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