2014 Mustang Workshop Manual

SECTION 308-03B: Manual Transaxle/Transmission — TR6060	2014 Mustang Workshop Manual
DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES	Procedure revision date: 01/07/2013

Special Tool(s)
	Puller, Bearing 205-D064 (D84L-1123-A)
	Remover/Installer, Bearing Tube 308-025 (T75L-7025-C)

Material
Item	Specification
MERCON® V Automatic Transmission Fluid XT-5-QM (or XT-5-QMC) (US); CXT-5-LM12 (Canada)	MERCON® V

Disassembly

Item	Part Number	Description
1	7025	Axial thrust washer
2	7A082	Snap ring
3	7124	3rd/4th gear synchronizer assembly
4	7107	3rd gear synchronizer ring assembly
5	—	Synchronizer ring (part of 7107)
6	—	Synchronizer outer cone (part of 7107)
7	—	Synchronizer inner cone (part of 7107)
8	7117	Spacer
9	7B340	3rd gear
10	7M037	3rd gear needle bearing
11	7061	Output shaft
12	7102	2nd gear
13	7M037	2nd gear needle bearing
14	7117	Spacer
15	7107B	2nd gear synchronizer ring assembly
16	—	Synchronizer inner cone (part of 7107)
17	—	Synchronizer outer cone (part of 7107)
18	—	Synchronizer ring (part of 7107)
19	7124A	1st/2nd gear synchronizer assembly
20	7A082A	Split ring
21	7A082A	Retainer
22	7107A	1st gear synchronizer ring assembly
23	—	Synchronizer ring (part of 7107)
24	—	Synchronizer outer cone (part of 7107)
25	—	Synchronizer inner cone (part of 7107)
26	7100	1st gear
27	7025	1st gear needle bearing
28	7025	Output shaft rear bearing
29	7L047	6th driven gear

NOTE: Slide the synchronizer sleeve up while removing the pressure pieces.
Remove the 3rd/4th gear synchronizer sleeve, the 3 pressure pieces and the axial thrust washer.

NOTICE: Hand-tighten the Bearing Puller to prevent gear damage.
NOTICE: Support the output shaft while using the press to prevent damage to the shaft or gears.
Using the Bearing Puller and a press, remove the 1st gear, the output shaft rear bearing and the 6th driven gear.
- Discard the output shaft bearing.
- Inspect the gears for wear or damage. Install new gears as necessary.

Remove the 1st gear needle bearing.
- Inspect the needle bearing for wear or damage. Install a new needle bearing as necessary.

NOTE: Note the position of each synchronizer ring component before removal.
Remove the 1st gear synchronizer ring assembly.
- Inspect the 1st gear synchronizer ring assembly for wear or damage. Install a new synchronizer ring assembly as necessary.

NOTE: Slide the synchronizer sleeve up while removing the pressure pieces.
Remove the 1st/2nd gear synchronizer sleeve and the 3 pressure pieces.

NOTE: Note the position of each synchronizer ring component before removal.
Remove the 2nd gear synchronizer ring assembly.
- Inspect the 2nd gear synchronizer ring assembly for wear or damage. Install a new synchronizer ring assembly as necessary.

Remove the 2nd gear.
- Inspect 2nd gear for wear or damage. Install a new gear as necessary.

Remove the 2nd gear needle bearing and the spacer.
- Inspect the needle bearing for wear or damage. Install a new needle bearing as necessary.

NOTICE: Hand-tighten the Bearing Puller to prevent gear damage.
NOTICE: Support the output shaft while using the press to prevent damage to the shaft or gears.
NOTE: Note the position of each synchronizer ring component before removal.
Using the Bearing Puller, remove the 3rd/4th gear synchronizer hub, the 3rd gear synchronizer ring assembly and the 3rd gear.
- Inspect the gear for wear or damage. Install a new gear as necessary.

Remove the 3rd gear needle bearing and the spacer.
- Inspect the needle bearing for wear or damage. Install a new needle bearing as necessary.

Inspect the synchronizer assemblies for the following:
- Check for worn, nicked or broken teeth. Install a new synchronizer assembly as necessary.
- Check pressure pieces for wear or distortion. Check the pressure piece springs for distortion. Install a new synchronizer assembly as necessary.

Inspect the output shaft for scoring or worn or damaged splines. Install a new output shaft as necessary.

Assembly

Position the 3rd/4th gear synchronizer hub and the 3rd gear synchronizer ring assembly on the Bearing Puller.
- Align the synchronizer ring tabs with the synchronizer hub slots.

NOTE: Align the synchronizer ring tabs with the gear slots.
Install the 3rd gear, the spacer and the 3rd gear needle bearing.
1. 3rd gear
1. Spacer
1. 3rd gear needle bearing

NOTICE: Align the synchronizer hub splines with the output shaft splines before using the press or damage to the synchronizer hub can occur.
Using the Bearing Puller, press the output shaft into place.

Install the 2nd gear needle and the bearing spacer.
- Apply petroleum jelly to the bearing.

Install the 2nd gear synchronizer ring assembly.
- Align the synchronizer ring tabs with the 2nd gear slots.

NOTICE: The marked side of the 1st/2nd gear synchronizer sleeve must face the 2nd gear, or transmission shifting concerns will occur.
NOTE: Slide the synchronizer sleeve down while installing the pressure pieces.
Install the 1st/2nd gear synchronizer sleeve and the 3 pressure pieces.
- Install the 1st/2nd gear synchronizer sleeve with the 2nd gear mark facing 2nd gear.

Install the 1st gear synchronizer ring assembly.
- Align the synchronizer ring tabs with the synchronizer hub slots.

Install the 1st gear.
- Align the synchronizer ring tabs with the 1st gear slots.

Using the Bearing Tube Remover/Installer, install a new rear output shaft bearing.

NOTICE: The marked side of the 3rd/4th gear synchronizer sleeve must face the 4th gear, or transmission shifting concerns will occur.
NOTE: Slide the synchronizer sleeve on while installing the pressure pieces.
Install the 3rd/4th gear synchronizer sleeve, the 3 pressure pieces and the axial thrust washer.
- Install the 3rd/4th gear synchronizer sleeve with the 4th gear mark facing the 4th gear.
- Apply petroleum jelly to hold the axial thrust washer.