Ford Mustang (1999-2004) Service Manual: Disassembly

1. Remove the retaining ring above fifth gear.

Output Shaft

2. CAUTION: Hand tighten the special tool to prevent gear damage.

CAUTION: Support the output shaft while using the press to prevent damage to the shaft or gears.

Using the special tool, press fifth gear, the spacer, the output shaft bearing and reverse gear from the output shaft.

  • Discard the output shaft bearing.

Output Shaft

3. Remove reverse gear needle bearing.

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

Output Shaft

4. Remove the check ball and the blocking ring.

  • Inspect the blocking ring for wear or damage. Install new blocking rings as necessary.

Output Shaft

5. NOTE: Install the special tool with the flat side facing first gear.

Using the special tools, press the bearing spacer, the reverse gear synchronizer cone and first gear from the output shaft.

Output Shaft

6. Remove the first gear needle bearing.

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

Output Shaft

7. Remove the first gear synchronizer inner cone, the first gear synchronizer outer cone and the first gear synchronizer blocking ring.

  • Inspect all components for wear or damage. Install new components as necessary.

Output Shaft

8. NOTE: Reposition the output shaft on the press with the input shaft end facing upward.

  • Remove and discard the retaining ring.

Output Shaft

9. Remove the third/fourth synchronizer hub.

Output Shaft

10. Remove the third/fourth blocking ring.

Output Shaft

11. Remove the third gear.

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

Output Shaft

12. Remove the third gear needle bearing.

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

Output Shaft

13. NOTE: Install the special tool behind second gear with the flat side of the tool facing second gear.

Using the special tool, remove the spacer, second gear thrust washer and second gear.

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

Output Shaft

14. Remove the check ball and second gear needle bearing.

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

Output Shaft

15. Remove the second gear synchronizer inner cone, second gear synchronizer outer cone and the second gear synchronizer blocking ring.

  • Inspect all components for wear or damage. Install new components as necessary.

Output Shaft

16. Remove the snap ring, then using the special tool, press off the first/second gear synchronizer.

Output Shaft

    Output Shaft
    Special Tool(s) Remover, Drive Pinion Bearing Cone 205-D002 (D79L-4621-A) or equivalent Installer, Drive Pinion Bearing Cone 205-011 (T57L-4621-B) ...

    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 s ...

    Other materials:

    Rocker Arm
    Removal CAUTION: If removing more than one rocker arm (6564), mark the components removed for correct location. 1. Remove the valve covers. For additional information, refer to Valve Cover-LH and Valve Cover RH in this section. 2. Remove the rocker ...

    Parking Brake (Description and Operation)
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    Refrigerant Oil Adding
    CAUTION: During normal A/C operation, oil is circulated through the system with the refrigerant, and a small amount is retained in each component. If certain components of the system are removed for new installation, some of the refrigerant oil will go with ...