Ford Mustang (1999-2004) Service Manual: Synchronizers
Disassembly and Assembly
NOTE: This procedure applies to all synchronizer assemblies.
1. Scribe an alignment mark on the sliding sleeve and the hub for assembly reference.
2. Remove the sliding sleeve, then remove the synchronizer struts and the springs.
3. Install the synchronizer struts and the springs.
4. 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.
Install the sliding sleeve.
Countershaft Bearing
Special Tool(s)
Remover, Drive Pinion Bearing
Cone
205-D002 (D79L-4621-A) or
equivalent
Installer, Drive Pinion Bearing
Cone
205-011 (T57L-4621-B)
Disassembly and A ...
Gearshift Rail Bushing
Special Tool(s)
Universal Puller Set
303-DS005 (D80L-100-A) or
equivalent
Installer, Shift Rail Bushing
308-244 (T96P-7025-F)
Slide Hammer
100-001 (T50T-100- ...
Other materials:
Personal Safety System
The Personal Safety System provides an improved overall level of frontal
crash protection to front seat occupants and is designed to help further
reduce the risk of airbag-related injuries. The system is able to analyze
different occupant conditions and crash ...
Installation
1. Align the blend door driver to the full heat position.
2. Place the temperature control knob in the full WARM position.
3. Attach the cable drive to the control head.
4. Rotate the knob back and forth from full WARM to full COOL.
5. Check the cable ...
Knock
Knock, which can occur on all driving phases, has several causes including
damaged teeth or gearset.
In most cases, one of the following conditions will occur:
1. A gear tooth damaged on the drive side is a common cause of the knock.
This can usually be
cor ...
