and bearing and the clutch release lever.
3. Attach the transmission to the special tool.
4. Rotate the transmission to a horizontal position.
5. NOTE: Position a drain pan under the transmission.
If the transmission was not drained during removal, drain the transmission. 6. Remove the vent hose. Klj . 2 ba
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50. Install the rear offset shift lever, then install a new roll pin.
zInstall the pin until it is flush with the lever.
51. Install the vent hose.
52. NOTE: Before installing the transmission, the ball stud, the clutch release lever and the input
shaft guide tube must be cleaned and lubricated.
Install the clutch release lever and the clutch release hub and bearing. Klj . 17 ba
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