2003 FORD MUSTANG manual transmission

DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES
Output Shaft
Disassembly
1. Using the special tool and a press, remove the third/fourth gear synchronizer assembly (7124), the third speed synchronizer blocking ring (7107), and the third gear (7B340) as an assembly.
2. Remove the third speed bearing (7B369) and the third speed gear bearing spacer (7B320).
3. Remove the snap ring.
SECTION 308-
03A: Manual Transaxle/Transmission — T5OD 2003 Mustang Workshop Manual Special Tool(s)
Pinion Bearing Cone Remove
205-
D002 (D79L-4621- A) or
Equivalent Spiral Snap Ring Replacer
308-
096 (T85P-7025- A) Klj . 1 ba
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Assembly
1. Soak the blocking rings in transmission fluid for ten minutes. zUse MERCON® Multi- Purpose ATF Transmission Fluid XT -2-QDX or equivalent.
2. Assemble the first and second synchronizer. 1. Install the synchronizer hub insert springs and the synchronizer inserts into the synchronizer hub.
2. Install the sliding sleeve onto the hub.
3. NOTE: If not done so previously, soak the blocking ring in MERCON® Multi- Purpose ATF
Transmission Fluid XT -2-QDX or equivalent for ten minutes.
NOTE: Align the slots in the synchronizer blocking ring with the tabs in the first and second
speed synchronizer.
Install the second speed synchronizer blocking ring and the inner and outer cones as an
assembly.
4. Install the second speed synchronizer thrust washer.
5. Using the special tool, install the output shaft bearing snap ring. Klj . 5 ba
102003 Mustang Workshop Manual
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6. Install the second speed gear bearing spacer and the second speed bearing.
7.
NOTE: Align the slots in the second gear with the tabs on the synchronizer blocking ring.
Install the second gear onto the output shaft.
8. Install the thrust washer and the snap ring.
9. NOTE: If not done so previously, soak the blocking ring in MERCON® Multi- Purpose ATF
Transmission Fluid XT -2-QDX or equivalent for ten minutes. Klj . 6 ba
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17. Install the third speed gear bearing spacer and the third speed bearing.
18.
CAUTION: Before pressing the components together, verify that the synchronizer
hub faces the short end of the output shaft. Hold the third gear against the synchronizer
to maintain the synchronizer blocking ring alignment.
NOTE: If not done so previously, soak the blocking ring in MERCON® Multi- Purpose ATF
Transmission Fluid XT -2-QDX or equivalent for ten minutes.
Using a 1- 1/2 inch deep well socket and a press, install the third gear, the third speed
synchronizer blocking ring, and the third/fourth gear synchronizer assembly. Klj . 9 ba
102003 Mustang Workshop Manual
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DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES
Countershaft Bearing
Disassembly SECTION 308-
03A: Manual Transaxle/Transmission — T5OD 2003 Mustang Workshop Manual Special Tool(s)
Bearing Replacer
308-
061 (T77J-7025- L) Front Bearing Replacer
308-
062 (T77J-7025- M) Mainshaft Front Bearing
Replacer
308-
081 (T82T-7003- DH) Pinion Bearing Cone Remover
205-
D002 (D79L-4621- A) or
Equivalent Pinion Bearing Cone Replacer
205-
011 (T57L-4621- B) Remover and Replacer Tube
308-
024 (T75L-7025- B) Remover and Replacer Tube
308-
052 (T77J-7025- B) Klj . 1 ba
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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
32003 Mustang Workshop Manual
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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
22003 Mustang Workshop Manual
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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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