TR3650 MANUAL TRANSMISSION - JUMPS OUT OF GEAR 2ND AND/OR 3RD - CLASH NOISE AND/OR RASPY FEEL ON GEAR ENGAGEMENT
Publication Date: July 20, 2004
Some 2001-2003 Mustang vehicles, equipped with TR3650 5 speed manual transmission may exhibit a clash noise and/or a raspy (rough) feel on gear engagement during 1-2 or 2-3 shifts. The transmission may also exhibit a jump-out from 2nd and/or 3rd gear. The condition may be more pronounced when the transmission is colder than 40° F (5° C).
To service, install a Synchro Kit. The kit includes 2nd main shaft gear, 1-2 synchronizer assembly, 3rd main shaft gear, 3-4 synchronizer assembly, the 1-2 and 3-4 shift fork and rail assemblies, blocking rings and an oil fill level sticker. Add new transmission fluid and fill to the revised lower level. Refer to the following Service Procedure.
ALL COMPONENTS IN THE KIT ARE REVISED AND MUST BE REPLACED.
BLOCKING RINGS MAY APPEAR DIFFERENT THAN THOSE BEING REMOVED FROM THE TRANSMISSION.
REFER TO THE WORKSHOP MANUAL SECTION 308-03 TO AID IN THE FOLLOWING PROCEDURE.
Remove the transmission from the vehicle.
Disassemble the transmission.
Install all of the revised components included in kit 3R3Z-7124-AC.
Clean oil from area 26 mm (1") below the transmission fill plug (Figure 1) and install the oil fill sticker included in the kit.
Figure 1 - Article 04-15-6
THIS TSB DOES NOT AUTHORIZE REPLACEMENT OF THE CLUTCH ASSEMBLY AND RELEASE BEARING FOR NORMAL WEAR. IF SUFFICIENTLY WORN, THE CUSTOMER MAY WISH TO HAVE THEM REPLACED AT THEIR EXPENSE. SOME DISCOLORATION AND LIGHT SCRATCHES ON THE FLYWHEEL OR PRESSURE PLATE ARE CONSIDERED NORMAL AND RESURFACING IS NOT REQUIRED.
Reinstall the transmission.
Fill the transmission with 3.0 liters (6.3 pints) of Motorcraft Mercon ATF (XT-2-QDX). The full fill level is approximately 19 mm (0.75") below the fill hole.
SHIFT QUALITY MAY IMPROVE FURTHER WITH BREAK IN, APPROXIMATELY 644 KILOMETERS (400 MILES) OF DRIVING.
Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
Install Components Included In Kit (Includes Time To Remove And Install Transmission And Final Road Test)