2003 FORD MUSTANG lock

SPECIFICATIONS
SECTION 308-
03B: Manual Transaxle/Transmission — TR3650 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 Silicone Rubber
D6AZ-
19562- BA ESB-
M4G92- A Pipe Sealant with Teflon®
D8AZ-
19554- A ESR-
M18P7- A Motorcraft MERCON® Multi-Purpose (ATF)
Transmission Fluid
XT -2-QDX MERCON®
Synchronizer
Synchronizer blocking ring to conical face runout 0.5 mm (0.02 in)
End Play
Input shaft end play 0.02286 mm (0.0009 in) -
0.0508 mm
(0.002 in) Countershaft cluster gear end play 0.0 mm (0.0 in) -
0.076 mm (0.003 in) Output shaft end play 0.0012 mm (0.0005 in) -
0.100 mm (0.004
in)
Torque Specifications Description Nm lb-
ft lb-
in Gearshift lever to extension housing bolt 23 13 —
Gear shift lever to gear shift stub shaft bolt 37 27 —
OSS to case bolt 10 — 89
Reverse idler gear bolt 27 20 —
Fifth/reverse lockout bolt 20 15 —
Clutch housing to transmission main case bolt 31 23 —
Extension housing to transmission main case bolt 31 23 —
Drain plug 23 17 —
Reversing lamp switch 37 27 —
Fill plug 17 13 —
Transmission to engine bolt 75 55 —
Engine plate to transmission bolt 27 20 —
Crossmember to frame bolt 41 30 — Klj . 1 ba
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DESCRIPTION AND OPERATION
Manual Transmission
The TR3650 five-
speed manual transmission features the following:
z The fifth speed gear functions as an overdrive gear.
z The forward gears are synchronized and helical cut.
z The reverse gear operates through a constant- mesh, fully synchronized system.
z The shift interlock system prevents the engagement of more than one gear.
z The countershaft is serviced as an assembly.
z An aluminum main case, extension housing and bell housing. Transmission Internal Components — Disassembled View SECTION 308-
03B: Manual Transaxle/Transmission — TR3650 2003 Mustang Workshop Manual Klj . 1 ba
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8 7064 Retaining ring
9 7124 Third/fourth gear synchronizer assembly
10 7107 Third/fourth gear synchronizer blocking ring
11 — Third/fourth gear synchronizer spring (part of
7124)
12 — Third/fourth gear synchronizer insert (part of
7124)
13 — Third/fourth gear synchronizer hub (part of 7124)
14 — Third/fourth gear synchronizer sleeve (part of
7124)
15 7B340 Third gear
16 7B369 Third gear needle bearing
17 — Third gear bushing
18 — Check ball
19 — Thrust washer
20 — Second gear needle bearing
21 7102 Second gear
22 7175 First/second gear synchronizer inner cone
23 7174 First/second gear synchronizer outer cone
24 7061 Output shaft
25 — Retaining ring
26 7124 First/second gear synchronizer assembly
27 7107 First/second gear synchronizer blocking ring
28 — First/second gear synchronizer spring (part of
7124)
29 — First/second gear synchronizer hub (part of 7124)
30 — First/second gear synchronizer insert (part of
7124)
31 — First/second gear synchronizer sleeve (part of
7124)
32 7127 First gear needle bearing
33 7100 First gear
34 — Reverse clutch cone
35 7124 Reverse gear synchronizer assembly
36 7107 Reverse gear synchronizer blocking ring
37 — Reverse gear synchronizer spring (part of 7124)
38 — Reverse gear synchronizer hub (part of 7124)
39 — Reverse gear synchronizer insert (part of 7124)
40 — Reverse gear synchronizer sleeve (part of 7124)
41 — Retaining ring
42 7N168 Reverse needle bearing
43 7C238 Reverse driven gear
44 — Reverse gear bushing Klj . 3 ba
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Transmission Case and Shift Components — Disassembled View 45 — Selector gate
46 7025 Mainshaft rear bearing and cup
47 7K316 Mainshaft fifth gear
48 — Retaining ring
49 7H150 Output shaft speed (OSS) sensor
50 — Retaining ring
51 7L172 Shim
52 7025 Countershaft front bearing and cup
53 7113 Countershaft
54 7025 Countershaft rear bearing and cup
55 — Thrust bearing
56 7144 Countershaft fifth gear
57 — Countershaft fifth gear needle bearing
58 — Countershaft fifth gear bearing spacer
59 — Retaining ring
60 7124 Fifth gear synchronizer assembly
61 7107 Fifth gear synchronizer blocking ring
62 — Fifth gear synchronizer spring (part of 7124)
63 — Fifth gear synchronizer hub (part of 7124)
64 — Fifth gear synchronizer insert (part of 7124)
65 — Fifth gear synchronizer sleeve (part of 7124)
66 — Fifth gear clutch cone
67 — Retaining ring
68 — Reverse idler gear support
69 7140 Reverse idler gear shaft
70 7141 Reverse idler gear
71 7E169 Reverse idler gear needle bearing
72 — Reverse idler gear bearing spacer Klj . 4 ba
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Transmission Identification
The transmission identification tag is located under the lower bolt that retains the extension housing to
the main case.
The five speed overdrive (TR3650) transmission is available for the Mustang 4.6L (2V).
Transmission Identification 16 7240 Main shift rail
17 7F018 Gearshift offset lever
18 — Spacer
19 — Bearing
20 7210 Gearshift lever
21 — Gearshift plate and spring
22 — Shipping seal
23 7052 Output shaft seal
24 — Extension housing bushing
25 7A039 Extension housing
26 7034 Vent
27 — Vehicle speed sensor (VSS)
28 — Fifth/reverse gear lockout
29 7L027 Magnet
30 7K201 Shift interlock plate
31 7005 Transmission main case
32 — Interlock pins
33 7A010 Drain plug
34 15520 Reverse lamp switch
35 — Detent plug
36 — Detent spring
37 — Detent
38 6392 Clutch housing
39 7B602 Ball stud
40 — Bearing
Part Klj . 6 ba
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10. Remove the 12 bolts.
11. Using a flat-
blade screwdriver, separate the extension housing, then remove the gearshift offset
lever from the transmission case.
zRemove and discard the split pin from the gearshift offset lever during removal.
12. Remove the fifth/reverse gear lockout bolt.
13. Remove the fifth/reverse gear lockout. Klj . 4 ba
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22. Remove the fifth gear synchronizer blocking ring.
zInspect the blocking ring for wear or damage. Install new blocking rings as necessary.
23. Remove the fifth gear synchronizer sleeve from the synchronizer hub.
24. Remove the synchronizer inserts and the springs.
25. Remove the needle bearings and the thrust washer. zThe fifth gear needle bearing is three separate pieces: bearing, spacer, bearing Klj . 7 ba
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29. Remove the main shift rail and the plastic spacer.
30. Remove the bolts and the shift interlock plate.
31. Using a magnet, remove the interlock pins.
zOne lock pin in the center rail, two between the rails.
32. Remove the three detent plugs, springs and the detents. Klj . 9 ba
152003 Mustang Workshop Manual
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