Ford Mustang (1999-2004) Service Manual: Torque Converter (Disassembly and Assembly of Subassemblies)

1. A new or remanufactured torque converter must be installed if one or more of the following statements is true:

  • A torque converter malfunction has been determined based on complete diagnostic procedures.
  • Converter stud or studs, impeller hub or bushing are damaged.
  • Discoloration (due to overheating).
  • The torque converter is found to be out of specification when carrying out one of the following torque converter checks:
  • One-Way Clutch Check
  • End Play Check
  • Stator to Turbine Interference Check
  • Stator to Impeller Interference Check
  • Torque Converter Leak Check
  • Evidence of transmission assembly or fluid contamination due to the following transmission or converter failure modes:
  • Major metallic failure.
  • Multiple clutches or clutch plate failures.
  • Sufficient component wear which results in metallic contamination.
    Assembly
    1. NOTE: Lubricate direct clutch piston inner seal and seal protector with petroleum jelly. Using the special tool, install the inner piston seal. Install the seal with sealing lip facing down. ...

    Torque Converter Cleaning And Inspection
    Material Item Specification MERCON V Automatic Transmission Fluid XT-5-QM, XT-5-DM MERCON V 1. If a new torque converter is being installed, continue with Substep 2 of Step 2. ...

    Other materials:

    Safety Belt Maintenance
    WARNING: All safety belt assemblies include retractors, buckles, front seat belt buckle support assemblies (slide bar, if so equipped), shoulder belt height adjuster (if equipped), child safety seat tether bracket assemblies (if equipped) and attaching hardw ...

    Lamp Assembly - Headlamp
    Removal 1. NOTE: Make sure that the headlamp switch and the ignition switch are in the OFF position. Raise the headlamp retainers. 2. Remove the headlamp assembly. Disconnect the electrical connectors and replace the lamp if necessary. Instal ...

    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 Assembly 1. Cut the outer cage, then remove the outer cage an ...