Ford Mustang (1999-2004) Service Manual: Assembly

1. Lubricate all components with the recommended transmission fluid when reassembling.

2. Using the special tools, press the output shaft front bearing on the output shaft.

Output Shaft

3. Install the third gear bearing.

  • Apply petroleum jelly to the bearing.

Output Shaft

4. Install third gear, the third gear synchronizer blocking ring and the third/fourth gear synchronizer assembly. Position the output shaft with the output end facing upward. Using the special tool, press the third/fourth gear synchronizer assembly into place.

  • Install the synchronizer body with the groove facing third gear.
  • Stop press operation before keys engage the blocking ring slots. Lift and rotate the third gear and the blocking ring until the keys are seated in the blocking ring.

Output Shaft

5. Install a new snap ring.

Output Shaft

6. Install the second gear needle bearing.

  • Apply petroleum jelly to the bearing.

Output Shaft

7. Install second gear.

Output Shaft

8. Install the second gear synchronizer thrust washer, the inner cone, the friction cone and the second gear synchronizer blocking ring.

  • Align the blocking ring tabs with the second gear slots.

Output Shaft

9. Install the first/second gear synchronizer assembly. Position the output shaft with the output end facing downward. Using the special tools, press the first/second gear synchronizer assembly into place.

  • Install the synchronizer with the groove on the sleeve facing first gear.
  • Stop press operation before keys engage the blocking ring slots. Lift and rotate the second gear and the blocking ring until the keys are seated in the blocking ring.

Output Shaft

10. Install the first gear synchronizer thrust washer, the inner cone, the friction cone and the first gear synchronizer blocking ring.

Output Shaft

11. Install a new snap ring.

Output Shaft

12. Install the first gear needle bearing.

  • Apply petroleum jelly to the bearing.

Output Shaft

13. Install first gear.

  • Rotate the gear to align the gear slots with the inner cone tabs.

Output Shaft

14. Install a new rear output shaft bearing.

Output Shaft

15. Using the special tools, install the fifth driven gear.

    Disassembly
      1. CAUTION: Hand tighten the special tool to prevent gear damage. CAUTION: Support the output shaft while using the press to prevent damage to the shaft or gears. Using the special tool and ...

    Countershaft
    Special Tool(s) Plate, Bearing Oil Seal 205-090 (T75L-1165-B) Puller, Bearing 205-D064 (D84L-1123-A) Installer, Drive Pinion Bearing Cone 205-004 (T53T-4621- ...

    Other materials:

    Waxing
    Regular waxing is necessary to protect the paint on your car from the elements. We recommend that you wash and wax the painted surface once or twice a year. When washing and waxing, park your vehicle in a shaded area out of direct sunlight. Always wash your v ...

    Removal
    WARNING: The restraints control module (RCM) orientation is critical for proper system operation. If a vehicle equipped with an air bag supplemental restraint system (SRS) has been involved in a collision in which the center tunnel area has been damaged, in ...

    Inspection and Verification
    1. Verify the customer's concern by operating the active restraint system to duplicate the condition. 2. Inspect to determine if any of the following mechanical or electrical concerns apply: Visual Inspection Chart Mechanical Electrical ...