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.

Synchronizers

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:

    Cable and Conduit
    Removal NOTE: The RH rear is shown, the LH is similar. 1. CAUTION: If any component in the parking brake system requires repair or if the rear axle housing (4010) is removed, the cable tension must be released. Release the cable tension. For additional ...

    Unique Calibration
    The Emissions/CAFE/CO2 Compliance Department is responsible for assigning these calibration numbers. Unique calibration identifications are assigned to cover similar vehicles to differentiate tires, drive configurations, final drive ratios and other calibrat ...

    Mass Air Flow (MAF) Sensor - 3.8L
    Removal CAUTION: The mass air flow (MAF) sensor hot wire sensing element and housing are calibrated as a unit and must be repaired as a complete assembly. Do not damage the sensing element (internal to housing) or possible failure to the mass air f ...