Ford Mustang (1999-2004) Service Manual: Synchronizers
Disassembly and Assembly
NOTE: This procedure applies to all synchronizer assemblies.
1. Scribe an alignment mark on the sliding sleeve and the hub for assembly reference.
2. Remove the sliding sleeve, then remove the synchronizer struts and the springs.
3. Install the synchronizer struts and the springs.
4. CAUTION: Match the alignment marks made during disassembly. The sleeve and the hub have an extremely close fit. Hold the sleeve and hub square to prevent jamming. Do not force the sleeve onto the hub.
Install the sliding sleeve.
Countershaft Bearing
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)
Disassembly and A ...
Gearshift Rail Bushing
Special Tool(s)
Universal Puller Set
303-DS005 (D80L-100-A) or
equivalent
Installer, Shift Rail Bushing
308-244 (T96P-7025-F)
Slide Hammer
100-001 (T50T-100- ...
Other materials:
Pinpoint Tests
CAUTION: Before removing and installing the GEM or its connectors,
disconnect the
battery. Failure to follow this caution will result in the GEM storing many
erroneous DTCs and it
may exhibit erratic operation after installation.
CAUTION: Be careful when pr ...
Connecting Rod - Bearing Journal Clearance
Special Tool(s)
Plastigage
303-D031 (D81L-6002-B) or
equivalent
NOTE: The crankshaft connecting rod journals must be within
specifications to check the connecting
rod bearing journal clearance.
1. Remove the connecting rod bearing cap.
2. ...
Front End Body Panels
Torque Specifications
Front End Body Panels
The front end body panel components consist of the following:
air deflectors
cowl grille
fenders
fender splash shields
hood
hood hinges
hood weatherstrip
radiator grille opening panel
...
