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Ford Mustang 2005, User Manual

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Ford Mustang 2005 User Manual Download Page 2

307-01-2

307-01-2

Automatic Transaxle/Transmission

ASSEMBLY (Continued)

Special Tool(s)

Material

Compressor, Cushion Spring

Item

Specification

307-401

MERCON

 V Automatic

MERCON

 V

Transmission Fluid
XT-5-QM

Multi-Purpose Grease

ESR-M1C159-A

XG-4

1.

Thoroughly clean the transmission case and

Aligner, Valve Body

extension housing in solvent and blow dry with

307-334 (T95L-70010-C)

compressed air.

2.

Inspect the transmission case for the following:

•

Stripped bolt hole threads

•

Gasket and mating surfaces for burrs or

Alignment Pins, Transmission

nicks

Pump

•

Obstructions to vent and fluid passages

307-399

•

Cracks or warpage

Aligner, Flex Plate
307-403

Air Test Plate
307-433-01, 307-433-2,
307-433-3

3.

Inspect the extension housing for cracks, burrs
or warpage.

Installer, Drive Pinion flange
205-479

Installer, Output Shaft Flange
307-404

2005 Mustang, 12/2004 

Summary of Contents for Mustang 2005

Page 1: ... Aligner Fluid Pump Pilot 307 432 Depth Micrometer 303 D026 D80P 4201 A or equivalent Gauge Bar 307 400 Alignment Gauge TR Sensor 307 351 T97L 70010 A Compressor Servo Cover 307 402 Installer Transmission Extension Housing Oil Seal 307 038 T74P 77052 A Installer Shift Shaft Fluid Seal 307 050 T74P 77498 A Sizer Piston Seal 307 338 T95L 70010 G Handle Torque Converter 307 091 T81P 7902 C Continued ...

Page 2: ...ing in solvent and blow dry with 307 334 T95L 70010 C compressed air 2 Inspect the transmission case for the following Stripped bolt hole threads Gasket and mating surfaces for burrs or Alignment Pins Transmission nicks Pump Obstructions to vent and fluid passages 307 399 Cracks or warpage Aligner Flex Plate 307 403 Air Test Plate 307 433 01 307 433 2 307 433 3 3 Inspect the extension housing for ...

Page 3: ... WARNING Make sure the lock pin on bench mounted holding fixture is secure Failure to follow these instructions may result in personal injury Using the special tool install the transmission into the bench with the converter housing facing up 8 Install the manual control lever 6 Using the special tool install the manual control lever shaft seal and lubricate it with petroleum jelly 2005 Mustang 12 ...

Page 4: ...pin bore in the transmission case Install the manual control lever shaft spring pin Tap the manual control lever shaft spring pin into the transmission case 10 CAUTION Align the flats on the manual valve inner lever with the flats on the manual control lever shaft Install the manual control lever shaft 13 CAUTION To avoid damage do not allow the wrench to strike the manual valve inner lever pin Ti...

Page 5: ...ly seated Install the output shaft thrust washer No 11 Coat the output shaft thrust washer with petroleum jelly 18 CAUTION Make sure band is resting on the 2 anchor pins in the case Install the low reverse band over the reverse drum 15 Install the park gear on the output shaft 19 NOTE The reverse band actuating lever must 16 Install the output shaft and park gear fit into the notches in the band I...

Page 6: ...nto place when correctly installed Install the output shaft sleeve 21 Install the No 10 needle bearing into the case 25 Install low reverse planetary carrier needle 22 CAUTION Do not damage the seal bearing No 9 onto the output shaft ring gear against the case during assembly and hub assembly Install the output shaft ring gear hub and seal 23 CAUTION Always install a new output shaft retaining rin...

Page 7: ...erse planetary assembly 30 Install the input shell and sun gear assembly 27 CAUTION The low reverse brake drum must be pulled forward to install the low reverse planet retaining ring Install the retaining ring 31 NOTE The No 13 bearing must be properly seated in the forward planet assembly so the sun gear can be installed correctly Install the forward planetary assembly 28 Install the No 8 thrust ...

Page 8: ...t into the forward ring gear and hub assembly bearing into the forward ring gear and hub Use petroleum jelly to hold the bearing in place 36 Install the forward clutch cylinder 33 Install the No 6B forward clutch thrust washer onto the forward ring gear hub 37 Install the No 5 thrust bearing 34 Install the forward ring gear and hub as an assembly 2005 Mustang 12 2004 ...

Page 9: ...Add the 4 measurements divide by 4 and record as dimension A 39 Using the special tool install the retaining ring 42 CAUTION The torque specifications are critical for this procedure Failure to use the correct torque specifications may cause transmission damage Install the special tool 1 Install the special tool and the bolts using the 2 pump screw locations at approximately 6 and 12 o clock posit...

Page 10: ...rt Number Dimension E 7D014 Bearing Thickness Identification Notches 1 69 1 87 mm XW4Z CA 2 65 2 80 mm None 0 066 0 074 in 0 104 0 110 in 1 88 2 04 mm XW4X DA 2 83 2 98 mm One 0 073 0 080 in 0 111 0 116 in 2 05 2 22 mm XW4Z EA 3 01 3 16 mm Two 0 081 0 088 in 0 118 0 124 in 2 23 2 43 mm XW4Z FA 3 21 3 36 mm Three 0 088 0 096 in 0 126 0 132 in 47 NOTE Make sure that the intermediate band apply strut...

Page 11: ...he band case side and the large U shape notch toward the main control side Position the strut in the transmission case 1 Band case side of the anchor small U notch 2 Main control side of the anchor large U notch 52 Install the intermediate band apply strut 50 CAUTION If the strut is installed incorrectly transmission damage will occur Check to make sure that the intermediate band anchor strut is i...

Page 12: ...ill occur Check to make sure that the intermediate band apply strut is installed in the correct orientation to the case and piston rod 57 Loosely install the screw 54 Install the selected No 4 thrust washer on the direct clutch drum Coat the thrust washer with petroleum jelly 55 NOTE Align the center support screw hole with correct case hole Install the center support 2005 Mustang 12 2004 ...

Page 13: ...ng ring 1 Make sure the center support retaining ring is installed with the tapered side facing up 2 Make sure the opening of the center support retaining ring is positioned correctly 60 Install the overdrive ring gear overdrive one way clutch and center shaft assembly 61 CAUTION Do not bend the trigger wheel Make sure that the No 2 thrust bearing is in this assembly Install the planetary gear ove...

Page 14: ...trut is aligned with the band notch NOTE The new overdrive band is dark in color This is a normal condition of the band Hairline cracks in the band are also considered normal Do not install a new band based solely on the color Install the overdrive band 63 Install the overdrive band servo piston and spring Lubricate the servo bore with clean automatic transmission fluid 66 Install the overdrive an...

Page 15: ...ll U notch 2 Main control side of the anchor large U notch 70 Loosely install the screw 68 CAUTION If the strut is installed incorrectly transmission damage will occur 71 Install the overdrive apply strut Check to make sure that the intermediate band anchor strut is installed in the correct orientation to the case and adjustment screw 69 CAUTION If the strut is installed incorrectly transmission d...

Page 16: ...fications are critical for this procedure Failure to use the correct torque specifications may cause 75 Add dimension A to B divide by 2 and record transmission damage as dimension C Install the special tool 76 Subtract the thickness of the gauge bar 17 78 1 Install the special tool and the bolts using mm 0 70 in from dimension C and record as the 2 pump screw locations at dimension D approximatel...

Page 17: ...1 52 1 53 F7TZ SA 2 15 2 20 mm 0 095 0 097 Yellow in in 78 Install the selected No 1 fluid pump input thrust washer Coat the fluid pump input thrust washer with petroleum jelly 81 CAUTION Make sure that the fluid pump inlet thrust washer No 1 selective thrust washer fluid pump gasket and the fluid pump to case O ring seal remain in the correct position throughout this step 79 Install the special t...

Page 18: ... plate 85 CAUTION Do not allow overdrive band adjustment screw to back out Band strut could fall out of position CAUTION Install but do not tighten a new locknut on the band adjustment screw Apply petroleum jelly to the locknut seal Install a new locknut on the band adjustment 83 Install screws Tighten the screws in a star screw pattern Tighten to 25 Nm 18 lb ft 84 Remove the special tools and ins...

Page 19: ... and hold that position Tighten to 14 Nm 10 lb ft 87 Tighten the overdrive band locknut 1 Hold the overdrive band adjustment screw stationary 2 Tighten the overdrive band locknut X Tighten to 54 Nm 40 lb ft 90 Tighten the intermediate band locknut 1 Hold the intermediate band adjustment screw stationary 2 Tighten the intermediate band locknut X Tighten to 54 Nm 40 lb ft 88 CAUTION Do not allow the...

Page 20: ...ighten to 11 Nm 8 lb ft 1 Install the short screw 2 Install the screw with the larger head 3 Install the remaining screws 92 Using the special tools carry out the air pressure test procedure For additional information refer to Special Testing Procedures in this section 95 Remove the special tools and loosely install the screw 93 Install the special tools into the transmission case 2005 Mustang 12 ...

Page 21: ... sequence shown Tighten to 10 Nm 89 lb in 97 With the manual lever in the NEUTRAL 98 Install new O ring seals on the solenoid body position install the manual valve detent spring connector Lubricate the O ring seals with clean automatic transmission fluid Tighten to 10 Nm 89 lb in 2005 Mustang 12 2004 ...

Page 22: ...uld be reused Install the transmission fluid pan and gasket and loosely install the screws 100 Install the reverse servo Tighten the bolts in the sequence shown in 2 stages Stage 1 Tighten to 5 Nm 44 lb in Stage 2 Tighten to 11 Nm 8 lb ft 103 Tighten the 16 screws in a crisscross sequence Tighten to 11 Nm 8 lb ft 101 CAUTION Lubricate the fluid filter seals with clean automatic transmission fluid ...

Page 23: ...ring 3 Install the parking pawl 4 Install a new gasket 108 Install a new nut Tighten to 131 Nm 97 lb ft 105 Install the extension housing Tighten to 25 Nm 18 lb ft 109 CAUTION The digital transmission range sensor must fit flush against the boss on the case to prevent damage to the sensor 106 Using the special tool install the extension Install the digital transmission range TR housing seal sensor...

Page 24: ... the sensor to bind or become damaged NOTE The manual lever must be in the NEUTRAL position Using the special tool align the digital TR sensor and tighten the screws in an alternating sequence Tighten 10 Nm 89 lb in 113 Remove the special tool 111 CAUTION The splines of the input shaft are not the same length on both ends The shaft end with the shorter splines goes into the fluid pump Install the ...

Page 25: ...In order to correctly install the special service tool it must be installed using one round and one oblong hole Using two oblong holes will cause damage to the transmission NOTE Position the adapter plate on the torque converter and identify the position of the orange or green paint daub on the converter face 115 WARNING The torque converter can If the vehicle is equipped use the special tool fall...

Page 26: ...all remaining torque converter flex plate adapter new if damaged Lubricate the O ring seals nuts with petroleum jelly to prevent damage to the O ring seals Tighten to 44 Nm 33 lb ft Install the sensors Tighten to 10 Nm 89 lb in 119 Using one of the speed sensor holes fill the transmission with 8 5L 9 quarts of automatic transmission fluid 2005 Mustang 12 2004 ...

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