1-2 SHIFT CLASH, GRIND OR HARD TO SHIFT - TR3650 5 SPEED MANUAL TRANSMISSION
Publication Date: December 21, 2004
Some 2004 Mustang vehicles, equipped with the TR3650 5 speed manual transmission, may exhibit a clash or grind noise when shifting from 1st to 2nd gear. There may also be a loss of 2nd gear.
Order and install a synchronizer kit. The kit includes a 2nd main shaft gear, 1-2 synchronizer assembly, 1-2 shift fork and rail, synchro rings and cones and a new transmission fluid and fill label. Refer to the following Service Procedure.
ALL COMPONENTS IN THE KIT ARE REVISED AND MUST BE REPLACED. DO NOT INTERCHANGE.
REFER TO THE WORKSHOP MANUAL SECTION 308-03 TO AID IN THE FOLLOWING PROCEDURE.
Remove the transmission from the vehicle.
Disassemble the transmission assembly.
Remove and replace ALL parts that are included in the kit.
Clean oil from area 1" (26 mm) below the transmission fill plug and install the oil fill sticker included in the kit (Figure 1).
Reinstall the transmission.
Fill the transmission with 6.3 pints (3.0L) of Motorcraft Mercon® Multi-Purpose ATF (XT-2-QDX). The new full fill level is approximately 0.75" (19 mm) below the fill hole.
Figure 1 - Article 04-26-13
Motorcraft Mercon® Multi-Purpose ATF
Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
2004 Mustang: Install Components Included In Kit (Includes Time To Remove And Install Transmission And Final Road Test)