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.
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- ...
Gearshift Rail and Fork
Disassembly and Assembly
1. Disassemble the first/second and third/fourth shift rail as follows:
Rotate the interlock plate until it is opposite of the shift links.
Slide off the third/fo ...
Other materials:
Compressor Manifold and Tube Assembly - 4.6L
Material
Item
Specification
PAG Refrigerant Compressor
Oil (R-134a Systems)
F7AZ-19589-DA (Motorcraft YN-
12-C)
WSH-M1C231-
B
Removal and Installation
NOTE: Installation of a new suction accumulator is not required when
repairing the ...
Sitting in the correct position
WARNING: Sitting improperly out of position or with the seat
back reclined too far can take off weight from the seat cushion
and affect the decision of the passenger sensing system, resulting in
serious injury or death in a crash. Always sit upright against yo ...
Battery Disconnect
WARNING: Batteries normally produce explosive gases which can
cause personal injury.
Therefore, do not allow flames, sparks or lighted substances to come
near the battery, always
shield your face and protect your eyes. Always provide ventilation.
...