Ford Mustang (1999-2004) Service Manual: Synchronizers

Disassembly and Assembly

NOTE: This procedure applies to all synchronizer assemblies.

1. NOTE: Synchronizer components are not interchangeable. During disassembly, mark each individual synchronizer for assembly. Synchronizer hubs and sleeves are a selected assembly and should be kept together as originally assembled. Blocking rings are not interchangeable, do not mix.

Scribe an alignment mark on the sliding sleeve and the hub for assembly reference.

2. Using a screwdriver, remove the spring. Turn the synchronizer over and remove the second spring. Remove the sliding sleeve and the synchronizer struts from the hub.

3. 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.

Assemble the synchronizer as follows:

• Position the synchronizer sleeve on the hub. Make sure to align key openings in the hub with the synchronizer sleeve.
• Install the keys with the slots facing the hub.
• Install the spring. Locate the tang to one of the key slots and position into place. Install the second spring. Locate the spring tang on the same key but position in the opposite direction.