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:
Exhaust Gas Recirculation (EGR) Valve - Mach I
Removal and Installation
1. Remove the air intake scoop. For additional information, refer to
Section.
2. Remove the exhaust gas recirculation (EGR) valve.
1. Disconnect the EGR tube upper fitting.
2. Disconnect the vacuum hose.
3. Remove the tw ...
Output Shaft and Direct Clutch Cylinder
Special Tool(s)
Compressor, Clutch Spring
307-015 (T65L-77515-A)
Protector, Piston Seal
307-080 (T80L-77234-A)
Protector, Transmission Direct
Clutch Outer Fluid Seal
307-422
Material
Item
Specification
...
Universal Joints
The universal joints are:
lubed-for-life design and require no lubrication.
equipped with nylon thrust washers, located at each base of the bearing
cup, which control end
play, position the needle bearing and improve grease movement.
Item ...
