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:
Cleaning
1. Fabricate a cleaning tool from a 1/8 inch diameter brazing rod.
2. Cut an abrasive pad from maroon colored 3M Scotch Brite with the
dimensions corresponding
to the coupling size.
3. Assemble the pad to the tool.
4. Coat the abrasive pad with PAG Refri ...
Cable Adjustment
1. NOTE: Make sure that the range selector lever is tight
against the rearward overdrive stop.
Place the transmission range selector lever in the overdrive
position.
2. Raise and support the vehicle. For additional information, refer
to Section.
...
Digital Transmission Range (TR) Sensor
Special Tool(s)
Alignment Gauge, TR Sensor
307-351 (T97L-70010-A)
Removal
1. Disconnect the battery ground cable. For additional information, refer
to Section.
2. Raise and support the vehicle. For additional information, refer to
Sectio ...