Ford Mustang (1999-2004) Service Manual: Assembly

1. Inspect the clutch cylinder thrust surfaces, piston bore and clutch plate serrations for scores or burrs. Minor scores or burrs may be removed with crocus cloth. Install a new clutch cylinder if badly scored or damaged.

2. Check the fluid passage in the clutch cylinder for obstructions. Clean out all fluid passages.

Inspect the clutch piston for scores and install a new piston if necessary. Inspect check balls for freedom of movement and correct seating.

3. Check the clutch release spring for distortion and cracks. Install a new spring (including the wave spring) if distorted or cracked.

4. Inspect composition clutch plates, steel clutch plates and clutch pressure plate for worn or scored bearing surfaces. Install new parts if they are deeply scored or burred.

5. Check the clutch plates for flatness and fit on the clutch hub serrations. Discard any plate that does not slide freely on serrations or that is not flat.

6. Check the clutch hub thrust surfaces for scores and the clutch hub splines for wear.

7. NOTE: To aid handling, the forward clutch assembly may be set in the extension housing or a hole in the work bench.

Install the inner and outer forward clutch piston seals. Note the direction of the sealing rings before installation.

Forward Clutch - Disassembled View

8. NOTE: Coat the piston seals and clutch drum sealing area with petroleum jelly.

Position the special tools on the clutch piston.

Forward Clutch - Disassembled View

9. Using the special tools, install the forward clutch piston into the clutch drum.

  • Push the piston to the bottom of the drum using even pressure.

Forward Clutch - Disassembled View

10. Using the special tool, compress the piston return spring and install the retaining ring.

Forward Clutch - Disassembled View

11. Slowly release the press pressure and remove the forward clutch.

12. NOTE: Before assembly, soak the new clutch discs in clean automatic transmission fluid for 15 minutes.

Install the clutch pack assembly.

1. Install the pressure ring.

2. Install the clutch pack.

3. Install the pressure plate.

Forward Clutch - Disassembled View

13. Install the clutch pack retaining ring.

Forward Clutch - Disassembled View

14. Install the special tool on the forward clutch pack.

  • Push downward on the clutch pack.
  • Release pressure and zero the dial indicator.

Forward Clutch - Disassembled View

15. Using the special tool, check the clutch pack clearance.

1. Lift up on the clutch pack until it fully seats against the clutch pressure plate retainer.

2. Read the dial indicator.

  • If the clearance is not within specifications, install the correct size retaining ring.

Selective Retaining Ring

Specification

Selective Retaining Ring

 

Selective Retaining Ring

16. NOTE: Make sure the scarf-cut seals are mated correctly.

Slide the two scarf-cut seals on the input shaft.

Selective Retaining Ring

17. Install the two scarf-cut seals on the input shaft.

Selective Retaining Ring

18. Install the No. 3 forward clutch hub front bearing and the forward clutch hub.

Selective Retaining Ring

    Disassembly
    1. Inspect the clutch cylinder thrust surfaces, piston bore and clutch plate serrations for scores or burrs. Minor scores or burrs may be removed with crocus cloth. Install a new clutch cylinder if ...

    Planetary Gear Support Assembly and Planetary One-Way Clutch
      Disassembly and Assembly 1. NOTE: Inspect the outer and inner races for scores or damaged surface areas where rollers contact the races. Inspect the rollers and springs for excessive wear ...

    Other materials:

    Mirror - Motor
    Removal 1. Push in the upper edge of the mirror glass to the maximum travel. 2. Grasp the bottom of the mirror glass, pull outward and remove the mirror glass. 3. Remove the mirror motor screws. 4. Disconnect the mirror motor electrical connector. 5. ...

    Engine System - General Information
    General Specifications Engine NOTE: This section contains information, steps and procedures that may not be specific to your engine. This section covers general procedures and diagnosis and testing of the engine system, except for exhaust emission control ...

    Driveshaft - Cobra
    Material Item Specification Threadlock and Sealer E0AZ-19554-AA WSK-M2G351-A5 (type II) Silicone Lubricant (Aerosol) F5AZ-19553-AA ESR-M13P4-A Removal and Installation 1. Raise and support the vehicle. 2. NOTE: To aid disass ...