SECTION 308-03BManual Transaxle/Transmission — T45

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308-03B-1Manual Transaxle/Transmission — T45308-03B-1Manual Table of ContentsSECTION 308-03B Manual Transaxle/Transmission — T45CONTENTSPAGESPECIFICATIONS .308-03B-2DESCRIPTION AND OPERATIONManual Transmission.308-03B-3DIAGNOSIS AND TESTINGManual Transmission.308-03B-11GENERAL PROCEDURESBearings — Inspection .308-03B-12IN-VEHICLE REPAIRSeal.308-03B-15Gearshift Lever and Boot .308-03B-17Output Shaft Speed (OSS) Sensor LYTransmission.308-03B-25DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIESExtension Housing.308-03B-38Input Shaft and Bearing .308-03B-40Output Shaft.308-03B-42Countershaft Bearing.308-03B-52Reverse Idler Gear .308-03B-54Synchronizers .308-03B-55Gearshift Rail Bushing.308-03B-57Gearshift Rail and Fork .308-03B-59Transmission Case TIONTransmission.308-03B-8103-03 Development Copy2001 Mustang, 10/2000

308-03B-2Manual Transaxle/Transmission — T45308-03B-2SPECIFICATIONSSuperseded by:SGML id ‘‘n51785 ’’Effect:Frozen: ‘‘N’’ ‘‘1999’’ ‘‘FOJMUSTANG’’ ‘‘08’’ ‘‘03B’’Effect:Frozen: ‘‘N’’ ‘‘1999’’ ‘‘FOMMUSTANG’’ ‘‘08’’ ‘‘03B’’Effect:Frozen: ‘‘N’’ ‘‘1999’’ ‘‘MUSTANG’’ ‘‘08’’ ‘‘03B’’Effect:Frozen: ‘‘N’’ ‘‘2000’’ ‘‘FOMMUSTANG’’ ‘‘08’’ ‘‘03B’’Effect:Frozen: ‘‘N’’ ‘‘2000’’ ‘‘MUSTANG’’ ‘‘08’’ ‘‘03B’’Effect:Frozen: ‘‘N’’ ‘‘2000’’ ‘‘SUPPFOJMUST’’ ‘‘08’’ ‘‘03B’’Effect:Frozen: ‘‘N’’ ‘‘2001’’ ‘‘FOJMUSTANG’’ ‘‘08’’ ‘‘03B’’Effect:Frozen: ‘‘N’’ ‘‘2001’’ ‘‘FOMMUSTANG’’ ‘‘08’’ ‘‘03B’’Effect:Frozen: ‘‘N’’ ‘‘2001’’ ‘‘MUSTANG’’ ‘‘08’’ ‘‘03B’’General SpecificationTorque SpecificationsItemSpecificationInspection Standards and TolerancesSynchronizer blocking ring0.5 mm (0.02 in)to conical face runoutAssembly StandardsInput shaft end play0.02286 mm (0.0009 in) 0.0508 mm (0.002 in)Countershaft cluster gear0.0 mm (0.0 in) - 0.076end playmm (0.003 in)Rev driven gear-to-rev0.0508 mm (0.002 in) synchro hub clearance0.3048 mm (0.012 in)Output shaft end play0.0012 mm (0.0005 in) 0.100 mm (0.004 in)Output shaft pre-load0.012 mm (0.0005 in) 0.100 mm (0.004 in)Lubrication/Adhesive/Cleaner SpecificationsMulti-Purpose GreaseESB-M1C93-BD0AZ-19584-AAThreadlock and SealerWSK-M2G351-A5E0AZ-19554-AAClear Silicone RubberESB-M4G92-AD6AZ-19562-AAPipe Sealant with Teflon ESR-M18P7-AD8AZ-19554-AMERCON Multi-PurposeMercon ATF Transmission FluidXT-2-QDXLubricant Refill CapacitiesMERCON Multi-Purpose3.1L (6.6 pt)ATF Transmission FluidXT-2-QDXDescriptionBolt retaining gear shiftlever to gear shift stubshaftBolt retaining OSS tocaseBolt retaining reverseidler gear shift bracketto caseInterlock boltFifth/reverse lever pivotboltBolt retaining flywheelhousing to caseBolt retaining extensionhousing to caseDrain plugReversing lamp switchFill plugBolt retainingtransmission to blockBolt retaining engineplate to transmissionBolt retainingcrossmember to frameBolt retainingcrossmember totransmission supportBolt retaining driveshaftflange to pinion ��4130—5843—11283—Torque SpecificationsDescriptionBolt retaining gearshiftlever to extensionhousingScrew retaining innershift boot to floor panNmlb-ftlb-in1813—10—89(Continued)03-03 Development Copy2001 Mustang, 10/2000

308-03B-3Manual Transaxle/Transmission — T45308-03B-3DESCRIPTION AND OPERATIONSuperseded by:SGML id ‘‘n51684’’Effect:Frozen: ‘‘N’’ ‘‘1999’’ ‘‘FOMMUSTANG’’ ‘‘08’’‘‘03B’’Effect:Frozen: ‘‘N’’ ‘‘1999’’ ‘‘MUSTANG’’ ‘‘08’’‘‘03B’’Effect:Frozen: ‘‘N’’ ‘‘2000’’ ‘‘FOMMUSTANG’’ ‘‘08’’‘‘03B’’Effect:Frozen: ‘‘N’’ ‘‘2000’’ ‘‘MUSTANG’’ ‘‘08’’‘‘03B’’Effect:Frozen: ‘‘N’’ ‘‘2000’’ ‘‘SUPPFOJMUST’’ ‘‘08’’‘‘03B’’Effect:Frozen: ‘‘N’’ ‘‘2001’’ ‘‘FOJMUSTANG’’ ‘‘08’’‘‘03B’’Effect:Frozen: ‘‘N’’ ‘‘2001’’ ‘‘FOMMUSTANG’’ ‘‘08’’‘‘03B’’Effect:Frozen: ‘‘N’’ ‘‘2001’’ ‘‘MUSTANG’’ ‘‘08’’‘‘03B’’ The forward gears are synchronized and helicalcut. The reverse gear operates through aconstant-mesh, double-disconnect system. The shift interlock system prevents theengagement of more than one gear.Manual Transmission(id n144504)The T45 five-speed manual transmission features thefollowing: The fifth speed gear functions as an overdrivegear.03-03 Development Copy2001 Mustang, 10/2000

308-03B-4Manual Transaxle/Transmission — T45308-03B-4DESCRIPTION AND OPERATION (Continued)Manual Transmission—Five Speed03-03 Development Copy2001 Mustang, 10/2000

308-03B-5Manual Transaxle/Transmission — T45308-03B-5DESCRIPTION AND OPERATION (Continued)ItemPart 7277025Clutch release lever studBoltFlywheel housing (includestube)Main shift rail bushingDowelCountershaft front bearingshimCountershaft bearingassemblyCountershaft cluster gearSealShimInput shaft front bearingassemblyInput shaftInput shaft pocket bearingThird/fourth synchronizerblocking ringRetaining ringSynchronizer blocking spring(also part of 7124)Third/fourth synchronizer hub(part of 7124)Third/fourth synchronizerstrut (also part of 7124)Third/fourth synchronizersleeve (part of 7124)Third/fourth synchronizerassemblyBearing spacerNeedle bearingThird gearOutput shaftSecond gearThrust washerFirst and second gearsynchronizer inner coneFirst and second gearsynchronizer outer coneFirst/second synchronizerblocking ringSynchronizer blocking spring(also part of 7124)First/second synchronizer hub(part of (Continued)03-03 Development CopyItem32Part cond synchronizerstrut (also part of 7124)First/second synchronizersleeve (part of 7124)First/second synchronizerassemblyFirst gear bearingFirst gearOutput shaft bearing assemblyInterlock boltCaseFifth/reverse lever retainingclipFifth/reverse gear shift leverFifth/reverse lever pivot boltReversing lamp switchassemblyMagnetFifth/reverse gear shift railSplit pinGear shift fork insertFifth/reverse gear shifter forkFifth driven gearReverse synchronizer hub(part of 7124)Reverse synchronizer sleeve(part of 7124)Reverse synchronizerassemblyRetaining ringBearing spacerNeedle bearingReverse driven gearThrust washerOutput shaft rear bearingRetaining ringTone wheel (output shaftspeed)Retaining ringCountershaft bearingShoulder boltReverse idler shift bracketSpring washerReverse idler gear(Continued)2001 Mustang, 10/2000

308-03B-6Manual Transaxle/Transmission — T45308-03B-6DESCRIPTION AND OPERATION (Continued)Item676869707172Part erse idler gear bearingReverse idler shaftExtension housing (4.6L 2V)Fifth gearFifth/Reverse Blocking ringSynchronizer blocking spring(also part of 7124)Fifth/reverse synchronizer hub(part of 7124)Fifth/reverse synchronizerstrut (also part of 7124)Fifth/reverse synchronizersleeve (part of 7124)Fifth/reverse synchronizerassemblyRetaining ringReverse gearThrust washerRetaining ringExtension housing bushing(part of 7A039)Item828384858687888990919293949596979899Part 44372777358723073027N2327K2017230DescriptionFull fill seal (part of 7A039)SealCase plugVentDetent plate (part of 7A039)Detent ballDetent springGearshift offset leverDamper sleeveGearshift leverBolt (4 req’d)Gearshift lever bootMain shift railFirst/second gear shifter forkSelector assemblyGear shift plateGear selector interlock sleeveThird/fourth gear shifter fork(Continued)Transmission IdentificationThe transmission identification tag is located underthe lower left bolt that retains the extension housingto the case.03-03 Development CopyThe five speed overdrive (T45) transmission is theonly manual transmission available for the Mustang4.6L (2V) and the Mustang Cobra 4.6L (4V).2001 Mustang, 10/2000

308-03B-7Manual Transaxle/Transmission — T45308-03B-7DESCRIPTION AND OPERATION (Continued)Transmission Identification TagItemPart NumberDescription1—2—Transmission assemblynumberBuild date code—monthItem345678Part Number——————DescriptionBuild date code—dayBuild date code—yearShift numberSerial numberService repair codeWg. identification number(located on the extensionhousing bolt on the LH sideof the transmission)(Continued)Powerflow in NeutralItem123Part NumberDescription7124712471243-4 synchronizer1-2 synchronizerFifth/reverse synchronizer03-03 Development Copy2001 Mustang, 10/2000

308-03B-8Manual Transaxle/Transmission — T45308-03B-8DESCRIPTION AND OPERATION (Continued)Powerflow in 1st GearItem123Part NumberDescription7124710070611-2 synchronizer1st gear drivenOutput shaftItem45Part Number71137017DescriptionCountershaftInput shaftItem345Part Number706171137017DescriptionOutput shaftCountershaftInput shaft(Continued)Powerflow in 2nd GearItem12Part NumberDescription710271242nd gear driven1-2 synchronizer(Continued)03-03 Development Copy2001 Mustang, 10/2000

308-03B-9Manual Transaxle/Transmission — T45308-03B-9DESCRIPTION AND OPERATION (Continued)Powerflow in 3rd GearItem123Part NumberDescription71247B34070613-4 synchronizer3rd gear drivenOutput shaftItem45Part Number71137017DescriptionCountershaftInput shaftItem345Part Number706171137017DescriptionOutput shaftCountershaftInput shaft(Continued)Powerflow in 4th GearItem12Part NumberDescription711271244th gear driven3-4 synchronizer(Continued)03-03 Development Copy2001 Mustang, 10/2000

308-03B-10Manual Transaxle/Transmission — T45308-03B-10DESCRIPTION AND OPERATION (Continued)Powerflow in 5th GearItem123Part NumberDescription7K316706171245th gear drivenOutput shaftFifth/reverse synchronizerItem456Part Number714471137017DescriptionFifth gearCountershaftInput shaft(Continued)Powerflow in Reverse Gear03-03 Development Copy2001 Mustang, 10/2000

308-03B-11Manual Transaxle/Transmission — T45308-03B-11DESCRIPTION AND OPERATION (Continued)ItemPart NumberDescription1—237C2387061Reverse gear synchronizersleeve (part of 7124)Reverse gear drivenOutput shaftItem4567Part Number7141712471137017DescriptionReverse idler gearFifth/reverse synchronizerCountershaftInput shaft(Continued)DIAGNOSIS AND TESTINGSuperseded by:SGML id ‘‘n51685 ’’Effect:Frozen: ‘‘N’’ ‘‘1999’’ ‘‘FOJMUSTANG’’ ‘‘08’’‘‘03B’’Effect:Frozen: ‘‘N’’ ‘‘1999’’ ‘‘FOMMUSTANG’’ ‘‘08’’‘‘03B’’Effect:Frozen: ‘‘N’’ ‘‘1999’’ ‘‘MUSTANG’’ ‘‘08’’‘‘03B’’Effect:Frozen: ‘‘N’’ ‘‘2000’’ ‘‘FOMMUSTANG’’ ‘‘08’’‘‘03B’’Effect:Frozen: ‘‘N’’ ‘‘2000’’ ‘‘MUSTANG’’ ‘‘08’’‘‘03B’’Effect:Frozen: ‘‘N’’ ‘‘2001’’ ‘‘FOJMUSTANG’’ ‘‘08’’‘‘03B’’Effect:Frozen: ‘‘N’’ ‘‘2001’’ ‘‘FOMMUSTANG’’ ‘‘08’’‘‘03B’’Effect:Frozen: ‘‘N’’ ‘‘2001’’ ‘‘MUSTANG’’ ‘‘08’’‘‘03B’’Effect:Frozen: ‘‘N’’ ‘‘2001’’ ‘‘MUSTANG’’ ‘‘08’’‘‘03C’’Effect:Frozen: ‘‘N’’ ‘‘2002’’ ‘‘FOMMUSTANG’’ ‘‘08’’‘‘03B’’Effect:Frozen: ‘‘N’’ ‘‘2002’’ ‘‘MUSTANG’’ ‘‘08’’‘‘03B’’Effect:Frozen: ‘‘N’’ ‘‘2003’’ ‘‘FOCMUSTANG’’ ‘‘08’’‘‘03B’’Effect:Frozen: ‘‘N’’ ‘‘2003’’ ‘‘FOCMUSTANG’’ ‘‘08’’‘‘03C’’Effect:Frozen: ‘‘N’’ ‘‘2003’’ ‘‘FOMMUSTANG’’ ‘‘08’’‘‘03B’’Effect:Frozen: ‘‘N’’ ‘‘2003’’ ‘‘MUSTANG’’ ‘‘08’’‘‘03B’’Effect:Frozen: ‘‘N’’ ‘‘2003’’ ‘‘MUSTANG’’ ‘‘08’’‘‘03C’’Effect:Frozen: ‘‘N’’ ‘‘2004’’ ‘‘MUSTANG’’ ‘‘08’’‘‘03B’’Effect:Frozen: ‘‘N’’ ‘‘2004’’ ‘‘MUSTANG’’ ‘‘08’’‘‘03C’’Manual Transmission(id n144505)Refer toSection 308-00.03-03 Development Copy2001 Mustang, 10/2000

308-03B-12Manual Transaxle/Transmission — T45308-03B-12GENERAL PROCEDURESSuperseded by:SGML id ‘‘n51784 ’’Effect:Frozen: ‘‘N’’ ‘‘1999’’ ‘‘FOJMUSTANG’’ ‘‘08’’ ‘‘03B’’Effect:Frozen: ‘‘N’’ ‘‘1999’’ ‘‘FOMMUSTANG’’ ‘‘08’’ ‘‘03B’’Effect:Frozen: ‘‘N’’ ‘‘1999’’ ‘‘MUSTANG’’ ‘‘08’’ ‘‘03B’’Effect:Frozen: ‘‘N’’ ‘‘2000’’ ‘‘FOMMUSTANG’’ ‘‘08’’ ‘‘03B’’Effect:Frozen: ‘‘N’’ ‘‘2000’’ ‘‘MUSTANG’’ ‘‘08’’ ‘‘03B’’Effect:Frozen: ‘‘N’’ ‘‘2001’’ ‘‘FOJMUSTANG’’ ‘‘08’’ ‘‘03B’’Effect:Frozen: ‘‘N’’ ‘‘2001’’ ‘‘FOMMUSTANG’’ ‘‘08’’ ‘‘03B’’Effect:Frozen: ‘‘N’’ ‘‘2001’’ ‘‘MUSTANG’’ ‘‘08’’ ‘‘03B’’Effect:Frozen: ‘‘N’’ ‘‘2001’’ ‘‘MUSTANG’’ ‘‘08’’ ‘‘03C’’Effect:Frozen: ‘‘N’’ ‘‘2002’’ ‘‘FOMMUSTANG’’ ‘‘08’’ ‘‘03B’’Effect:Frozen: ‘‘N’’ ‘‘2002’’ ‘‘MUSTANG’’ ‘‘08’’ ‘‘03B’’Effect:Frozen: ‘‘N’’ ‘‘2003’’ ‘‘FOCMUSTANG’’ ‘‘08’’ ‘‘03B’’Effect:Frozen: ‘‘N’’ ‘‘2003’’ ‘‘FOMMUSTANG’’ ‘‘08’’ ‘‘03B’’Effect:Frozen: ‘‘N’’ ‘‘2003’’ ‘‘MUSTANG’’ ‘‘08’’ ‘‘03B’’Effect:Frozen: ‘‘N’’ ‘‘2004’’ ‘‘MUSTANG’’ ‘‘08’’ ‘‘03B’’Bearings — Inspection(id n144521)NOTE: If any of the following conditions exist,install a new bearing.03-03 Development Copy1.Inspect the bearing for a bent cage.2.Inspect bearings for galling (metal smears onroller ends). Galling is caused by overheating, poorlubrication or an overload situation. If galling is found, install a new bearing andinspect the seals.2001 Mustang, 10/2000

308-03B-13Manual Transaxle/Transmission — T45308-03B-13GENERAL PROCEDURES (Continued)3.Inspect the bearing for brinelling (surfaceindentations in the raceway).4.Inspect bearing for cracked inner race.5.Inspect the bearing and raceway for etching. 6.Inspect the bearing for heat discoloration (darkblue). 03-03 Development CopyIf etching is present, inspect the seals.If heat discoloration is evident, check thebearing and race for loss of temper. Draw afile across the component. If the file cuts themetal, there is a loss of temper.2001 Mustang, 10/2000

308-03B-14Manual Transaxle/Transmission — T45308-03B-14GENERAL PROCEDURES (Continued)7.03-03 Development CopyInspect the bearing for fatigue spalling (metalflaking).2001 Mustang, 10/2000

308-03B-15Manual Transaxle/Transmission — T45308-03B-15IN-VEHICLE REPAIRSuperseded by:SGML id ‘‘n51712 ’’Effect:Frozen: ‘‘N’’ ‘‘1999’’ ‘‘FOJMUSTANG’’ ‘‘08’’ ‘‘03A’’Effect:Frozen: ‘‘N’’ ‘‘1999’’ ‘‘FOMMUSTANG’’ ‘‘08’’ ‘‘03A’’Effect:Frozen: ‘‘N’’ ‘‘1999’’ ‘‘MUSTANG’’ ‘‘08’’ ‘‘03A’’Effect:Frozen: ‘‘N’’ ‘‘2000’’ ‘‘FOMMUSTANG’’ ‘‘08’’ ‘‘03A’’Effect:Frozen: ‘‘N’’ ‘‘2000’’ ‘‘MUSTANG’’ ‘‘08’’ ‘‘03A’’Effect:Frozen: ‘‘N’’ ‘‘2000’’ ‘‘MUSTANG’’ ‘‘08’’ ‘‘03B’’Effect:Frozen: ‘‘N’’ ‘‘2001’’ ‘‘FOJMUSTANG’’ ‘‘08’’ ‘‘03A’’Effect:Frozen: ‘‘N’’ ‘‘2001’’ ‘‘FOJMUSTANG’’ ‘‘08’’ ‘‘03B’’Effect:Frozen: ‘‘N’’ ‘‘2001’’ ‘‘FOMMUSTANG’’ ‘‘08’’ ‘‘03A’’Effect:Frozen: ‘‘N’’ ‘‘2001’’ ‘‘FOMMUSTANG’’ ‘‘08’’ ‘‘03B’’Effect:Frozen: ‘‘N’’ ‘‘2001’’ ‘‘MUSTANG’’ ‘‘08’’ ‘‘03A’’Effect:Frozen: ‘‘N’’ ‘‘2001’’ ‘‘MUSTANG’’ ‘‘08’’ ‘‘03B’’Effect:Frozen: ‘‘N’’ ‘‘2001’’ ‘‘MUSTANG’’ ‘‘08’’ ‘‘03C’’Effect:Frozen: ‘‘N’’ ‘‘2002’’ ‘‘FOMMUSTANG’’ ‘‘08’’ ‘‘03A’’Effect:Frozen: ‘‘N’’ ‘‘2002’’ ‘‘FOMMUSTANG’’ ‘‘08’’ ‘‘03B’’Effect:Frozen: ‘‘N’’ ‘‘2002’’ ‘‘MUSTANG’’ ‘‘08’’ ‘‘03A’’Effect:Frozen: ‘‘N’’ ‘‘2002’’ ‘‘MUSTANG’’ ‘‘08’’ ‘‘03B’’Effect:Frozen: ‘‘N’’ ‘‘2003’’ ‘‘FOCMUSTANG’’ ‘‘08’’ ‘‘03A’’Effect:Frozen: ‘‘N’’ ‘‘2003’’ ‘‘FOCMUSTANG’’ ‘‘08’’ ‘‘03B’’Effect:Frozen: ‘‘N’’ ‘‘2003’’ ‘‘FOMMUSTANG’’ ‘‘08’’ ‘‘03A’’Effect:Frozen: ‘‘N’’ ‘‘2003’’ ‘‘FOMMUSTANG’’ ‘‘08’’ ‘‘03B’’Effect:Frozen: ‘‘N’’ ‘‘2003’’ ‘‘MUSTANG’’ ‘‘08’’ ‘‘03A’’Effect:Frozen: ‘‘N’’ ‘‘2003’’ ‘‘MUSTANG’’ ‘‘08’’ ‘‘03B’’Effect:Frozen: ‘‘N’’ ‘‘2004’’ ‘‘MUSTANG’’ ‘‘08’’ ‘‘03A’’Effect:Frozen: ‘‘N’’ ‘‘2004’’ ‘‘MUSTANG’’ ‘‘08’’ ‘‘03B’’Seal(id n143130)Special Tool(s)Installer, TransmissionExtension Housing Oil Seal308-227 (T94P-7657-A)Slide Hammer100-001 (T50T-100-A)Remover, Bushing307-001 (TOOL-1175-AC) orEquivalentRemoval1.03-03 Development CopyWith the vehicle in NEUTRAL, raise andsupport the vehicle. For additional information,refer to Section 100-02.2001 Mustang, 10/2000

308-03B-16Manual Transaxle/Transmission — T45308-03B-16IN-VEHICLE REPAIR (Continued)2.CAUTION: Index-mark the driveshaftflange and pinion flange, and the driveshaftslip yoke and transmission output shaft.Remove the driveshaft. For additionalinformation, refer to Section 205-01.3.Using the special tools, remove the extensionhousing fluid seal.Installation1.Using the special tool, install the extensionhousing fluid seal.2.CAUTION: Align the index marks.Install the driveshaft. For additionalinformation, refer to Section 205-01.03-03 Development Copy3.Check the transmission fluid level, add fluid ifnecessary.4.Lower the vehicle.2001 Mustang, 10/2000

308-03B-17Manual Transaxle/Transmission — T45308-03B-17IN-VEHICLE REPAIR (Continued)Superseded by:SGML id ‘‘n165175 ’’Effect:Frozen: ‘‘N’’ ‘‘2000’’ ‘‘MUSTANG’’ ‘‘08’’ ‘‘03A’’Effect:Frozen: ‘‘N’’ ‘‘2000’’ ‘‘MUSTANG’’ ‘‘08’’ ‘‘03B’’Effect:Frozen: ‘‘N’’ ‘‘2001’’ ‘‘FOJMUSTANG’’ ‘‘08’’ ‘‘03A’’Effect:Frozen: ‘‘N’’ ‘‘2001’’ ‘‘FOJMUSTANG’’ ‘‘08’’ ‘‘03B’’Effect:Frozen: ‘‘N’’ ‘‘2001’’ ‘‘FOMMUSTANG’’ ‘‘08’’ ‘‘03A’’Effect:Frozen: ‘‘N’’ ‘‘2001’’ ‘‘FOMMUSTANG’’ ‘‘08’’ ‘‘03B’’Effect:Frozen: ‘‘N’’ ‘‘2001’’ ‘‘MUSTANG’’ ‘‘08’’ ‘‘03A’’Effect:Frozen: ‘‘N’’ ‘‘2001’’ ‘‘MUSTANG’’ ‘‘08’’ ‘‘03B’’Effect:Frozen: ‘‘N’’ ‘‘2001’’ ‘‘MUSTANG’’ ‘‘08’’ ‘‘03C’’Effect:Frozen: ‘‘N’’ ‘‘2002’’ ‘‘FOMMUSTANG’’ ‘‘08’’ ‘‘03A’’Effect:Frozen: ‘‘N’’ ‘‘2002’’ ‘‘FOMMUSTANG’’ ‘‘08’’ ‘‘03B’’Effect:Frozen: ‘‘N’’ ‘‘2002’’ ‘‘MUSTANG’’ ‘‘08’’ ‘‘03A’’Effect:Frozen: ‘‘N’’ ‘‘2002’’ ‘‘MUSTANG’’ ‘‘08’’ ‘‘03B’’Effect:Frozen: ‘‘N’’ ‘‘2003’’ ‘‘FOCMUSTANG’’ ‘‘08’’ ‘‘03A’’Effect:Frozen: ‘‘N’’ ‘‘2003’’ ‘‘FOCMUSTANG’’ ‘‘08’’ ‘‘03B’’Effect:Frozen: ‘‘N’’ ‘‘2003’’ ‘‘FOMMUSTANG’’ ‘‘08’’ ‘‘03A’’Effect:Frozen: ‘‘N’’ ‘‘2003’’ ‘‘FOMMUSTANG’’ ‘‘08’’ ‘‘03B’’Effect:Frozen: ‘‘N’’ ‘‘2003’’ ‘‘MUSTANG’’ ‘‘08’’ ‘‘03A’’Effect:Frozen: ‘‘N’’ ‘‘2003’’ ‘‘MUSTANG’’ ‘‘08’’ ‘‘03B’’Effect:Frozen: ‘‘N’’ ‘‘2004’’ ‘‘MUSTANG’’ ‘‘08’’ ‘‘03A’’Effect:Frozen: ‘‘N’’ ‘‘2004’’ ‘‘MUSTANG’’ ‘‘08’’ ‘‘03B’’Gearshift Lever and Boot(id n165178)MaterialsItemClear Silicone RubberD6AZ-19562-AA orequivalentSpecificationESB-M4G92-ARemoval and Installation03-03 Development Copy1.Remove the gearshift lever knob.2.Remove the console panel gearshift plate. Liftthe gearshift lever boot over the gearshift lever.2001 Mustang, 10/2000

308-03B-18Manual Transaxle/Transmission — T45308-03B-18IN-VEHICLE REPAIR (Continued)3.Remove the bolts and the shift lever.4.Remove the screws and the inner shifter boot.5.Remove the bolts and the gearshift lever.6.Remove the gearshift lever boot.7.CAUTION: Cover the opening in theextension housing to prevent contamination.Clean the gearshift lever mounting surfaces.8.To install, reverse the removal procedure. 03-03 Development CopyApply a 3.2-mm (1/8-in) bead of siliconerubber to the sealing surface on the gearshiftlever.2001 Mustang, 10/2000

308-03B-19Manual Transaxle/Transmission — T45308-03B-19IN-VEHICLE REPAIR (Continued)Superseded by:SGML id ‘‘n147997 ’’Effect:Frozen: ‘‘N’’ ‘‘1999’’ ‘‘FOJMUSTANG’’ ‘‘08’’ ‘‘03A’’Effect:Frozen: ‘‘N’’ ‘‘1999’’ ‘‘FOMMUSTANG’’ ‘‘08’’ ‘‘03A’’Effect:Frozen: ‘‘N’’ ‘‘1999’’ ‘‘MUSTANG’’ ‘‘08’’ ‘‘03A’’Effect:Frozen: ‘‘N’’ ‘‘2000’’ ‘‘FOMMUSTANG’’ ‘‘08’’ ‘‘03A’’Effect:Frozen: ‘‘N’’ ‘‘2000’’ ‘‘MUSTANG’’ ‘‘08’’ ‘‘03A’’Effect:Frozen: ‘‘N’’ ‘‘2000’’ ‘‘MUSTANG’’ ‘‘08’’ ‘‘03B’’Effect:Frozen: ‘‘N’’ ‘‘2001’’ ‘‘FOJMUSTANG’’ ‘‘08’’ ‘‘03A’’Effect:Frozen: ‘‘N’’ ‘‘2001’’ ‘‘FOJMUSTANG’’ ‘‘08’’ ‘‘03B’’Effect:Frozen: ‘‘N’’ ‘‘2001’’ ‘‘FOMMUSTANG’’ ‘‘08’’ ‘‘03A’’Effect:Frozen: ‘‘N’’ ‘‘2001’’ ‘‘FOMMUSTANG’’ ‘‘08’’ ‘‘03B’’Effect:Frozen: ‘‘N’’ ‘‘2001’’ ‘‘MUSTANG’’ ‘‘08’’ ‘‘03A’’Effect:Frozen: ‘‘N’’ ‘‘2001’’ ‘‘MUSTANG’’ ‘‘08’’ ‘‘03B’’Effect:Frozen: ‘‘N’’ ‘‘2001’’ ‘‘MUSTANG’’ ‘‘08’’ ‘‘03C’’Effect:Frozen: ‘‘N’’ ‘‘2002’’ ‘‘FOMMUSTANG’’ ‘‘08’’ ‘‘03A’’Effect:Frozen: ‘‘N’’ ‘‘2002’’ ‘‘FOMMUSTANG’’ ‘‘08’’ ‘‘03B’’Effect:Frozen: ‘‘N’’ ‘‘2002’’ ‘‘MUSTANG’’ ‘‘08’’ ‘‘03A’’Effect:Frozen: ‘‘N’’ ‘‘2002’’ ‘‘MUSTANG’’ ‘‘08’’ ‘‘03B’’Effect:Frozen: ‘‘N’’ ‘‘2003’’ ‘‘FOCMUSTANG’’ ‘‘08’’ ‘‘03A’’Effect:Frozen: ‘‘N’’ ‘‘2003’’ ‘‘FOCMUSTANG’’ ‘‘08’’ ‘‘03B’’Effect:Frozen: ‘‘N’’ ‘‘2003’’ ‘‘FOMMUSTANG’’ ‘‘08’’ ‘‘03A’’Effect:Frozen: ‘‘N’’ ‘‘2003’’ ‘‘FOMMUSTANG’’ ‘‘08’’ ‘‘03B’’Effect:Frozen: ‘‘N’’ ‘‘2003’’ ‘‘MUSTANG’’ ‘‘08’’ ‘‘03A’’Effect:Frozen: ‘‘N’’ ‘‘2003’’ ‘‘MUSTANG’’ ‘‘08’’ ‘‘03B’’Effect:Frozen: ‘‘N’’ ‘‘2004’’ ‘‘MUSTANG’’ ‘‘08’’ ‘‘03A’’Effect:Frozen: ‘‘N’’ ‘‘2004’’ ‘‘MUSTANG’’ ‘‘08’’ ‘‘03B’’Output Shaft Speed (OSS) Sensor(id n147998)Removal and Installation03-03 Development Copy1.With the vehicle in NEUTRAL, raise andsupport the vehicle. For additional information,refer to Section 100-02.2.Disconnect the electrical connector.2001 Mustang, 10/2000

308-03B-20Manual Transaxle/Transmission — T45308-03B-20IN-VEHICLE REPAIR (Continued)3.Remove the output shaft speed (OSS) sensor.4.To install, reverse the removal procedure.REMOVALSuperseded by:SGML id ‘‘n51714 ’’Effect:Frozen: ‘‘N’’ ‘‘1999’’ ‘‘FOJMUSTANG’’ ‘‘08’’ ‘‘03B’’Effect:Frozen: ‘‘N’’ ‘‘1999’’ ‘‘FOMMUSTANG’’ ‘‘08’’ ‘‘03B’’Effect:Frozen: ‘‘N’’ ‘‘1999’’ ‘‘MUSTANG’’ ‘‘08’’ ‘‘03B’’Effect:Frozen: ‘‘N’’ ‘‘2000’’ ‘‘FOMMUSTANG’’ ‘‘08’’ ‘‘03B’’Effect:Frozen: ‘‘N’’ ‘‘2000’’ ‘‘MUSTANG’’ ‘‘08’’ ‘‘03B’’Effect:Frozen: ‘‘N’’ ‘‘2000’’ ‘‘SUPPFOJMUST’’ ‘‘08’’ ‘‘03B’’Effect:Frozen: ‘‘N’’ ‘‘2001’’ ‘‘FOJMUSTANG’’ ‘‘08’’ ‘‘03B’’Effect:Frozen: ‘‘N’’ ‘‘2001’’ ‘‘FOMMUSTANG’’ ‘‘08’’ ‘‘03B’’Effect:Frozen: ‘‘N’’ ‘‘2001’’ ‘‘MUSTANG’’ ‘‘08’’ ‘‘03B’’Effect:Frozen: ‘‘N’’ ‘‘2001’’ ‘‘MUSTANG’’ ‘‘08’’ ‘‘03C’’Effect:Frozen: ‘‘N’’ ‘‘2002’’ ‘‘FOMMUSTANG’’ ‘‘08’’ ‘‘03B’’Effect:Frozen: ‘‘N’’ ‘‘2002’’ ‘‘MUSTANG’’ ‘‘08’’ ‘‘03B’’Effect:Frozen: ‘‘N’’ ‘‘2003’’ ‘‘FOCMUSTANG’’ ‘‘08’’ ‘‘03B’’Effect:Frozen: ‘‘N’’ ‘‘2003’’ ‘‘FOMMUSTANG’’ ‘‘08’’ ‘‘03B’’Effect:Frozen: ‘‘N’’ ‘‘2003’’ ‘‘MUSTANG’’ ‘‘08’’ ‘‘03B’’Effect:Frozen: ‘‘N’’ ‘‘2004’’ ‘‘MUSTANG’’ ‘‘08’’ ‘‘03B’’Transmission(id n144509)03-03 Development Copy1.Disconnect the battery ground cable. Foradditional information, refer to Section414-01.2.Remove the gearshift lever knob.2001 Mustang, 10/2000

308-03B-21Manual Transaxle/Transmission — T45308-03B-21REMOVAL (Continued)3.Remove the console panel gearshift plate. Liftthe gearshift lever boot over the gearshift lever.4.Remove the bolts and the shift lever.5.With the vehicle in NEUTRAL, raise andsupport the vehicle. For additional information,refer to Section 100-02.6.Remove the dual converter H-pipe. Foradditional information, refer to Section309-00.7.CAUTION: Index-mark the driveshaftflange and pinion flange, and the driveshaftslip yoke and transmission output shaft.Remove the driveshaft. For additionalinformation, refer to Section 205-01.03-03 Development Copy2001 Mustang, 10/2000

308-03B-22Manual Transaxle/Transmission — T45308-03B-22REMOVAL (Continued)8.Disconnect the reversing lamp switch electricalconnector. Disconnect the wiring harness fromthe transmission.9.Remove the starter motor. For additionalinformation, refer to Section 303-06.10. Remove the bolts.11. Remove the starter solenoid nuts and positionthe wires aside.12. Remove the starter motor.03-03 Development Copy2001 Mustang, 10/2000

308-03B-23Manual Transaxle/Transmission — T45308-03B-23REMOVAL (Continued)13. Disconnect the OSS sensor electrical connector.Disconnect the wiring harness from thetransmission.14. Remove the bolt and the clutch release levercover.15.CAUTION: To prevent componentdamage, do not depress the clutch pedal withthe transmission removed.Disengage the clutch release cable from theclutch release fork.16. Remove the clutch cable retainer and removethe clutch cable from the transmission.03-03 Development Copy2001 Mustang, 10/2000

308-03B-24Manual Transaxle/Transmission — T45308-03B-24REMOVAL (Continued)17. If transmission disassembly is necessary, drainthe transmission fluid.18. Position a transmission jack and support thetransmission.19. Remove the bolts and the transmissioncrossmember.20. Remove the bolts.03-03 Development Copy2001 Mustang, 10/2000

308-03B-25Manual Transaxle/Transmission — T45308-03B-25REMOVAL (Continued)21. Lower the transmission and remove the fivebolts.DISASSEMBLYSuperseded by:SGML id ‘‘n51715 ’’Effect:Frozen: ‘‘N’’ ‘‘1999’’ ‘‘FOJMUSTANG’’ ‘‘08’’ ‘‘03B’’Effect:Frozen: ‘‘N’’ ‘‘1999’’ ‘‘FOMMUSTANG’’ ‘‘08’’ ‘‘03B’’Effect:Frozen: ‘‘N’’ ‘‘1999’’ ‘‘MUSTANG’’ ‘‘08’’ ‘‘03B’’Effect:Frozen: ‘‘N’’ ‘‘2000’’ ‘‘FOMMUSTANG’’ ‘‘08’’ ‘‘03B’’Effect:Frozen: ‘‘N’’ ‘‘2000’’ ‘‘MUSTANG’’ ‘‘08’’ ‘‘03B’’Effect:Frozen: ‘‘N’’ ‘‘2000’’ ‘‘SUPPFOJMUST’’ ‘‘08’’ ‘‘03B’’Effect:Frozen: ‘‘N’’ ‘‘2001’’ ‘‘FOJMUSTANG’’ ‘‘08’’ ‘‘03B’’Effect:Frozen: ‘‘N’’ ‘‘2001’’ ‘‘FOMMUSTANG’’ ‘‘08’’ ‘‘03B’’Effect:Frozen: ‘‘N’’ ‘‘2001’’ ‘‘MUSTANG’’ ‘‘08’’ ‘‘03B’’Transmission(id n144510)Special Tool(s)Special Tool(s)Bearing Puller308-058 (T77J-7025-H)Hub Removal Collet308-242 (T96P-7025-D)Forcing Screw308-092 (T84T-7025-B)Hub Remover Collet Sleeve308-243 (T96P-7025-E)Holding Fixture307-003 (T57L-500-B)Impact Slide Hammer100-001 (T50T-100-A)(Continued)03-03 Development Copy(Continued)2001 Mustang, 10/2000

308-03B-26Manual Transaxle/Transmission — T45308-03B-26DISASSEMBLY (Continued)Special Tool(s)Special Tool(s)Puller307-001 (TOOL-1175-AC) orequivalentRemover and Replacer Tube308-024 (T75L-7025-B)Puller Ring308-059 (T77J-7025-J)Remover and Replacer Tube308-052 (T77J-7025-B)(Continued)03-03 Development Copy1.Remove the clutch release hub and bearing andthe clutch release lever. For additionalinformation, refer to Section 308-01.2.Attach the transmission to the special tool.3.Remove the lower case plug (7A010).2001 Mustang, 10/2000

308-03B-27Manual Transaxle/Transmission — T45308-03B-27DISASSEMBLY (Continued)4.Remove the reversing lamp switch assembly(15520).5.Using the special tools, remove the extensionhousing fluid seal (7052).6.NOTE: Position the gearshift lever (7210) inNEUTRAL.Remove the bolts and the gearshift lever.7.CAUTION: Do not attempt to removethe gearshift offset lever (7F018) with theextension housing (7A039) bolted in place. Alug, located on the bottom of the gearshiftoffset lever, meshes with the detent platepreventing enough rearward movement ofthe gearshift offset lever to allow removal.Using a 5/32-inch drift and a hammer, drive thesplit pin downward as far as possible.03-03 Development Copy2001 Mustang, 10/2000

308-03B-28Manual Transaxle/Transmission — T45308-03B-28DISASSEMBLY (Continued)8.Remove the 11 bolts and the identification tag.9.CAUTION: The gearshift offset lever isunder spring pressure.NOTE: Use a flat-blade screwdriver to separatethe extension housing from the transmissioncase.While applying downward pressure on thegearshift offset lever, remove the extensionhousing and the gearshift offset lever as anassembly.10. Remove the gearshift offset lever, the split pin,the detent spring (7234), and the detent ball(7E172).11. Position the transmission with the output shaft(7061) facing upward.03-03 Development Copy2001 Mustang, 10/2000

308-03B-29Manual Transaxle/Transmission — T45308-03B-29DISASSEMBLY (Continued)12. Remove the full fill seal.13. Remove the retaining ring, the OSS tone wheel(7H150), and the retaining ring.14. Remove the retaining ring.03-03 Development Copy2001 Mustang, 10/2000

308-03B-30Manual Transaxle/Transmission — T45308-03B-30DISASSEMBLY (Continued)15. Using the special tools, remove the output shaftrear bearing (7025). Discard the bearing.16. Remove the retaining ring.17. Remove the selectable thrust washer (7738).03-03 Development Copy2001 Mustang, 10/2000

308-03B-31Manual Transaxle/Transmission — T45308-03B-31DISASSEMBLY (Continued)18. Remove the reverse driven gear (7C238) andthe needle bearing (7N168).19. Remove the bearing spacer (7C240).20. Remove the retaining ring.21. Remove the retaining ring.03-03 Development Copy2001 Mustang, 10/2000

308-03B-32Manual Transaxle/Transmission — T45308-03B-32DISASSEMBLY (Continued)22. Remove the thrust washer (7E254).23. Remove the reverse gear (7142).24. NOTE: Mark the location of the blocking ring(7107) for assembly.Remove the reverse speed blocking ring.25. Remove the split pin from the fifth/reverse gearshifter fork (7230).03-03 Development Copy2001 Mustang, 10/2000

308-03B-33Manual Transaxle/Transmission — T45308-03B-33DISASSEMBLY (Continued)26.CAUTION: Do not damage the hubsplines.Using a brass drift and a hammer, remove thereverse synchronizer hub.27.CAUTION: Prevent the assembly frombind

Transmission Identification The five speed overdrive (T45) transmission is the The transmission identification tag is located underonly manual transmission available for the Mustang the lower left bolt that retains the extension housing4.6L (2V) and the Mustang Cobra 4.6L (4V). to the case. 03-03 Development Copy 2001 Mustang, 10/2000

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