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Klj . 3 ba
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DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES
Extension Housing
Disassembly and Assembly
SECTION 308-
03C: Manual Transaxle/Transmission — T56 2003 Mustang Workshop Manual Special Tool(s)
Installer, Bearing Cup
204-
039 (T77F-1217- B) Adapter for 303-
224 (Handle)
205- 153 (T80T-4000- W) Klj . 1 ba
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Item Part Number Description
1 — Countershaft extension bearing cup
2 — Countershaft extension bearing shim
3 — Fluid funnel
4 — Case plug
5 — Reverse idler shaft bracket
6 — Reverse idler gear thrust washer
7 7141 Reverse idler gear
8 — Reverse idler gear needle bearing
9 7140 Reverse idler gear shaft
10 7052 Extension housing seal
11 — Snap ring
12 — Mainshaft bearing cup
13 — Output shaft speed (OSS) sensor
14 — Reverse lockout solenoid
15 — O-
ring Klj . 2 ba
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1. Remove the bolt and the output shaft speed (OSS) sensor.
2. Remove the bolt and the reverse lockout solenoid.
3. Remove the bolts and the reverse idler shaft bracket.
4. Remove the reverse idler gear thrust washer. 16 7A039 Extension housing Klj . 3 ba
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5. Remove the reverse idler gear.
6.
NOTE: If the countershaft extension bearing was installed new, install a new bearing cup.
Remove the reverse idler gear needle bearing and countershaft extension bearing cup. zInspect the needle bearing for wear or damage. Install a new bearing as necessary.
z Inspect the bearing cup for wear or damage. Install a new bearing and bearing cup as
necessary.
7. Remove the reverse idler gear thrust washer and the reverse idler gear shaft.
8. Remove the countershaft extension bearing shim and the fluid funnel. Klj . 4 ba
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9. Remove the snap ring.
10. NOTE: If the mainshaft bearing was install new, install a new bearing cup.
Position the extension housing with the seal facing upward. Using a brass drift, remove the
mainshaft bearing cup.
11. Remove and discard the extension housing seal. Klj . 5 ba
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12.
WARNING: Make sure protective eye wear is in place.
Clean the housing with solvent and dry with compressed air. Clean and check the sealing
surface for nicks or scratches. Inspect the housing for cracks. zIf the housing is cracked, install a new housing. If the sealing surface has nicks or
scratches, use a soft stone or crocus cloth to remove.
13. Using the special tools, install the mainshaft bearing cup.
14. Using a suitable driver, install the extension housing seal. zInstall the seal with the drain hole at the six o'clock position.
15. To assemble, reverse the disassembly procedure. Klj . 6 ba
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