Ford Mustang (1999-2004) Service Manual: Synchronizers
Disassembly and Assembly
NOTE: This procedure applies to all synchronizer assemblies.
1. Scribe an alignment mark on the sliding sleeve and the hub for assembly reference.
2. Remove the sliding sleeve, then remove the synchronizer struts and the springs.
3. Install the synchronizer struts and the springs.
4. CAUTION: Match the alignment marks made during disassembly. The sleeve and the hub have an extremely close fit. Hold the sleeve and hub square to prevent jamming. Do not force the sleeve onto the hub.
Install the sliding sleeve.
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 ...
Gearshift Rail Bushing
Special Tool(s)
Universal Puller Set
303-DS005 (D80L-100-A) or
equivalent
Installer, Shift Rail Bushing
308-244 (T96P-7025-F)
Slide Hammer
100-001 (T50T-100- ...
Other materials:
A/C Compressor and Clutch Assembly
NOTE: Internal A/C compressor components are not serviced separately.
The FS-10 A/C compressor
is serviced only as an assembly. The A/C clutch pulley, A/C clutch field coil
(19D798) and the shaft
seal are serviceable.
The FS-10 A/C compressor has the follo ...
Piston - Pin Diameter
1. Measure the piston pin diameter in two directions at the points shown.
Verify the diameter is
within specification.
Refer to the appropriate section in Group for the procedure.
If out of specification, install new components as necessary. Refer
...
Disconnect
1. Remove the A/C tube lock coupling clip (19E746), if equipped.
2. Fit the special tool to the spring lock coupling.
3. Push the tool into the cage opening to release the female fitting from the
A/C tube lock coupling
spring (19E576).
4. Pull the sprin ...
