light FORD MUSTANG 2003 Owners Manual

(operating at steady speed, i.e. 64 km/h (40 mph)
regardless of transmission range. Verify by
manually selecting 2nd, OD cancel, and OD. —
REFER to Section 100 - 04 and
Diagnosis By Symptom —
Noise/Vibration Routine 254/354 in
this section for further diagnosis. No ·
GO to Step 4. 4) Is the problem engine-
rpm dependent?
(Occurs at the same engine rpm independent of
transmission gear. Verify by holding same rpm in
each transmission gear.) Yes ·
Not torque converter clutch shudder
— REFER to Section 100 - 04 and
Diagnosis By Symptom —
Noise/Vibration Routine 254/354 in
this section for further diagnosis. No ·
GO to Step 5. 5) Does the problem occur in coast, steady
speed, or reverse range? Yes ·
Not torque converter clutch shudder
— REFER to Section 100 - 04 and
Diagnosis By Symptom —
Noise/Vibration Routine 254/354 in
this section for further diagnosis. No ·
GO to Step 6. 6) Does vibration occur during extended light
brake application? Yes ·
Not torque converter clutch shudder
— REFER to Section 100 - 04 ,
Section 206 - 00 and
Diagnosis By Symptom —
Noise/Vibration Routine
254/354 in this section for further
diagnosis. No ·
GO to Step 7. 7) If one of the driving modes in Step 2 identifies
a vibration which was not present in Steps 3-
6,
then there is a strong possibility that the vibration
is caused by the torque converter clutch function.
Carry out the repair procedures as found under
Disassembly/Assembly. Klj . 3 ba
42003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2748/S3B~us~en~ ...

DIAGNOSIS AND TESTING
Transmission Drive Cycle Test
NOTE:
Always drive the vehicle in a safe manner according to driving conditions and obey all traffic
laws.
NOTE: The Transmission Drive Cycle Test must be followed exactly. Malfunctions must occur four
times consecutively for shift error DTC code to be set, and five times consecutively for continuous TCC
code to set.
NOTE: When carrying out the Transmission Drive Cycle Test, refer to the Solenoid Application Chart
for correct solenoid operation.
After carrying out the Quick Test, use the Transmission Drive Cycle Test for checking continuous
codes.
1. Record and then erase Quick Test codes.
2. Warm engine to normal operating temperature.
3. Make sure transmission fluid level is correct.
4. With transmission in OVERDRIVE, moderately accelerate from stop to 80 km/h (50 mph). This allows the transmission to shift into fourth gear. Hold speed and throttle open steady for a
minimum of 15 seconds.
5. With transmission in fourth gear and maintaining steady speed and throttle opening, lightly apply and release brake to operate stoplamps. Then hold speed and throttle steady for a
minimum of five seconds.
6. Brake to a stop and remain stopped for a minimum of 20 seconds.
7. Repeat steps 4 through 6 at least five times.
8. Carry out Quick Test and record continuous DTCs. zIf the DTCs are still present, refer to the Diagnostic Trouble Code Chart. Repair all non
transmission DTCs first as they can directly affect the operation of the transmission.
Repeat the Quick Test and the Road Test to verify the correction. Erase the DTCs, carry
out the Drive Cycle Test and repeat the Quick Test after completing repair on the DTC.
z If the continuous test passes and a concern is still present, refer to Diagnosis By Symptom in this section, OASIS messages, and TSBs for concerns.
After On- Board Diagnostic
NOTE: The vehicle wiring harness, PCM and non- transmission sensors may affect transmission
operations. Repair these concerns first.
After the on- board diagnostic procedures are completed, repair all DTCs.
Begin with non- transmission related DTCs, then repair any transmission related DTCs. Use the
diagnostic trouble code chart for information on condition and symptoms. This chart will be helpful in
referring to the correct manual(s) and aids in diagnosing internal transmission concerns and external
non- transmission inputs. The pinpoint tests are used in diagnosing transmission electrical concerns.
Make sure that the vehicle wiring harness and the PCM are diagnosed as well. The Powertrain SECTION 307-
01: Automatic Transaxle/Transmission 2003 Mustang Workshop Manual Klj . 1 ba
22003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2748/S3B~us~en~ ...

manual.
P1460 A/C A/C clutch
cycling
pressure
switch error A/C or defrost on
condition may
result from A/C
clutch being on
during on-
board
diagnostic. DTC set during on-
board diagnostic,
repeat with A/C off.
Failed on, EPC
pressure slightly
low with A/C OFF. REFER to the
Powertrain
Control/Emissions
Diagnosis (PC/ED)
manual.
P1636 PCM PCM detected
internal error — — REFER to the
Powertrain
Control/Emissions
Diagnosis (PC/ED)
manual.
P1703 BPP BPP switch
circuit failed. Brake ON/OFF
circuit failure. Failed ON or not
connected —
torque converter
clutch will not
engage at less than
1/3 throttle. Failed
OFF or not
connected —
torque converter
clutch will not
disengage when
brake is applied. REFER to the
Powertrain
Control/Emissions
Diagnosis (PC/ED)
manual.
P1703 BPP Brake not
actuated
during on-
board
diagnostic Brake not cycled
during KOER. Failed OFF or not
connected —
torque converter
clutch will not
engage at less than
1/3 throttle. Failed
OFF or not
connected —
torque converter
clutch will not
disengage when
brake is applied. REFER to the
Powertrain
Control/Emissions
Diagnosis (PC/ED)
manual.
P0740 TCC, wiring,
PCM TCC electrical
circuit failure TCC circuit fails to
provide voltage
drop across
solenoid. Circuit
open or shorted or
PCM driver failed
during on-
board
diagnostic. Short circuit: engine
stalls in second
(OD, 2 range) at
low idle speeds with
brake applied.
Open circuit: torque
converter clutch
never engages.
Flashing
Transmission
Control Indicator
Lamp (TCIL). Go To Pinpoint
Test A .
P1740 TCC TCC
malfunction Mechanical failure
of the solenoid
detected. Failed ON —
Engine stalls in 2nd
(O/D, Manual 2
ranges) at low idle
speeds with brake
applied. Failed OFF
—
Torque
Converter never
applies. Go To Pinpoint
Test F .
P1741
b TCC,
internal Excessive
torque Excessive
variations in slip Engine rpm
oscillation is Go To Pinpoint
Test A . Klj . 6 ba
82003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2748/S3B~us~en~ ...

following areas of possible leakage should also be checked to determine if engine oil leakage is
causing the concern.
a. Leakage at the engine valve cover gasket may allow oil to flow over the torque converter housing or seep down between the torque converter housing and cylinder block causing oil to
be present in or at the bottom of the torque converter housing.
b. Oil galley plug leaks will allow oil to flow down the rear face of the cylinder block to the bottom of the torque converter housing.
c. Leakage at the crankshaft rear oil seal will work back to the flexplate, and then into the torque converter housing.
d. Leakage at engine oil pressure sensor.
Leak Check Test 1. Remove the fluid level indicator and note the color of the fluid. Original factory fill fluid is dyed red to aid in determining if leakage is from the engine or transmission. Unless a considerable
amount of makeup fluid has been added or the fluid has been changed, the red color should
assist in pinpointing the leak.
2. Remove the torque converter housing cover. Clean off any fluid from the top and bottom of the torque converter housing, front of the case and rear face of the engine and oil pan. Clean the
torque converter area by washing with a suitable nonflammable solvent and blow dry with
compressed air.
3. Wash out the torque converter housing, the front of the flexplate and the converter drain plugs. The torque converter housing may be washed out using cleaning solvent and a squirt- type oil
can. Blow all washed areas dry with compressed air.
4. Start and run the engine until the transmission reaches its normal operating temperature. Observe the back of the cylinder block and top of the torque converter housing for evidence of
fluid leakage. Raise the vehicle on a hoist; refer to Section 100 - 02 and run the engine at fast
idle, then at engine idle, occasionally shifting to the Overdrive and Reverse ranges to increase
pressure within the transmission. Observe the front of the flexplate, back of the cylinder block
(in as far as possible), and inside the torque converter housing and front of the case. Run the
engine until fluid leakage is evident and the probable source of leakage can be determined.
Leak Check Test With Black Light Used With 12 Volt Master UV Diagnostic Inspection Kit
Oil soluble aniline or fluorescent dyes premixed at the rate of 2.5ml (1/2 teaspoon) of dye powder to
0.235L (1/2 pint) of transmission fluid have proved helpful in locating the source of fluid leakage. Such
dyes may be used to determine whether an engine oil or transmission fluid leak is present, or if the
fluid in the fluid cooler leaks into the engine cooling system. A black light must be used with the
fluorescent dye solution. Klj . 4 ba
52003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2748/S3B~us~en~ ...

Assembly
1. CAUTION: Before beginning assembly, carry out and inspect the following:
When building up subassemblies and assembling the transmission, ALWAYS use new
gaskets and seals.
All fasteners must be tightened to the torque specification indicated. In addition to
appearing in the section, the necessary torques can be found in the General
Specifications Chart.
When building up subassemblies, each component part should be lubricated with clean
transmission fluid. It is also good practice to lubricate the subassemblies as they are
installed in the case.
Needle bearings, thrust washers and seals should be lightly coated with petroleum jelly
during subassembly buildup or transmission assembly.
Many components and surfaces in the transmission are precision machined. Careful
handling during disassembly, cleaning, inspection and assembly can prevent
unnecessary damage to machined surfaces.
Install the valve body cover plate. 1. Position the valve body cover plate gasket and cover plate.
2. Install the two guide pin bolts.
3. Install the bolts.
2. Tighten the bolts in the sequence shown. Klj . 5 ba
82003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2748/S3B~us~en~ ...

CAUTION: Before beginning assembly, carry out and inspect the following:
When building up subassemblies and assembling the transmission, ALWAYS use new gaskets
and seals.
All fasteners must be tightened to the torque specification indicated. In addition to appearing in
the section, the necessary torques can be found in the General Specifications Chart.
When building up subassemblies, each component part should be lubricated with clean
transmission fluid. It is also good practice to lubricate the subassemblies as they are installed
in the case.
Needle bearings, thrust washers and seals should be lightly coated with petroleum jelly during
subassembly buildup or transmission assembly.
Many components and surfaces in the transmission are precision machined. Careful handling
during disassembly, cleaning, inspection and assembly can prevent unnecessary damage to
machined surfaces.
1. Use the special tools to install the rear case bushing if removed. 1. Position the rear case bushing and the special tool inside the case.
2. Assemble the special tools through the back of the case.
2. Place the transmission in the vertical position.
3. Coat the No. 9 case rear bearing with petroleum jelly and install on the case boss.
4. CAUTION: Be sure the No. 7 needle bearing and direct clutch hub are installed as
shown in the Subassembly section. Internal damage and shift problems may occur. D0AZ-
19584- AA B
MERCON® V Automatic
Transmission Fluid
XT
-5-QM, XT -5-DM MERCON® V Klj . 3 ba
252003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2748/S3B~us~en~ ...

68. Lightly lubricate the converter hub with clean automatic transmission fluid.
69.
WARNING: The torque converter can fall out if the transmission is tipped.
CAUTION: Make sure the converter hub is fully engaged in the front pump support
and gear and rotates freely. Do not damage the hub seal.
CAUTION: If the torque converter slides out, the hub seal may be damaged.
Using the special tools, install the torque converter.
70. Lubricate the torque converter pilot hub with multi- purpose grease. Klj . 24 ba
252003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2748/S3B~us~en~ ...

Pinpoint Tests
PINPOINT TEST A: THE SHIFT INTERLOCK SYSTEM DOES NOT
RELEASE/LOCK CORRECTLY z
The shift control is
out of correct gear
relationship z
Transmission shift
cable and bracket.
z Retainer bracket.
z Shift control linkage
out of adjustment. z
Go To Pinpoint Test B .
z Transmission range
indicator does not
correspond to the
gear z
Transmission shift
cable bracket. z
TIGHTEN the bolts
holding transmission
shift cable bracket.
z Transmission shift
cable loose from the
transmission
retainer bracket. z
TIGHTEN the bolts.
z Shift linkage. zVERIFY digital
transmission range
(DTR) sensor range for
correct adjustment.
REFER to Section 307 -
01 .
z The Transmission
Control Switch (TCS)
Is Inoperative z
CJB Fuse 28 (15A).
z TCS.
z TCS not cycled
during self- test.
z Powertrain control
module (PCM).
z Circuitry. z
Go To Pinpoint Test C .
z The Transmission
Control Indicator
Lamp (TCIL) Is Not
Operating Correctly z
Bulb.
z Instrument cluster.
z Powertrain control
module. z
REFER to Section 413 -
01 .
z Excessive Shift Effort zTransmission shift
cable. z
INSTALL a new
transmission shift cable.
z Cable bracket. zADJUST the cable.
TIGHTEN the screws.
z Transmission Range
Selector Lever Will
Not Shift z
Transmission shift
cable. z
INSTALL a new
transmission shift cable.
z Broken transmission
shift cable. z
INSTALL a new
transmission shift cable. Test Step Result / Action to Take
A1 TEST THE BRAKE LIGHTS
z
Key in ON position.
z Apply the brake pedal and observe the stoplamps.
z Do the stoplamps illuminate? Yes
GO to
A2 .
No
REFER to Section 417 -Klj . 2 ba
62003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2748/S3B~us~en~ ...

PINPOINT TEST D: CLUTCH PEDAL PULSATION clutch disengaged and engine idling, move
the shift lever to a position halfway between
REVERSE and NEUTRAL.
z Slowly engage clutch. The transmission will
behave as if it is in NEUTRAL.
z Gear clash can now be heard if an attempt
is made to shift into REVERSE with the
clutch engaged. Reserve can now be
measured.
z While maintaining light pressure on the shift
selector, slowly press the clutch pedal to the
floor. The gear clash will stop and the shift
selector will slide into the REVERSE
position.
z Is there a minimum 19.05 mm (0.750 inch)
clutch pedal reserve? CHECK the clutch pressure plate and clutch
disc. INSTALL a new clutch pressure plate
or clutch disc if necessary. REFER to
Section 308
- 01 . TEST the system for
normal operation. Test Step Result / Action to Take
D1 CHECK THE CLUTCH PEDAL
PULSATION z
Key in START position.
z With the transmission in NEUTRAL,
slowly press the clutch pedal.
z Does the clutch pedal pulsate while
being pressed? Yes
GO to
D2 .
No
VERIFY customer concern. GO to Symptom Chart if necessary.
D2 INSPECT PRESSURE PLATE BOLTS
z
Inspect the pressure plate- to-flywheel
bolts.
z Are any of the pressure plate- to-
flywheel bolts loose? Yes
TIGHTEN or INSTALL new bolts. REFER to
Section 308
- 01 . TEST the system for normal
operation.
No
GO to D3 .
D3 INSPECT THE CLUTCH PRESSURE
PLATE z
Remove the clutch pressure plate.
Refer to Section 308 - 01 .
z INSPECT the clutch pressure plate for
damage. Refer to Pressure Plate Check .
z Are there any signs of damage
present on the clutch pressure plate? Yes
INSTALL a new clutch pressure plate. REFER
to
Section 308 - 01 . TEST the system for normal
operation.
No
GO to D4 .
D4 INSPECT THE CLUTCH DISC
z
Carry out the clutch disc inspection
procedure. Refer to Disc Check .
z Is the clutch disc OK? Yes
GO to
D5 .
No
INSTALL a new clutch disc. REFER to Section 308 - 01 . TEST the system for normal operation.
D5 INSPECT THE FLYWHEEL Klj . 9 ba
152003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2308/S3B~us~en~ ...

13. Remove the self-
adjusting mechanism.
14. Remove the self- adjusting mechanism shaft bushings.
Installation 1. NOTE: Before the installation of the clutch pedal shaft or clutch pedal, remove and inspect the
brake and clutch pedal bushings. Clean and lubricate with a light film of engine oil meeting Ford
specification WSS- M2C153-G and replace the brake and clutch pedal bushing if excessive wear
is evident.
To install, reverse the removal procedure. Klj . 4 ba
62003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2308/S3B~us~en~ ...