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:
Exhaust Manifold LH
Removal and Installation
1. Position the steering wheel straight ahead and lock the column.
2. Disconnect the battery ground cable. For additional information, refer to
Section.
3. Raise the vehicle. For additional information, refer to Section.
4. Remove ...
Removal
1. Disconnect the battery negative cable.
2. Drain the engine cooling system.
3. Remove the RH exhaust manifold. For additional information, refer to Exhaust
Manifold RH in
this section.
4. Remove the lower intake manifold. For additional information, re ...
Removal
1. Use a suitable suction device to lower the brake fluid level in
the master cylinder reservoir.
2. Raise and support the vehicle.
3. Remove the wheel and tire assembly.
4. Inspect the pads for wear or contamination, install new if worn to ...