2003 FORD MUSTANG manual transmission

41. Remove the input shaft bearing cup and input shaft 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.
42. Remove and discard the input shaft seal.
43. WARNING: Make sure protective eye wear is in place.
Clean the transmission adapter plate with solvent and dry with compressed air. Inspect the
adapter plate for cracks. Clean and check the sealing surface for nicks or scratches. zIf the adapter plate is cracked, install a new plate. If the sealing surface has nicks or
scratches, use a soft stone or crocus cloth to remove. Klj . 12 ba
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DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES
Input Shaft and Bearing
Disassembly and Assembly
SECTION 308-
03C: Manual Transaxle/Transmission — T56 2003 Mustang Workshop Manual Special Tool(s)
Plate, Bearing/Oil Seal
205-
090 (T75L-1165- B) Puller, Bearing
205-
D064 (D84L-1123- A) Installer, Drive Pinion Bearing
Cone
205-
004 (T53T-4621- B) Adapter Set, Step Plate
205-
DS011 (D80L-630- A) Universal Puller Set
303-
DS005 (D80L-100- A) Klj . 1 ba
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DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES
Output Shaft
Disassembly
SECTION 308-
03C: Manual Transaxle/Transmission — T56 2003 Mustang Workshop Manual Special Tool(s)
Puller, Bearing
205-
D064 (D84L-1123- A) Adapter for 303-
224 (Handle)
205- 153 (T80T-4000- W) Installer, Output Shaft Rear
Bearing
308-401
Remover/Installer, Bearing
Tube
308-
025 (T75L-7025- C) Item Part Number Description
1 7025 Output shaft front bearing Klj . 1 ba
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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
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DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES
Countershaft
Disassembly and Assembly SECTION 308-
03C: Manual Transaxle/Transmission — T56 2003 Mustang Workshop Manual Special Tool(s)
Plate, Bearing Oil Seal
205-
090 (T75L-1165- B) Puller, Bearing
205-
D064 (D84L-1123- A) Installer, Drive Pinion Bearing
Cone
205-
004 (T53T-4621- B) Remover/Installer, Bearing
Tube
308-
025 (T75L-7025- C) Installer, Output Shaft Rear
Bearing
308-401
Adapter for 303-
224 (Handle)
205- 153 (T80T-4000- W) Klj . 1 ba
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DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES
Synchronizers
Disassembly and Assembly
NOTE:
This procedure applies to all synchronizer assemblies.
1. NOTE: Synchronizer components are not interchangeable. During disassembly, mark each
individual synchronizer for assembly. Synchronizer hubs and sleeves are a selected assembly
and should be kept together as originally assembled. Blocking rings are not interchangeable, do
not mix.
Scribe an alignment mark on the sliding sleeve and the hub for assembly reference.
2. Using a screwdriver, remove the spring. Turn the synchronizer over and remove the second spring. Remove the sliding sleeve and the synchronizer struts from the hub.
3. CAUTION: Match the alignment marks made during disassembly. The sleeve and
the hub have an extremely close fit. Hold the sleeve and hub square to prevent jamming.
Do not force the sleeve onto the hub.
Assemble the synchronizer as follows:
zPosition the synchronizer sleeve on the hub. Make sure to align key openings in the hub
with the synchronizer sleeve.
z Install the keys with the slots facing the hub.
z Install the spring. Locate the tang to one of the key slots and position into place. Install
the second spring. Locate the spring tang on the same key but position in the opposite
direction.
SECTION 308-
03C: Manual Transaxle/Transmission — T56 2003 Mustang Workshop Manual Klj . 1 ba
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DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES
Gearshift Rail and Fork
Disassembly and Assembly
1. Disassemble the first/second and third/fourth shift rail as follows: zRotate the interlock plate until it is opposite of the shift links.
z Slide off the third/fourth shift fork and shift link. Separate the link from the fork.
z Slide off the first/second shift fork and shift link. Separate the link from the fork.
SECTION 308-
03C: Manual Transaxle/Transmission — T56 2003 Mustang Workshop Manual Item Part Number Description
1 — First/second shift fork pad
2 — First/second shift fork
3 — Interlock plate
4 — Shift link
5 — First/second, third/fourth shift rail
6 — Gear select solenoid lever
7 — Roll pin
8 — Selector pin
9 — Roll pin
10 — Shift link
11 — Third/fourth shift fork pad
12 — Third/fourth shift fork
13 — Shift rail collar
14 — Roll pin
15 — Fifth/sixth shift rail
16 — Roll pin
17 — Fifth/sixth shift rail lever
18 — Reverse shift rail lever Klj . 1 ba
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DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES
Extension Housing
Disassembly and Assembly
SECTION 308-
03C: Manual Transaxle/Transmission — T56 2003 Mustang Workshop Manual Special Tool(s)
Installer, Bearing Cup
204-
039 (T77F-1217- B) Adapter for 303-
224 (Handle)
205- 153 (T80T-4000- W) Klj . 1 ba
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