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.

Synchronizers

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:

    Pinpoint Test N: DTC B1869 - Air Bag Indicator Inoperative
    Normal Operation The air bag indicator is designed to illuminate for 6 (+/-2) seconds when the ignition switch is turned to the RUN position. This initial 6 seconds of illumination is considered normal operation and is called proveout of the air bag ind ...

    Electronic Leak Detection
    Special Tool(s) H10PM Refrigerant Leak Detector With Battery 216-00001 or equivalent CAUTION: Good ventilation is necessary in the area where electronic A/C leak testing is to be carried out. If the surrounding air is contaminated with refri ...

    Index Card
    Place an index card or a piece of paper between the weatherstrip and the sealing surface, then close the door. Slowly withdraw the index card or paper after the door is closed and check the amount of pressure on the weatherstrip. There should be a medium amo ...