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:

    Handle - Interior Door
    Removal 1. Remove the door trim panel (23942). For additional information, refer to Section. 2. Remove the rivet. 3. Remove the cable clip. 4. Release the cable housing from the interior handle. 5. Release the actuating cable from the interior ha ...

    Assembly
    1. Lubricate all components with the recommended transmission fluid when reassembling. 2. Using the special tools, press the output shaft front bearing on the output shaft. 3. Install the third gear bearing. Apply petroleum jelly to the bearing. 4. I ...

    Bulb
    Removal and Installation 1. Remove the floor console. For additional information, refer to Section. 2. Remove the bolts, then position the bezel upward. 3. Remove the bulb socket from the bezel. 4. Remove the bulb. 5. To install, reverse the removal ...