Section 07-03: Transmission, Manual—T5OD
1994 Mustang Workshop Manual
CLEANING AND INSPECTION

Synchronizers

  1. Inspect gear teeth on synchronizer blocking ring (7107) . If there is evidence of chipping or excessively worn teeth, replace with new parts.
  1. Inspect synchronizer blocking ring for wear. To check the wear of synchronizer blocking ring , fit synchronizer blocking ring evenly to gear cone. Measure clearance between side faces of synchronizer blocking ring and gear with a feeler gauge. If clearance is less than 0.8mm (0.031 inch), replace synchronizer blocking ring or gear.

    NOTE: First/second, third/fourth and fifth/reverse synchronizer-to-gear clearance specifications are the same.

  1. Inspect contact between inner surface of reverse (brass) synchronizer blocking ring and cone surface of reverse idler gear and bushing (7141) . To inspect, apply a thin coat of Prussian Blue or equivalent on cone surface of reverse idler gear and bushing and fit it into the synchronizer blocking ring . If the contact pattern is poor, correct this by applying compound and lapping surfaces together.
  1. Inspect synchronizer blocking ring for evidence of wear, flaking, glazing and burned or missing lining material.
  1. Ensure clutch sleeve slides easily onto clutch hub.
  1. Check synchronizer hub inserts (7A044) , inner surface of clutch sleeve, and insert groove on clutch hub for wear.
  1. Check synchronizer blocking spring (7109) / synchronizer hub insert for tension.
 

Shift Fork/Clutch Hub Sleeve

Check the contact surfaces of the gear shifter fork (7230) and clutch hub sleeve for evidence of wear or damage. Verify that clearance exists between gear shifter fork and slot in hub sleeve. Measure from gear shifter fork to the clutch hub sleeve. Clearance should not exceed 0.8mm (0.031 inch).

 

Clutch Hub

  1. Check operation of clutch hub sleeve installed onto hub.
  1. Position clutch hub and sleeve horizontally. Lift the hub approximately three-quarters of the way off the sleeve. Release the hub and observe downward motion. Hub should slide downward into sleeve on its own. It should not be necessary to push hub into sleeve. Service as necessary.