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:

    Installation
    1. Install the lower intake manifold gaskets. 2. Connect the fuel charging wiring harness to the rear of the lower intake manifold and install the manifold. 3. Install the intake manifold fasteners and tighten in the sequence shown. 4. Position the fuel ...

    Disassembly
    1. NOTE: Mark the position of each gear shifter fork (7230). Place the gear shift plates (7N232) and the gear selector interlock sleeve (7K201) in the neutral position to center the gear shift plates and the selector body (7302). 2. Rotate the main shif ...

    Keyless Entry (Diagnosis and Testing)
    Refer to Wiring Diagrams Cell 59 , Generic Electronic Module for schematic and connector information. Refer to Wiring Diagrams Cell 111 , Remote Keyless Entry (RKE) for schematic and connector information. Special Tool(s) 73 Digital M ...