2003 FORD MUSTANG manual transmission

DISASSEMBLY
Transmission
Disassembly
NOTE:
During disassembly, if any roll pins, retaining rings or bearings are removed, install new
components. Install bearings and bearing cups as a set only.
1. WARNING: Make sure protective eye wear is in place. SECTION 308-
03C: Manual Transaxle/Transmission — T56 2003 Mustang Workshop Manual Special Tool(s)
Holding Fixture, Transmission
307-
003 (T57L- 500-B) Puller, Bearing
205-
D064 (D84L-1123- A) 2 or 3 Jaw Puller
205-
D027 (D80L-1013- A) Remover, Mainshaft Bearing
308-
058 (T77J-7025- H) Remover/Installer, Bearing
Tube
308-
025 (T75L-7025- C) Removal Screw, Bearing Tube
308-
092 (T84T-7025- B) Klj . 1 ba
132003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2308/S3B~us~en~ ...

Clean the transmission exterior with solvent and dry with compressed air. During disassembly,
clean all components with solvent and dry with compressed air.
2. Remove the clutch release hub and bearing and the clutch release lever.
3. Attach the transmission to the special tool.
4. Rotate the transmission to a horizontal position.
5. NOTE: Position a drain pan under the transmission.
If the transmission was not drained during removal, drain the transmission. 6. Remove the vent hose. Klj . 2 ba
132003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2308/S3B~us~en~ ...

7.
NOTE: Position the gearshift lever in third/fourth neutral position.
Using a 5/32- inch drift and a hammer, drive the roll pin downward, then remove the rear offset
shift lever.
zInspect the rear offset shift lever for wear or damage. Install a new lever as necessary.
z Discard the roll pin.
8. Remove the eight bolts and carefully separate the extension housing from the transmission. Klj . 3 ba
132003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2308/S3B~us~en~ ...

9. Remove the plug from the transmission adapter plate.
10. NOTE: Rotate the transmission to a vertical position.
Remove the shipping seal.
11. Remove the output shaft speed (OSS) sensor tone wheel retaining ring.
12. Using the special tools, remove the OSS sensor tone wheel. Klj . 4 ba
132003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2308/S3B~us~en~ ...

blocking ring.
26. Using the special tools, remove the fifth/sixth driven gear.
27. Remove the fifth/sixth shift fork snap ring.
28. Rotate the transmission to the horizontal position, then remove the countershaft extension as an assembly.
29. Remove the shift detent cover. Klj . 8 ba
132003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2308/S3B~us~en~ ...

30. Remove the shift detent assembly.
31. Using a 5/32-
inch drift and a hammer, drive the roll pin downward.
32. Remove nine of the adapter- to-transmission case bolts.
33. NOTE: Rotate the transmission to a vertical position.
Remove the shift lever guide bolts. Klj . 9 ba
132003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2308/S3B~us~en~ ...

34. Remove the two remaining adapter-
to-transmission case bolts, then remove the transmission
case and the front offset lever.
zSlide the transmission case upward, off the mainshaft and shift rails. Hold the offset lever
against the guide plate to prevent the release of the dent ball and spring.
35. Remove the dent ball, spring and roll pin from the front offset lever.
36. Rotate the fifth/sixth and reverse shift levers from the shift interlock plate, then remove the fifth/sixth and reverse shift rail assembly. Klj . 10 ba
132003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2308/S3B~us~en~ ...

37. Lift up the mainshaft, then remove the countershaft.
38. Remove the mainshaft and shift rail as an assembly. Separate the shift rail assembly from the
mainshaft on the work bench.
39. Remove the input shaft and fourth gear synchronizer blocking ring.
40. Remove the countershaft bearing cup and the countershaft shim. zInspect the cup for wear or damage. Install a new cup and bearing as necessary.
z Inspect the cup bore for wear, scratches or grooves. Install a new transmission adapter
plate as necessary. Klj . 11 ba
132003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2308/S3B~us~en~ ...