Ford Mustang (1999-2004) Service Manual: Assembly

1. Carry out the following before reassembling:

  • Inspect the gears for broken or cracked teeth. Check for unusual wear patterns.
  • Inspect the thrust washers for face wear, cracks, scoring and for signs of heat damage.
  • Inspect the bearings, bearing cups and the synchronizers for wear or damage.
  • Inspect the output shaft for scoring or worn or damaged splines. Install new components as necessary.

2. Lubricate all components with the recommended transmission fluid when reassembling.

3. NOTE: Position the output shaft with the output end facing upward.

NOTE: Install the synchronizer assembly with the deeper center flange of the synchronizer hub facing toward the rear of the output shaft.

Install the first/second synchronizer assembly on the output shaft, then install a new retaining ring.

  • It may be necessary to press the hub into position on the shaft.

Output Shaft

 

Output Shaft

4. Install the first gear synchronizer blocking ring.

  • Align the blocking ring tabs with the synchronizer assembly.

Output Shaft

5. Install the outer first gear synchronizer cone.

Output Shaft

6. Install the inner first gear synchronizer cone. Rotate the inner cone till it is seated.

Output Shaft

7. Install the first gear needle bearing.

  • Apply petroleum jelly to the bearing.

Output Shaft

8. Install first gear.

  • Rotate the gear to align the gear slots with the inner cone tabs.

Output Shaft

9. Install the reverse synchronizer cone.

Output Shaft

10. Install the reverse gear blocking ring.

Output Shaft

11. Using the special tools, install the reverse gear bearing spacer.

Output Shaft

12. Install reverse gear needle bearing.

  • Apply petroleum jelly to the bearing.

Output Shaft

13. Install reverse gear.

  • Rotate the gear to align the gear slots with the inner cone tabs.

Output Shaft

14. Install the check ball.

  • Use petroleum jelly to hold the check ball in place.

Output Shaft

15. Install the thrust washer. Be sure to align the slot in the washer with the check ball.

Output Shaft

16. Install a new rear output shaft bearing, then fifth gear. Using the special tool, press both the bearing and gear into place.

Output Shaft

17. Reposition the output shaft with the input end facing upward.

18. Install the second gear synchronizer blocking ring. Rotate the blocking ring until seated.

Output Shaft

19. Install the second gear synchronizer outer cone and the second gear synchronizer inner cone.

Output Shaft

20. Install the second gear bearing.

  • Apply petroleum jelly to the bearing.

Output Shaft

21. Install second gear.

  • Rotate the gear to align the gear slots with the inner cone tabs.

Output Shaft

22. Install the check ball.

  • Use petroleum jelly to hold the check ball in place.

Output Shaft

23. Install the thrust washer. Be sure to align the slot in the washer with the check ball.

Output Shaft

24. Press the bearing spacer onto the output shaft.

Output Shaft

25. Install the third gear bearing.

  • Apply petroleum jelly to the bearing.

Output Shaft

26. Install third gear.

Output Shaft

27. Install the third gear synchronizer blocking ring.

Output Shaft

28. Install the third/fourth gear synchronizer body.

  • Install the synchronizer body with the raised center facing downward.
  • Rotate the blocking ring until seated.

Output Shaft

29. Install a new retaining ring.

Output Shaft

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