Ford Mustang (1999-2004) Service Manual: Transmission Case

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)

Disassembly and Assembly

1. Remove the bolts and the guide plate.

  • Inspect the plate for wear or damage. Install a new plate as necessary.

Transmission Case

2. Remove the case magnets.

Transmission Case

3. Remove the reverse lamp switch.

Transmission Case

4. Using the special tools, remove the countershaft bearing cup.

Transmission Case

5. Using a brass drift, remove mainshaft bearing cup.

Transmission Case

6. Inspect the countershaft and mainshaft bearing cups for wear or damage. Install new components as necessary.

7. WARNING: Make sure protective eye wear is in place.

Clean the case with solvent and dry with compressed air. Clean and check the sealing surface for nicks or scratches. Inspect the case for cracks.

  • If the case is cracked, install a new case. If the sealing surface has nicks or scratches, use a soft stone or crocus cloth to remove.

8. NOTE: If a new countershaft bearing is being installed, install a new bearing cup. Always install new bearings and cups in a set.

Using the special tools, install the countershaft bearing cup.

Transmission Case

9. NOTE: If a new mainshaft bearing is being installed, install a new bearing cup. Always install new bearings and cups in a set.

Using the special tools, install the mainshaft bearing cup.

Transmission Case

10. To assemble, reverse the disassembly procedure.

    Extension Housing
    Special Tool(s) Installer, Bearing Cup 204-039 (T77F-1217-B) Adapter for 303-224 (Handle) 205-153 (T80T-4000-W) Disassembly and Assembly   1. Remove the bolt and ...

    Transmission (Assembly)
    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/Inst ...

    Other materials:

    Camshaft Position (CMP) Sensor - 3.8L
    Removal 1. Disconnect the battery ground cable. For additional information, refer to Section. 2. Remove the camshaft position (CMP) sensor. Disconnect the connector. Remove the bolts and the sensor. Installation 1. To install, reverse t ...

    Accessory Drive Belt Tensioner - 4.6L (2V) and (4V)
    Removal and Installation Mach I 1. Remove the air intake scoop. For additional information, refer to Section. Cobra 2. Remove the supercharger drive belt cover. 3. Rotate the supercharger belt tensioner clockwise and remove the supercharger belt. 4. Remov ...

    Valve - Springs, Retainer and Valve Stem Seal
    Special Tool(s) Compressor, Valve Spring 303-452 (T93P-6565-AR) Installer, Valve Stem Oil Seal 303-383 (T91P-6571-A) Compressor, Valve Spring 303-567 (T97P-6565-AH) Spacer, Valve Spring Compressor 303 ...