Ford Mustang (1999-2004) Service Manual: Countershaft

Special Tool(s)

Plate, Bearing Oil Seal 205-090 (T75L-1165-B)
Puller, Bearing 205-D064 (D84L-1123-A)
Installer, Drive Pinion Bearing Cone 205-004 (T53T-4621-B)
Remover/Installer, Bearing Tube 308-025 (T75L-7025-C)
Installer, Output Shaft Rear Bearing 308-401
Adapter for 303-224 (Handle) 205-153 (T80T-4000-W)

Disassembly and Assembly

Countershaft

 

Countershaft

1. Remove the thrust washer.

Countershaft

2. Using the special tool and a press, remove the countershaft rear bearing.

Countershaft

3. Using the special tool and a press, remove the countershaft front bearing.

Countershaft

4. Place the special tool in a vise. Position the countershaft extension in the tool with the sixth drive gear facing upward. Remove the fifth/sixth shift fork.

Countershaft

5. Remove the sixth drive gear.

Countershaft

6. Remove the sixth drive gear needle bearing.

Countershaft

7. Remove the sixth drive gear synchronizer blocking ring.

Countershaft

8. Remove and discard the fifth/sixth synchronizer snap ring.

Countershaft

9. Using the special tool, press the fifth/sixth synchronizer and the fifth drive gear off the shaft.

Countershaft

10. Remove the fifth drive gear needle bearing.

Countershaft

11. Using the special tool, remove the countershaft extension bearing.

Countershaft

12. Inspect the countershaft and countershaft extension.

  • Check the shaft surface for wear or damage. Install a new shaft as necessary.
  • Check the gear teeth for wear, pitting, scoring, spalling or fractures. Install new components as necessary.

13. Disassemble the fifth/sixth gear synchronizer assembly.

Countershaft

14. Inspect the fifth/sixth synchronizer.

  • Check for worn, nicked or broken teeth. Install a new synchronizer as necessary.
  • Check keys for wear or distortion. Install a new synchronizer as necessary.
  • Check springs for distortion. Install a new synchronizer as necessary.

15. Inspect the fifth/sixth synchronizer blocking rings.

  • Check for wear or damage. Install new synchronizer blocking rings as necessary.
  • Check the clearance between the synchronizer blocking ring and the gear.
  • Position the blocking ring onto the gear. Make sure the correct blocking ring is measured with the correct gear and that the blocking ring is fully seated on the gear.
  • Insert a feeler gauge and measure the clearance, while applying pressure and rotating the blocking ring. The measurement should be the same around the entire circumference. If the clearance is less than 0.38 mm (0.015 in), install new blocking rings.

Countershaft

16. Using the special tools, install the countershaft rear bearing.

Countershaft

17. Using the special tools, install the countershaft front bearing.

Countershaft

18. Using the special tools, install the countershaft extension bearing.

Countershaft

19. To assemble, reverse the disassembly procedure.

  • Assemble the synchronizer assembly before installing.
    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 g ...

    Synchronizers
    Disassembly and Assembly NOTE: This procedure applies to all synchronizer assemblies. 1. NOTE: Synchronizer components are not interchangeable. During disassembly, mark each individual synchronizer f ...

    Other materials:

    Removal
    WARNING: Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel related components. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in personal injury ...

    Pilot Bearing
    Special Tool(s) Puller with Slide Hammer 308-001 (T58L-101-B) 1. Remove the clutch disc and the clutch pressure plate. For additional information, refer to Disc and Pressure Plate-3.8L and 4.6L (2V) Engines or Disc and Pressure Plate-4.6L (4V ...

    Installation
    1. Install the spring. 1. Position the spring and spring insulator in the front suspension lower control arm. 2. Swing the arm into the fender well. 2. Position a jack stand under the front suspension lower control arm inboard of the spring seat and r ...