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:
Engine Cooling (Diagnosis and Testing)
Special Tool(s)
Pressure Tester
014-R1072 or equivalent
73III Automotive Meter
105-R0057 or equivalent
Worldwide Diagnostic System
(WDS)
418-F224,
New Generation STAR (NGS)
Tester
418-F052, or equivalent scan ...
Brake Booster - Hydro-Boost (Description and Operation)
The Hydro-Boost brake booster is a hydraulically operated brake booster
powered by the power
steering pump (3A674). The power steering pump provides the fluid pressure to
operate both the
power brake booster and the power steering gear (3504).
A Hydro-Boost ...
Accelerator Cable Bracket - 3.8L
Removal and Installation
1. Disconnect the speed control cable from the throttle body and the bracket.
For additional
information, refer to Section.
2. Disconnect the accelerator cable from the throttle body by rotating the
throttle body full open
and align ...