Ford Mustang (1999-2004) Service Manual: Gearshift Rail and Fork

Disassembly and Assembly

Gearshift Rail and Fork

 

Gearshift Rail and Fork

1. Disassemble the first/second and third/fourth shift rail as follows:

  • Rotate the interlock plate until it is opposite of the shift links.
  • Slide off the third/fourth shift fork and shift link. Separate the link from the fork.
  • Slide off the first/second shift fork and shift link. Separate the link from the fork.
  • Remove the interlock plate.
  • Using a 5/32-inch drift and a hammer, remove and discard the roll pins. Slide the gear select solenoid lever and the selector pin from the shift rail.

2. Disassemble the fifth/sixth and reverse shift rail as follows:

  • Using a 5/32-inch drift and a hammer, remove and discard the roll pins. Slide the collar and the reverse shift lever from the shift rail.
  • Slide off the fifth/sixth shift lever and shift link.

3. Inspect the shift rail components.

  • Check the rails, shift forks, shift levers and shift links for wear or damage. Install new components as necessary.
  • Check the shift fork pads for wear. Install new pads as necessary.

4. To assemble, reverse the disassembly procedure.

  • Install new roll pins.

Gearshift Rail and Fork

 

Gearshift Rail and Fork

    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 ...

    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 ...

    Other materials:

    Installation
    1. Inspect the rear axle pinion flange seal journal for rust, nicks, and scratches prior to installing the flange. Polish the seal journal with fine crocus cloth, if necessary. 2. Lubricate the rear axle pinion flange splines. Use SAE 75W-140 High Performa ...

    Link - Stabilizer Bar
    Removal CAUTION: Suspension fasteners are critical parts because they affect performance of vital components and systems and their failure can result in major service expense. A new part with the same part number must be installed if installation becomes nec ...

    Camshaft Lobe Lift
    Special Tool(s) Dial Indicator Gauge with Holding Fixture 100-002 (TOOL-4201-C) or equivalent 1. Use a Dial Indicator Gauge with Holding Fixture to measure camshaft intake/exhaust lobe lift. Rotate the camshaft and subtract the lowest ...