2003 FORD MUSTANG lock

6. Disconnect the brake pedal-
to-power brake booster push rod.
1. Remove the self- locking pin.
2. Remove the BPP switch from the brake master cylinder push rod.
3. Remove the brake master cylinder push rod spacers (2B129).
4. Remove the brake master cylinder push rod bushing (2474).
7. Disconnect the clutch pedal position (CPP) switch electrical connector.
8. Disconnect the deactivation switch connector from the wiring harness. Klj . 2 ba
62003 Mustang Workshop Manual
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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
22003 Mustang Workshop Manual
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DESCRIPTION AND OPERATION
Manual Transmission
The T5OD 5-
speed transmission:
z fifth speed gear functions as an overdrive gear.
z forward gears are synchronized and helical cut.
z shift interlock system prevents the engagement of more than one gear. Transmission, Manual Five - Speed SECTION 308-
03A: Manual Transaxle/Transmission — T5OD 2003 Mustang Workshop Manual Klj . 1 ba
52003 Mustang Workshop Manual
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9 7N232 Gear shift plate
10 7K201 Gear selector interlock sleeve
11 305078-
S Pin
12 7302 Selector body
13 7230 Gear shifter fork 3-
4 shift 14 7160 Output shaft bearing snap ring
15 7117 Second speed synchronizer thrust washer
16 7175 First and second gear synchronizer inner cone
17 7174 First and second gear synchronizer outer cone
18 7107 Synchronizer blocking ring
19 7A044 Synchronizer hub insert (also part of 7124)
20 7K218 First and second speed synchronizer hub ball
21 7061 Output shaft assembly
22 7109 Synchronizer hub insert spring (also part of
7124)
23 7124 Sleeve (also part of 7061)
24 7173 First gear bearing spacer
25 7127 First gear bearing
26 7100 First gear
27 7065 Output shaft rear bearing
28 7D234 Thrust bearing
29 7D235 Thrust washer
30 — Synchronizer hub (part of 7124)
31 7124 Synchronizer assembly
32 7B340 Third gear
33 7B369 Third speed bearing
34 7B320 Third speed gear bearing spacer
35 7064 Snap ring
36 7119 Thrust washer
37 7102 Second gear
38 7728 Second speed gear bearing spacer
39 7693 Countershaft front bearing seal
40 7F431 Countershaft bearing assembly
41 7113 Countershaft cluster gear
42 7L172 Countershaft rear bearing adjustment shim
43 7195 Countershaft rear bearing retainer
44 7C210 Bolt
45 7144 Fifth speed cluster gear
46 7M000 Reverse brake ring
47 7G042 Thrust washer
48 7059 Fifth speed synchronizer retaining snap ring
49 7L276 Oil pick-
up funnel Klj . 3 ba
52003 Mustang Workshop Manual
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11. Remove the bolts.
12. Remove the case cover.
zLift the case cover and slide it toward the filler plug side of the case to clear the reverse
gearshift lever.
13. CAUTION: Support the reverse gear shift rail (7240) with a block of wood.
Remove the split pin. Klj . 4 ba
112003 Mustang Workshop Manual
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14. Remove the fifth speed synchronizer retaining snap ring, the thrust washer (7G042), the reverse
brake ring (7M000), and the synchronizer blocking ring (7107).
15. Remove the fifth speed cluster gear (7144), the synchronizer blocking ring (7107), the synchronizer assembly (7124), and the fifth gear shifter fork (7230) as an assembly.
16. Remove the reverse gearshift lever retaining clip.
17. NOTE: Do not remove the reverse gearshift lever (7K002) at this time.
Using a TORX® bit driver, remove the shift lever reverse pin (7K024). Klj . 5 ba
112003 Mustang Workshop Manual
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18. Remove the reversing lamp switch (15520).
19. Remove the reverse gear shift rail.
1. Rotate the reverse gear shift rail clockwise to disengage the ball stud from the reverse gearshift lever.
2. Pull the reverse gear shift rail rearward slightly.
3. Rotate the reverse gear shift rail counterclockwise to align the ball stud with the slot in the case and remove the reverse gear shift rail.
20. Remove the snap ring and the output shaft speed wheel (7H150). Klj . 6 ba
112003 Mustang Workshop Manual
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21. Remove the four bolts and the input shaft bearing retainer (7050).
22.
CAUTION: Do not drop the 15 roller bearings (7118), the input shaft bearing spacer
(7L357), the thrust bearing (7D234), and the thrust washer (7D235) from the rear of the
input shaft (7017).
Remove the input shaft.
zRotate the input shaft until the flat on the fourth gear clutching teeth aligns with the
countershaft cluster gear (7113).
23. Remove the thrust washer, the thrust bearing, the input shaft bearing spacer, and the 15 roller bearings.
24. Remove the fourth speed synchronizer blocking ring (7107). Klj . 7 ba
112003 Mustang Workshop Manual
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