2003 FORD MUSTANG manual transmission

DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES
Transmission Case
Disassembly and Assembly
1. Remove the bolts and the guide plate. zInspect the plate for wear or damage. Install a new plate as necessary. 2. Remove the case magnets. SECTION 308-
03C: Manual Transaxle/Transmission — T56 2003 Mustang Workshop Manual Special Tool(s)
Handle
205-
D055 (D81L-4000- A) Installer, Bearing Cup
204-
039 (T77F-1217- B) Installer, Drive Pinion Bearing
Cup
205-
054 (T71P-4616- A) Installer, Rear Axle Oil Seal
205-
155 (T80T-4000- Y) Klj . 1 ba
42003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2308/S3B~us~en~ ...

ASSEMBLY
Transmission
SECTION 308-
03C: Manual Transaxle/Transmission — T56 2003 Mustang Workshop Manual Special Tool(s)
Dial Indicator Gauge with
Holding Fixture
100-
002 (TOOL- 4201-C) or
equivalent Holding Fixture, Transmission
307-
003 (T57L- 500-B) Remover/Installer, Bearing
Tube
308-
025 (T75L-7025- C) Installer, Bearing Cup
204-
039 (T77F-1217- B) Adapter for 303-
224 (Handle)
205- 153 (T80T-4000- W) Installer, Axle Shaft Oil Seal
205-
123 (T78P-1177- A)
Material Item Specification
DEXRON III® (
ATF)
Transmission Fluid
XT -2-QDX or equivalent DEXRON III®
Premium Long Life Grease ESA-
M1C75- B Klj . 1 ba
182003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2308/S3B~us~en~ ...

1. Lubricate all components with transmission fluid during assembly.
2. Attach the transmission adapter plate to the special tool.
3.
NOTE: If a new front input shaft bearing or front countershaft bearing was installed, install new
bearing cups.
Install the input shaft bearing cup and the countershaft bearing cup. Do not install the shims at
this time.
4. Install the input shaft.
5. Install the mainshaft onto the input shaft. XG
-1-C, K or T Threadlock and Sealer
E0AZ-
19554- AA WSK-
M2G351- A5
(type II) Black Non-
Acid Cure
Silicone Rubber
E7TZ- 19562- A ESL-
M4G273- A Klj . 2 ba
182003 Mustang Workshop Manual
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6. Install the countershaft.
zLift the mainshaft upward, tilt the countershaft and install.
7. Install the transmission case and tighten the bolts. Klj . 3 ba
182003 Mustang Workshop Manual
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8.
NOTE: Rotate the transmission so that the input shaft is pointing downward.
NOTE: Rotate the input shaft/mainshaft to seat the bearings.
Using the special tools, measure the input shaft/mainshaft end play by applying an upward load
on the input shaft. Record the measurement.
9. Reposition the special tool on the countershaft. Place the tip of the dial between the fingers on the countershaft.
10. NOTE: Rotate the countershaft to seat the bearings.
Using the special tools, measure the countershaft gear end play by pushing upward on the
countershaft. Record the measurement. zUnscrew the installer from the handle. Insert the handle into the adapter plate plug hole. Klj . 4 ba
182003 Mustang Workshop Manual
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11. Remove the bolts and the transmission case.
12. Remove the countershaft. Klj . 5 ba
182003 Mustang Workshop Manual
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21. Install the fifth/sixth and reverse shift rail assembly and align the slots of the shift levers with the
shift interlock plate.
22. Clean the mating surfaces of the transmission main case and the transmission adapter plate. Apply a bead of silicone rubber to the sealing surface on the transmission adapter plate. Install
the spring and detent ball into the front offset lever, then install the transmission case and the
front offset lever.
zMake sure the transmission is in neutral to keep the third/fourth gear shift rail from
engaging.
z Compress the front offset lever against the guide plate when installing.
z Tighten the bolts in a star pattern. Klj . 9 ba
182003 Mustang Workshop Manual
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26. Clean the mating surfaces of the transmission main case and the shift detent cover. Apply a
bead of silicone rubber to the sealing surface on the transmission case. Install the cover and
tighten the bolts.
27. Rotate the transmission to a horizontal position. Install the countershaft extension assembly and the fifth/sixth gear shift fork. Make sure the splines are fully engaged.
28. NOTE: Remove the countershaft extension shim from the extension housing.
Install the extension housing and tighten the bolts.
29. NOTE: Rotate the transmission to the vertical position.
Using the special tools, measure the countershaft extension end play by pushing upward on the
countershaft extension. Record the measurement. zInsert a suitable bar into the adapter plate plug hole until it engages the countershaft
extension. Klj . 11 ba
182003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2308/S3B~us~en~ ...