Ford Mustang (1999-2004) Service Manual: Transmission Case

Special Tool(s)

Handle 205-D055 (D81L-4000-A)
Installer, Bearing Cup 204-039 (T77F-1217-B)
Installer, Drive Pinion Bearing Cup 205-054 (T71P-4616-A)
Installer, Rear Axle Oil Seal 205-155 (T80T-4000-Y)

Disassembly and Assembly

1. Remove the bolts and the guide plate.

  • Inspect the plate for wear or damage. Install a new plate as necessary.

Transmission Case

2. Remove the case magnets.

Transmission Case

3. Remove the reverse lamp switch.

Transmission Case

4. Using the special tools, remove the countershaft bearing cup.

Transmission Case

5. Using a brass drift, remove mainshaft bearing cup.

Transmission Case

6. Inspect the countershaft and mainshaft bearing cups for wear or damage. Install new components as necessary.

7. WARNING: Make sure protective eye wear is in place.

Clean the case with solvent and dry with compressed air. Clean and check the sealing surface for nicks or scratches. Inspect the case for cracks.

  • If the case is cracked, install a new case. If the sealing surface has nicks or scratches, use a soft stone or crocus cloth to remove.

8. NOTE: If a new countershaft bearing is being installed, install a new bearing cup. Always install new bearings and cups in a set.

Using the special tools, install the countershaft bearing cup.

Transmission Case

9. NOTE: If a new mainshaft bearing is being installed, install a new bearing cup. Always install new bearings and cups in a set.

Using the special tools, install the mainshaft bearing cup.

Transmission Case

10. To assemble, reverse the disassembly procedure.

    Extension Housing
    Special Tool(s) Installer, Bearing Cup 204-039 (T77F-1217-B) Adapter for 303-224 (Handle) 205-153 (T80T-4000-W) Disassembly and Assembly   1. Remove the bolt and ...

    Transmission (Assembly)
    Special Tool(s) Dial Indicator Gauge with Holding Fixture 100-002 (TOOL-4201-C) or equivalent Holding Fixture, Transmission 307-003 (T57L-500-B) Remover/Inst ...

    Other materials:

    Using voice recognition
    This system helps you control many features using voice commands. This allows you to keep your hands on the wheel and focus on what is in front of you. Initiating a Voice Session Push the voice icon; a tone sounds and Listening appears in the display. Say an ...

    Cleaning leather seats
    • Remove dust and loose dirt with a vacuum cleaner. • Clean spills and stains as quickly as possible. • For routine cleaning, wipe the surface with a soft, damp cloth. For more thorough cleaning, wipe the surface with a mild soap and water solution. In C ...

    Assembly
    All steering gears 1. Install the steering gear in the special tools. Steering gears equipped with travel restrictors 2. Install the travel restrictors. Install new travel restrictors as necessary. All steering gears 3. CAUTION: Place the steering gear at t ...