FORD MUSTANG 2003 Owners Manual

information, REFER to
Section 205
- 00 .
REPAIR as necessary.
z Transmission
rumble/growl— noise at
all speeds in forward
gears, more
pronounced in a heavy
acceleration condition z
Damaged or worn
transmission
bearing or gears
(high mileage
vehicles). z
CHECK transmission
fluid for excessive
metal particles.
REPAIR as necessary.
REFER to Section 308 -
03A for T50D
transmissions or
Section 308 - 03B for
TR3650 transmissions.
z Transfer case whine—
noise at all ranges z
Incorrect fluid level
or fluid quality. z
CHECK that the
transfer case is filled to
the correct level and
with the specified fluid.
REFER to Section 308 -
03A for T50D
transmissions or
Section 308 - 03B for
TR3650 transmissions.
z Worn oil pump. zDISASSEMBLE the
transfer case. CHECK
the oil pump for wear or
damage. REPAIR as
necessary.
z Under- inflated or
oversized tires. z
CONFIRM that the tires
and wheels are correct
for the vehicle. CHECK
that the tire inflation
pressures are correct.
z Transfer case
growl/rumble— noise at
all ranges (A small
amount of planetary
noise can be heard
when the transfer case
is operated in low
range.) z
Damaged or worn
bearings or
planetary gear. z
DISASSEMBLE the
transfer case. CHECK
the bearings or
planetary gear for wear
or damage. REPAIR as
necessary.
z Transfer case
scraping/grating—
noise at all ranges z
Excessively
stretched drive
chain hitting the
case. z
DISASSEMBLE the
transfer case. CHECK
the drive chain for wear
or damage. REPAIR as
necessary.
z Transfer case
howl/hum— noise at all
ranges or high range
only z
Worn or damaged
sun (input) gear,
clutch pack
(intermediate) gear
or output shaft gear. z
DISASSEMBLE the
transfer case. CHECK
the gears for wear or
damage. REPAIR as
necessary.
z Transfer case
howl/hum— noise at
low range only z
Worn or damaged
intermediate gear
and sliding gears
(clutch pack). z
DISASSEMBLE the
transfer case. CHECK
the gears for wear or
damage. REPAIR as
necessary.
z Transfer case
vibration— vibration felt
with vehicle in 4WD z
Transfer case
mounting.
z Driveshaft out of
balance.
z Excessive pinion z
Go To Pinpoint Test M . Klj . 44 ba
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flange runout.
Symptom Chart—
Transmission (Automatic) Noise/Vibration Condition
Possible Sources Action
z Rattle— occurs
at idle or at
light
acceleration
from a stop z
Damaged engine or
transmission mounts. z
CHECK the
powertrain/drivetrain mounts
for damage. REPAIR or
INSTALL new mounts as
necessary.
z A loose front exhaust
pipe heat shield. z
REPAIR or INSTALL a new
heat shield as necessary.
z Loose inspection
plate or dust cover
plate. z
CHECK for loose bolts.
TIGHTEN to specifications.
REFER to Section 307 - 01 .
z Loose flex plate to
converter nuts. z
CHECK for loose nuts.
TIGHTEN to specifications.
REFER to Section 307 - 01 .
z Whine— pitch
increases with
vehicle speed.
Starts in first
and second
gear,
decreases or
goes away at
higher gears z
Damaged or worn low
one- way clutch.
z Damaged or worn
intermediate one- way
clutch.
z Friction elements.
z Damaged or worn
planetary or sun gear. z
INSPECT the transmission
for wear or damage. REPAIR
or INSTALL new components
as necessary. REFER to
Section 307 - 01 .
z Whine— the
pitch changes
with engine
speed z
A worn or damaged
accessory drive
component. z
CARRY OUT the Engine
Accessory Test. REPAIR or
INSTALL new components as
necessary.
z Incorrect fluid level. zCHECK that the transmission
is filled to the correct level.
ADD fluid as necessary.
REFER to Section 307 - 01 .
z Partially blocked filter. zINSPECT the filter. CLEAN or
INSTALL a new filter as
necessary. REFER to Section 307 - 01 .
z Worn or damaged
torque converter. z
CARRY OUT the torque
converter service and
replacement check. REFER
to Section 307 - 01 .
z Worn or damaged
front pump. z
INSPECT the front pump.
INSTALL a new front pump
as necessary. REFER to
Section 307 - 01 .
z Whine— pitch
changes with
vehicle speed z
Speedometer cable
or gears. z
REPAIR or INSTALL new
cables or gears as necessary.
z Whine/moan
type noise—
pitch increases
or changes
with vehicle
speed z
Damaged engine or
transmission mount. z
CHECK the
powertrain/drivetrain mounts
for damage. CARRY OUT
Powertrain/Drivetrain Mount Neutralizing in this section.
z U-joints worn or zINSPECT the U- joints for Klj . 45 ba
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damaged.
wear or damage. INSTALL
new U-joints as necessary.
REFER to Section 205 - 01 .
z Damaged or worn
differential ring and
pinion. z
INSPECT the differential ring
and pinion for damage.
CARRY OUT the Checking
Tooth Contact Pattern and
Condition of the Ring and
Pinion component test in this
section. REPAIR or INSTALL
a new differential ring and
pinion as necessary. REFER
to Section 205 - 02A for Ford
7.5 rear axles or Section 205 -
02B for Ford 8.8 integral
axles.
z Planetary gears
nicked or chipped. z
CHECK the planetary gears
for damage. INSTALL new
components as necessary.
REFER to Section 307 - 01 .
z Whistle— noise
is high pitched,
constant.
Changes in
pitch with
throttle position z
Hydraulic pressure in
the main control. z
INSPECT the main control.
REPAIR or INSTALL new
components as necessary.
REFER to Section 307 - 01 .
z Incorrect band/clutch
apply pressure. z
CARRY OUT the line
pressure tests. REPAIR or
INSTALL components as
necessary. REFER to Section 307 - 01 .
z Worn or damaged
torque converter. z
CARRY OUT the torque
converter service and
replacement check. REFER
to Section 307 - 01 .
z Clunk— occurs
when shifting
from PARK to
a drive or
reverse
position z
Damaged powertrain
mounts. z
INSPECT the powertrain
mounts for damage. INSTALL
new mounts as necessary.
z Damaged or worn
pinion bearings. z
CHECK for abnormal bearing
play or roughness. INSTALL
new bearings as necessary.
REFER to Section 205 - 02A
for Ford 7.5 rear axles or
Section 205
- 02B for Ford 8.8
integral axles.
z Worn or galled
driveshaft slip yoke
splines. z
CLEAN and INSPECT the
splines of the yoke. INSTALL
a new slip yoke as necessary.
REFER to Section 205 - 01 .
z Worn friction
elements or
excessive clutch pack
end plate play. z
INSPECT the transmission
for wear. CHECK that all end
play and clearances are
within specification. REPAIR
or INSTALL new components
as necessary. REFER to
Section 307 - 01 . Klj . 46 ba
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Pinpoint Tests
The pinpoint tests are a step-by-
step diagnostic process designed to determine the cause of a z
Bump—occurs
when shifting
from PARK to
a drive or
reverse
position.
Similar to
Clunk but with
no sound z
Initial gear
engagement. z
Acceptable condition.
z Buzz or hiss zIncorrect driveline
angles. z
CHECK for correct driveline
angles. REPAIR as
necessary. REFER to Section 205 - 00 .
z Worn or damaged
main control
solenoids or valves. z
Using a transmission tester,
ACTIVATE the solenoids to
duplicate sound. INSTALL
new components as
necessary. REFER to Section 307 - 01 .
z Vibration— a
high frequency
(20–80 Hz) that
is felt through
the seat or
gear shifter.
Changes with
engine speed z
Transmission cooler
lines grounded out. z
CHECK the transmission
cooler lines. REPAIR as
necessary.
z Flexplate to torque
converter nuts loose. z
CHECK the flexplate nuts.
TIGHTEN to specification.
REFER to Section 307 - 01 .
z Fluid filler tube
grounded out. z
CHECK the fluid filler tube.
REPAIR as necessary.
z Shift cable incorrectly
routed, grounded out
or loose. z
CHECK the shift cable.
REPAIR as necessary.
Section 307 - 05 .
z Shutter or
chatter—
occurs with
light to medium
acceleration
from low
speeds or a
stop z
Electrical
inputs/outputs.
z Vehicle wiring
harness.
z Incorrect
inputs/outputs from
the powertrain control
module (PCM), digital
transmission range
(TR) sensor, brake
pedal position (BPP)
sensor, throttle
position (TP) sensor,
transmission speed
sensor (TSS), output
speed shaft (OSS)
sensor or the torque
converter clutch
(TCC). z
CARRY OUT a Torque
Converter Clutch Operation
Test. RUN on- board
diagnostics or self- test.
REFER to Section 307 - 01 .
CLEAR the DTC's, ROAD
TEST and RERUN on- board
diagnostics or self- test. Klj . 47 ba
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condition. It may not always be necessary to follow a pinpoint test to its conclusion. Carry out only the
steps necessary to correct the condition. Then, test the system for normal operation. Sometimes, it is
necessary to remove various vehicle components to gain access to the component requiring testing.
Reinstall all components after verifying system operation is normal.
PINPOINT TEST A: BRAKE VIBRATION/SHUDDER
Test Step Result / Action to Take
A1 ROAD TEST THE VEHICLE—
LIGHT BRAKING z
Check that the wheel and tires are correct for the vehicle.
Inspect the tires for abnormal wear patterns.
z Road test the vehicle. Warm the brakes by slowing the vehicle
a few times from 80– 32 km/h (50 to 20 mph) using light braking
applications. At highway speeds of 89–97 km/h (55- 60 mph),
apply the brake using a light pedal force.
z Is there a vibration/shudder felt in the steering wheel, seat
or brake pedal? Yes
GO to
A4 .
No
GO to A2 .
A2 ROAD TEST THE VEHICLE—
MODERATE TO HEAVY
BRAKING z
Road test the vehicle. At highway speeds of 89–97 km/h (55- 60
mph), apply the brake using a moderate to heavy pedal force.
z Is there a vibration/shudder? Yes
For vehicles with ABS,
GO to
A3 . For vehicles
with standard brakes,
GO to A4 .
No
Vehicle is OK. VERIFY
condition with customer.
TEST the vehicle for
normal operation. A3 NORMAL ACTUATION OF THE ABS SYSTEM DIAGNOSIS
z
During moderate to heavy braking, noise from the hydraulic
control unit (HCU) and pulsation in the brake pedal can be
observed. Pedal pulsation coupled with noise during heavy
braking or on loose gravel, bumps, wet or snowy surfaces is
acceptable and indicates correct functioning of the ABS
system. Pedal pulsation or steering wheel nibble, (frequency is
proportioned to the vehicle speed) indicates a concern with a
brake or suspension component.
z Is the vibration/shudder vehicle speed sensitive? Yes
GO to
A5 .
No
The brake system is
operating correctly. A4 APPLICATION OF THE PARKING BRAKE
z
NOTE: Begin at the front of the vehicle unless the vibration or
shudder has been isolated to the rear.
z This test is not applicable to vehicles with drum- in-hat type
parking brakes. For vehicles with drum- in-hat parking brakes,
proceed to the next test. For all other vehicles, apply the
parking brake to identify if the problem is in the front or rear
brake. At highway speeds of 89–97 km/h (55- 60 mph), lightly
apply the parking brake until the vehicle slows down. Release
the parking brake immediately after the test.
z Is there a vibration/shudder? Yes
GO to
A7 .
No
GO to A5 .
A5 CHECK THE FRONT WHEEL BEARINGS
z
Check the front wheel bearings. Refer to Wheel Bearing Check in this section.
z Are the wheel bearings OK? Yes
GO to
A6 . Klj . 48 ba
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PINPOINT TEST B: ENGINE TICKING NOISE No
INSPECT the wheel
bearings. ADJUST or
REPAIR as necessary.
TEST the system for
normal operation.
A6 CHECK THE FRONT SUSPENSION
z
Check the front suspension for:
zBroken or loose bolts.
z Damaged springs.
z Worn or damaged upper and lower control arm
bushings.
z Loose or rough front bearings.
z Uneven tire wear.
z Are all the suspension components in satisfactory
condition? Yes
GO to
A7 .
No
REPAIR or INSTALL
new components as
necessary. TEST the
system for normal
operation. A7 RESURFACE THE FRONT BRAKE DISCS
z
CAUTION: Do not use a bench lathe to machine brake
discs.
z NOTE: Follow the manufacturer's instructions to machine the
brake discs. After machining, make sure the brake disc meets
the thickness specification.
z Refer to Brake Disc Machining in this section. Resurface the
front brake discs. Road test the vehicle.
z Is the vibration/shudder present? Yes
GO to
A8 .
No
Vehicle is OK. A8 CHECK THE REAR SUSPENSION
z
Check the rear suspension for:
zBroken or loose bolts.
z Damaged or worn springs or spring bushings.
z Worn or damaged upper and lower control arm
bushings.
z Worn or damaged trailing arms.
z Loose or rough rear bearings.
z Uneven tire wear.
z Are all the suspension components in satisfactory
condition? Yes
GO to
A9 .
No
REPAIR or INSTALL
new components as
necessary. TEST the
system for normal
operation. A9 RESURFACE THE REAR BRAKE DISC OR DRUM
z
CAUTION: Do not use a bench lathe to machine brake
discs.
z NOTE: Follow the manufacturers instructions to machine the
brake discs. After machining, make sure the brake disc meets
the thickness specification.
z Refer to Brake Disc Machining in this section. Resurface the
rear brake discs or drums. Road test the vehicle.
z Is the vibration/shudder present? Yes
CHECK the front
suspension for wear or
damage. RESURFACE
the front brake discs.
TEST the system for
normal operation.
No
Vehicle is OK.
Test Step Result / Action to Take
B1 CHECK FOR TICKING NOISE AT THE FUEL
RAIL z
Disconnect the first fuel line clip. Yes Klj . 49 ba
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z
Is the ticking noise gone? CHECK for TSB for applicable vehicle.
REPAIR as necessary. TEST the system
for normal operation.
No
GO to
B2 .
B2 CHECK FOR TICKING NOISE AT THE FUEL
INJECTOR z
Using an EngineEAR, listen at the fuel
injectors by placing a probe on each injector.
To isolate the faulty injector, disconnect the
injector electrical connector and listen for the
noise.
z Is the fuel injector the source of the ticking
noise? Yes
INSTALL a new fuel injector. REFER to
Section 303
- 04A for 3.8L engines or
Section 303 - 04B for 4.6L (2V) engines.
TEST the system for normal operation.
No
GO to B3 .
B3 CHECK THE BELT TENSIONER FOR TICKING
NOISE z
Inspect the accessory drive. Check for the belt
tensioner bottoming at end of travel or not at
end of stroke.
z Using an EngineEAR, listen at the belt
tensioner.
z Is the belt tensioner the source of the
noise? Yes
INSTALL a new belt tensioner. TEST the
system for normal operation.
No
GO to
B4 .
B4 CHECK THE WATER PUMP FOR TICKING
NOISE z
Using an EngineEAR, listen at the water pump
for ticking noise.
z Is the water pump the source of the noise? Yes
INSTALL a new water pump. REFER to
Section 303
- 03A . TEST the system for
normal operation.
No
GO to B5 .
B5 CHECK FOR AN OBSTRUCTION OF THE
COOLING FAN z
Inspect the cooling fan for obstructions.
z Check the cooling fan and shroud for wear or
damage.
z Was there an obstruction or does the
cooling fan show signs of damage? Yes
REPAIR or INSTALL a new cooling fan.
REFER to
Section 303 - 03A . TEST the
system for normal operation.
No
GO to B6 .
B6 CHECK THE OIL PUMP FOR TICKING NOISE
z
Check the oil pump using EngineEARs and
probe at the oil filter adapter to verify the oil
pump as a source.
z Is the oil pump the source of the noise? Yes
INSTALL a new oil pump. REFER to
Section 303
- 01A for 3.8L engines or
Section 303 - 01B for 4.6L (2V) engines.
TEST the system for normal operation.
No
GO to B7 .
B7 CHECK VALVE LIFTERS OR LASH
ADJUSTERS FOR CORRECT OPERATION z
Check valve lifter/lash adjuster for correct
operation, using EngineEARs.
z Are the valve lifters/lash adjusters Yes
VERIFY customer concern. CONDUCT a
diagnosis of other suspect components. Klj . 50 ba
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PINPOINT TEST C: ACCESSORY DRIVE BEARING HOOT
PINPOINT TEST D: POWER STEERING MOAN
PINPOINT TEST E: ENGINE DRIVEN COOLING FAN MOAN operating correctly?
No
INSTALL a new valve lifter/lash adjuster
(s). TEST the system for normal
operation.
Test Step Result / Action to Take
C1 CHECK THE IDLER AND TENSIONER
PULLEY BEARINGS z
Carry out the Vehicle Cold Soak
Procedure in this section.
z Key in START position.
z Place an EngineEAR probe directly on the
pulley center post or bolt to verify which
bearing is making the noise.
z Key in OFF position.
z Is either bearing making the noise? Yes
INSTALL a new pulley/idler. CARRY OUT the
Vehicle Cold Soak Procedure and TEST the
system for normal operation.
No
CONDUCT a diagnosis on other suspect
accessory drive components.
Test Step Result / Action to Take
D1 CHECK THE POWER STEERING
SYSTEM z
Carry out the Vehicle Cold Soak
Procedure in this section.
z Key in START position.
z Turn the steering wheel while the noise
is occurring and listen for changes in
sound pitch or loudness.
z Key in OFF position.
z Does the sound pitch or loudness
change while turning the steering
wheel? Yes
GO to
D2 .
No
CONDUCT a diagnosis on other suspect
accessory drive components. D2 VERIFY THE SOURCE
z
Key in START position.
z Place an EngineEAR probe near the
power steering pump/reservoir while the
noise is occurring. While an assistant
turns the steering wheel, listen for
changes in sound pitch or loudness.
z Key in OFF position.
z Does the sound pitch or loudness
change while turning the steering
wheel? Yes
VERIFY that the supply tube to the pump is
unobstructed. CHECK the fluid condition and
level. DRAIN the fluid and REFILL. CARRY
OUT the Vehicle Cold Soak Procedure and
TEST the system for normal operation. REFER
to Section 211
- 02 .
No
Normal system operation. Test Step Result / Action to Take
E1 CHECK THE ENGINE DRIVEN COOLING
FAN AFTER A COLD SOAK Klj . 51 ba
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PINPOINT TEST F: DRUMMING NOISE z
Carry out the Vehicle Cold Soak Procedure
in this section.
z Key in START position.
z Assess the airflow.
z Raise the engine speed to 1500 rpm while
listening for the moan to increase in
proportion to the airflow.
z Key in OFF position.
z Does the moan increase in proportion to
the airflow? Yes
TEST the fan for normal operation. If the
fan tests normal, GO to
E2 . Otherwise,
REPAIR as necessary.
No
Normal system operation. E2 CHECK THE ENGINE DRIVEN COOLING
FAN AT NORMAL OPERATING TEMPERATURE z
Key in START position.
z Run the engine to normal operating
temperature while listening for the moan to
stop.
z Key in OFF position.
z Does the moan stop? Yes
Normal clutch operation.
No
INSTALL a new fan clutch. TEST the
system for normal operation.
Test Step Result / Action to Take
F1 CHECK THE EXHAUST SYSTEM
z
Key in START position.
z Increase the engine rpm until the noise is the loudest. Note
the engine rpm.
z Key in OFF position.
z Add approximately 9 kg (20 lb) of weight to the exhaust
system. First place the weight at the tail pipe and test, then
at the front pipe.
z Key in START position.
z Increase the engine rpm and listen for the drumming noise.
Note the engine rpm if the noise occurs.
z Key in OFF position.
z Using a vibration analyzer (VA), determine the amount of
vibration that occurs with the drumming noise.
z Is the noise/vibration reduced or eliminated, or does the
noise/vibration occur at a different rpm? Yes
CARRY OUT
Exhaust System Neutralizing in this
section. TEST the system
for normal operation.
No
GO to F2 .
F2 POWERTRAIN/DRIVETRAIN MOUNT NEUTRALIZING
z
Carry out Powertrain/Drivetrain Mount Neutralizing in this
section. Test the system for normal operation.
z Is the noise reduced or eliminated? Yes
Vehicle OK. TEST the
system for normal
operation.
No Klj . 52 ba
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PINPOINT TEST G: ENGINE TICKING, KNOCKING OR CONTINUOUS
RATTLE
PINPOINT TEST H: FRONT SUSPENSION NOISE CONDUCT diagnosis of
other suspect components.
Test Step Result / Action to Take
G1 CHECK FOR NOISE AT THE VALVE COVERS
AND THE FRONT COVERS (OHC ENGINES) z
Carry out the Vehicle Cold Soak Procedure in
this section.
z Key in START position.
z NOTE: For a short- duration ticking noise,
multiple engine starts may be necessary.
z Using an EngineEAR, listen closely at the valve
covers and the front covers (OHC engines) by
placing the probe near the surface of the valve
cover and then on the surface front cover.
z Key in OFF position.
z Is the noise source apparent? Yes
REMOVE the appropriate cover and
INSPECT for loose, worn/broken
components. REPAIR as necessary.
TEST the system for normal operation.
No
GO to
G2 .
G2 CHECK FOR NOISE AT THE CYLINDER
BLOCK z
Key in START position.
z Using an EngineEAR, listen closely at the
cylinder block by placing a probe on or near
each freeze plug.
z Key in OFF position.
z Is the noise source apparent? Yes
REPAIR or INSTALL new components
as necessary.
No
GO to
G3 .
G3 CHECK FOR NOISE WHILE DISCONNECTING
EACH FUEL INJECTOR ELECTRICAL
CONNECTOR, ONE AT A TIME z
Key in START position.
z Disconnect each fuel injector electrical
connector, one at a time, to decrease piston
force and listen for the noise.
z Key in OFF position.
z Is the noise reduced or eliminated? Yes
INSTALL a new fuel injector. TEST the
system for normal operation.
No
INSPECT accessory drive system or the
transmission as a possible source.
Test Step Result / Action to Take
H1 ROAD TEST THE VEHICLE
z
Test drive the vehicle.
z NOTE: An assistant will be needed for this road test.
z During the road test, drive the vehicle over a rough road.
Using ChassisEARs, determine from which
area/component the noise is originating.
z Is there a squeak, creak or rattle noise? Yes
GO to
H2 .
No
The suspension system is
OK. CONDUCT a diagnosis
on other suspect systems. H2 INSPECT THE STEERING SYSTEM
Yes Klj . 53 ba
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