2003 FORD MUSTANG manual transmission

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
142003 Mustang Workshop Manual
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14.
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.
Install the fourth speed synchronizer blocking ring. zAlign the notches in the synchronizer blocking ring and the synchronizer hub inserts.
15. NOTE: Verify that the fourth speed synchronizer blocking ring is still in position.
Align the flat on the fourth gear clutching teeth with the countershaft cluster gear and install the
input shaft.
16. NOTE: Do not install the end play shims at this time.
NOTE: Do not apply sealant to the input shaft bearing retainer at this time.
Install the bearing race in the bearing retainer.
17. Install the input shaft bearing retainer with the notch facing upward. Klj . 6 ba
142003 Mustang Workshop Manual
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21.
NOTE: If not done so previously, soak the blocking ring in transmission fluid for ten minutes.
Install the fifth speed cluster gear, the synchronizer blocking ring, the synchronizer assembly,
and the fifth gear shifter fork as an assembly.
22. CAUTION: To prevent component damage when installing the extension housing
(7A039), the alignment tab on the reverse brake ring (7M000) must engage the alignment
slot in the extension housing.
NOTE: If not done so previously, soak the blocking ring in transmission fluid for ten minutes.
Install the synchronizer blocking ring, the reverse brake ring, the thrust washer, and the fifth
speed synchronizer retaining snap ring.
23. Apply pipe sealant to the reversing lamp switch threads and install the switch.
24. Install the reverse gearshift lever retaining clip. Klj . 8 ba
142003 Mustang Workshop Manual
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25. Install the output shaft speed wheel and the snap ring.
26.
CAUTION: Do not under any circumstance apply silicone sealant to the top of the
transmission case. The sealant could fall into the transmission and affect transmission
operation.
Apply a 3.2- mm (1/8-in) bead of silicone rubber to the sealing surface on the case cover.
27. NOTE: Verify that all of the synchronizers are in the NEUTRAL position and the gear shifter
forks in the cover are in the NEUTRAL position.
Install the case cover.
zPosition the cover toward the filler plug side of the transmission and lower it until the gear
shifter forks engage the synchronizers. Continue to lower the cover and move it into
position to engage the reverse gearshift lever.
28. Install the bolts. Klj . 9 ba
142003 Mustang Workshop Manual
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32. Install the identification tag and the bolts.
33. Install the split pin and the gearshift shaft bushing.
34. Using the special tools, measure the output shaft end play.
1. Place the transmission in a vertical position.
2. Install the special tool.
3. Push upward on the input shaft and record the dial indicator reading. Klj . 11 ba
142003 Mustang Workshop Manual
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35.
CAUTION: Install the thickest shim closest to the front bearing cup to provide
support for the cup.
CAUTION: Although zero end play is the ideal, end play up to mm (0.002 in) is an
acceptable tolerance. Do not overload the bearings with a shim that is too thick as
damage may occur.
NOTE: Select a shim with a thickness equal to the dial indicator reading. This will provide zero
end play.
Rotate the transmission to the horizontal position and remove the input shaft bearing retainer.
Remove the bearing race and install the necessary shim(s).
36. CAUTION: Do not cover the notch in the input shaft bearing retainer with sealer.
Apply a 3.2- mm (1/8-inch) bead of silicone rubber to the sealing surface on the input shaft
bearing retainer.
37. Install the input shaft bearing retainer and the four bolts. Klj . 12 ba
142003 Mustang Workshop Manual
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38. Apply a 3.2-
mm (1/8-inch) bead of silicone rubber to the sealing surface on the gearshift lever.
39. Install the gearshift lever.
40. Using the special tool, install the extension housing fluid seal.
41. Install the case plug.
42. NOTE: Before installing the transmission, the ball stud, clutch release lever and the input shaft
must be cleaned and lubricated with grease.
Install the clutch release hub and bearing and the clutch release lever. For additional
information, refer to Section 308 - 01 . Klj . 13 ba
142003 Mustang Workshop Manual
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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. Refer to Transmission in this section.
z Check, and as necessary, fill the transmission with MERCON® Multi- Purpose ATF
Transmission Fluid XT -2-QDX or equivalent. The total fill capacity is 2.6L (2.8 qt).
SECTION 308-
03A: Manual Transaxle/Transmission — T5OD 2003 Mustang Workshop Manual Klj . 1 ba
12003 Mustang Workshop Manual
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