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:
Battery (Removal and Installation)
Removal and Installation
WARNING: Batteries normally produce explosive gases which can
cause personal injury.
Therefore, do not allow flames, sparks or lighted substances to come
near the battery. When
charging or working near a battery, always sh ...
Speed Control
Torque Specifications
Speed Control
The speed control system consists of the following components:
speed control actuator cable (9A825)
deactivator switch
output shaft sensor (OSS)
speed control actuator switches (9C888)
brake pedal position (BPP) switc ...
Assembly
1. NOTE: One tab that locks the reverse clutch drum into the reverse
sun shell may be removed.
This is done for balancing purposes.
Inspect the clutch cylinder thrust surfaces, piston bore and clutch plate
serrations for scores or
burrs. Minor scores or bu ...
