Ford Mustang (1999-2004) Service Manual: Piston - Selection

NOTE: The cylinder bore must be within the specifications for taper and out-of-round before fitting a piston.

1. Select a piston size based on the cylinder bore.

Piston - Selection

2. NOTE: For precision fit, new pistons are divided into three categories within each size range based on their relative position within the range. A paint spot on the new pistons indicates the position within the size range.

Choose the piston with the correct paint color.

  • Refer to the appropriate section in Group for the procedure

Piston - Selection

    Piston - Pin to Bore Diameter
    1. WARNING: Cover the end of the pin bore with a hand or shop rag when removing the retainer ring, since it has a tendency to spring out. Wear eye protection. NOTE: Piston and piston pins are a matc ...

    Piston - Ring End Gap
    CAUTION: Use care when fitting piston rings to avoid possible damage to the piston ring or the cylinder bore. CAUTION: Piston rings should not be transferred from one piston to another. NOTE: Cylin ...

    Other materials:

    Cleaning
    1. Fabricate a cleaning tool from a 1/8 inch diameter brazing rod. 2. Cut an abrasive pad from maroon colored 3M Scotch Brite with the dimensions corresponding to the coupling size. 3. Assemble the pad to the tool. 4. Coat the abrasive pad with PAG Refri ...

    Diagnostics
    Special Tool(s) Transmission Fluid Pressure Gauge 307-004 (T57L-77820-A) Air Test Plate, Transmission 307-246 (T92P-7006-A) Alignment Gauge, TR Sensor 307-351 (T97L-70010-A) Breakout Box, EEC-V Control S ...

    Pilot Bearing
    Special Tool(s) Puller with Slide Hammer 308-001 (T58L-101-B) 1. Remove the clutch disc and the clutch pressure plate. For additional information, refer to Disc and Pressure Plate-3.8L and 4.6L (2V) Engines or Disc and Pressure Plate-4.6L (4V ...