Mustang V8-5.4L SC (2008)
The following procedure is to be used to determine if the synchronizer assemblies in the transmission may have been damaged by attempting to operate
the vehicle with a dragging clutch.
1. Set parking brake.
2. Transmission in neutral.
3. Start engine and allow it to idle.
4. Clutch engaged - pedal fully released.
5. Attempt to shift transmission into first gear by firmly pushing shift lever approximately 5-10 lb-ft (22-45 N.m) force for 2-3 seconds.
6. If the synchronizers are okay, the transmission will not make any clash or grinding noise. You will not be able to move the gearshift lever into the
selected gear (the synchronizer will block out gear engagement) and the engine RPM will decrease slightly.
7. Repeat the synchronizer test (Step 5 and 6) on all of the other forward gears.
a. If the transmission passes the synchronizer test, the transmission will not require additional service; proceed with clutch/flywheel replacement
only. Refer to Clutch Replacement procedure.
b. If clash/grinding noise is found when performing the synchronizer diagnostic, the transmission will need to be repaired along with the
replacement of the clutch. Refer to Transmission Repair procedure.
Clutch Replacement
1. Remove the transmission per 2010 Workshop Manual (WSM), Section 308-03C.
2. Remove and replace flywheel per 2010 WSM, Section 303-01C. Discard old bolts and use new bolts.
3. Install new pilot bearing per 2010 WSM, Section 308-01.
4. Install new clutch disc and plate assembly per 2010 WSM, Section 308-01. Using new bolts.
5. Apply a small amount of Motorcraft(R) PTFE Lubricant to the clutch hub splines per 2010 WSM, Section 308-01.
6. Install new clutch slave cylinder and hydraulic line per 2010 WSM, Section 308-02.
7. Install the transmission per 2010 WSM, Section 308-03C.
8. Refer to Powertrain Control Module (PCM) Reprogramming.
Transmission Repair
1. Remove, drain, disassemble and clean the transmission per 2010 WSM, Section 308-03C.
2. Remove and replace input shaft and all synchronizer assemblies per 2010 WSM, Section 308-03C.
3. Assemble the transmission per 2010 WSM, Section 308-03C.
4. Install the transmission per 2010 WSM, Section 308-03C.
5. Refer to PCM Reprogramming.
PCM Reprogramming
The PCM must be reprogrammed after the clutch is replaced. Reprogram the PCM to the latest calibration using IDS release 65.07 and higher. This new
calibration is not included in the VCM 2010.1 DVD. Calibration files may also be obtained at the website.
