Ford Mustang (1999-2004) Service Manual: Assembly
1. Carry out the following before reassembling:
- Inspect the gears for broken or cracked teeth. Check for unusual wear patterns.
- Inspect the thrust washers for face wear, cracks, scoring and for signs of heat damage.
- Inspect the bearings, bearing cups and the synchronizers for wear or damage.
- Inspect the output shaft for scoring or worn or damaged splines. Install new components as necessary.
2. Lubricate all components with the recommended transmission fluid when reassembling.
3. NOTE: Position the output shaft with the output end facing upward.
NOTE: Install the synchronizer assembly with the deeper center flange of the synchronizer hub facing toward the rear of the output shaft.
Install the first/second synchronizer assembly on the output shaft, then install a new retaining ring.
- It may be necessary to press the hub into position on the shaft.
4. Install the first gear synchronizer blocking ring.
- Align the blocking ring tabs with the synchronizer assembly.
5. Install the outer first gear synchronizer cone.
6. Install the inner first gear synchronizer cone. Rotate the inner cone till it is seated.
7. Install the first gear needle bearing.
- Apply petroleum jelly to the bearing.
8. Install first gear.
- Rotate the gear to align the gear slots with the inner cone tabs.
9. Install the reverse synchronizer cone.
10. Install the reverse gear blocking ring.
11. Using the special tools, install the reverse gear bearing spacer.
12. Install reverse gear needle bearing.
- Apply petroleum jelly to the bearing.
13. Install reverse gear.
- Rotate the gear to align the gear slots with the inner cone tabs.
14. Install the check ball.
- Use petroleum jelly to hold the check ball in place.
15. Install the thrust washer. Be sure to align the slot in the washer with the check ball.
16. Install a new rear output shaft bearing, then fifth gear. Using the special tool, press both the bearing and gear into place.
17. Reposition the output shaft with the input end facing upward.
18. Install the second gear synchronizer blocking ring. Rotate the blocking ring until seated.
19. Install the second gear synchronizer outer cone and the second gear synchronizer inner cone.
20. Install the second gear bearing.
- Apply petroleum jelly to the bearing.
21. Install second gear.
- Rotate the gear to align the gear slots with the inner cone tabs.
22. Install the check ball.
- Use petroleum jelly to hold the check ball in place.
23. Install the thrust washer. Be sure to align the slot in the washer with the check ball.
24. Press the bearing spacer onto the output shaft.
25. Install the third gear bearing.
- Apply petroleum jelly to the bearing.
26. Install third gear.
27. Install the third gear synchronizer blocking ring.
28. Install the third/fourth gear synchronizer body.
- Install the synchronizer body with the raised center facing downward.
- Rotate the blocking ring until seated.
29. Install a new retaining ring.
Disassembly
1. Remove the retaining ring above fifth gear. 2. CAUTION: Hand tighten the special tool to prevent gear damage. CAUTION: Support the output shaft while using the press to prevent damage to the sha ...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 ...Other materials:
Throttle Body
Removal
WARNING: Do not smoke or carry lighted tobacco or open flame of any
type when
working on or near any fuel related components. Highly flammable mixtures are
always present
and can ignite. Failure to follow these instructions can result in personal
in ...
Locking and unlocking
You can use the power door lock control or the remote control to lock
and unlock your vehicle.
Power Door Locks
The power door lock control is located on the driver and front passenger
door panels.
A. Unlock
B. Lock
Remote Control
You can use the remote cont ...
Touchscreen climate controls
Press the CLIMATE hard button to access your climate control features.
Depending on your vehicle line and option package, your climate screen
may look different from the screen shown here.
Climate Control Voice Commands
If you are not viewing the climate co ...