2003 FORD MUSTANG lock

2. Remove the first gear needle bearing.
zInspect the needle bearing for wear or damage. Install a new needle bearing as
necessary.
3. Remove and discard the snap ring.
4. Remove the first gear synchronizer thrust washer, the inner cone, the friction cone and the first gear synchronizer blocking ring.
zInspect all components for wear or damage. Install new components as necessary. Klj . 3 ba
122003 Mustang Workshop Manual
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5. Remove the synchronizer spring, then remove the synchronizer sleeve.
6.
NOTE: Install the special tool behind second gear with the flat side of the tool facing second
gear.
Using the special tool, remove the second gear, the second gear synchronizer thrust washer,
the inner cone, the friction cone, the second gear synchronizer blocking ring and the
synchronizer hub.
zInspect the gear for wear or damage. Install a new gear as necessary.
z Inspect the all synchronizer components for wear or damage. Install a new components
as necessary. Klj . 4 ba
122003 Mustang Workshop Manual
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7. Remove the second gear needle bearing.
zInspect the needle bearing for wear or damage. Install a new needle bearing as
necessary.
8. NOTE: Reposition the output shaft on the press with the input shaft end facing upward.
Remove and discard the snap ring, then using the special tool, remove the third/fourth gear
synchronizer assembly, the third gear synchronizer blocking ring and the third gear. zInspect the gear for broken or cracked teeth. Install a new gear as necessary. Klj . 5 ba
122003 Mustang Workshop Manual
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9. Remove the third gear needle bearing.
zInspect the needle bearing for wear or damage. Install a new needle bearing as
necessary.
10. NOTE: Install the special tool with the flat side facing the bearing.
Using the special tool, press the output shaft front bearing from the output shaft.
11. Inspect the synchronizers. zCheck for worn, nicked or broken teeth. Install a new synchronizer as necessary.
z Check keys for wear or distortion. Install a new synchronizer as necessary.
z Check springs for distortion. Install a new synchronizer as necessary.
12. Inspect the synchronizer blocking rings. zCheck for wear or damage. Install new synchronizer blocking rings as necessary.
z Check the clearance between the synchronizer blocking ring and the gear.
„Position the blocking ring onto the gear. Make sure the correct blocking ring is
measured with the correct gear and that the blocking ring is fully seated on the
gear.
„ Insert a feeler gauge and measure the clearance, while applying pressure and
rotating the blocking ring. The measurement should be the same around the entire
circumference. If the clearance is less than 0.38 mm (0.015 in), install new
blocking rings. Klj . 6 ba
122003 Mustang Workshop Manual
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13. Inspect the output shaft for scoring or worn or damaged splines. Install a new output shaft as
necessary.
Assembly
1. Lubricate all components with the recommended transmission fluid when reassembling.
2. Using the special tools, press the output shaft front bearing on the output shaft.
3. Install the third gear bearing. zApply petroleum jelly to the bearing.
4. Install third gear, the third gear synchronizer blocking ring and the third/fourth gear synchronizer assembly. Position the output shaft with the output end facing upward. Using the special tool,
press the third/fourth gear synchronizer assembly into place.
zInstall the synchronizer body with the groove facing third gear.
z Stop press operation before keys engage the blocking ring slots. Lift and rotate the third
gear and the blocking ring until the keys are seated in the blocking ring. Klj . 7 ba
122003 Mustang Workshop Manual
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8. Install the second gear synchronizer thrust washer, the inner cone, the friction cone and the
second gear synchronizer blocking ring.
zAlign the blocking ring tabs with the second gear slots.
9. Install the first/second gear synchronizer assembly. Position the output shaft with the output end facing downward. Using the special tools, press the first/second gear synchronizer assembly
into place.
zInstall the synchronizer with the groove on the sleeve facing first gear.
z Stop press operation before keys engage the blocking ring slots. Lift and rotate the
second gear and the blocking ring until the keys are seated in the blocking ring. Klj . 9 ba
122003 Mustang Workshop Manual
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10. Install the first gear synchronizer thrust washer, the inner cone, the friction cone and the first
gear synchronizer blocking ring.
11. Install a new snap ring. Klj . 10 ba
122003 Mustang Workshop Manual
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1. Remove the thrust washer. Item Part Number Description
1 7025 Countershaft front bearing
2 7113 Countershaft
3 — Countershaft rear bearing
4 — Thrust washer
5 — Sixth gear needle bearing
6 — Sixth gear
7 — Synchronizer blocking ring
8 — Spacer
9 — Snap ring
10 — Fifth/sixth synchronizer assembly
11 — Fifth gear
12 — Fifth gear needle bearing
13 — Countershaft extension
14 — Countershaft extension bearing Klj . 2 ba
82003 Mustang Workshop Manual
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