FORD MUSTANG 2003 Workshop Manual

PINPOINT TEST I: REAR SUSPENSION NOISE z
WARNING: The electrical power to the air
suspension system must be shut off prior to hoisting,
jacking or towing an air suspension vehicle. This can
be accomplished by turning off the air suspension
switch. Failure to do so can result in unexpected
inflation or deflation of the air springs, which can result
in shifting of the vehicle during these operations.
z Raise and support the vehicle.
z Check the steering system for wear or damage. Carry out a
steering linkage test. Refer Section 211 - 00 .
z Inspect the tire wear pattern. Refer to Tire Wear Patterns
chart in this section.
z Are the steering components worn or damaged? REPAIR the steering
system. INSTALL new
components as necessary.
TEST the system for normal
operation.
No
GO to
H3 .
H3 FRONT SHOCK ABSORBER/STRUT CHECK
z
Check the front shock absorbers/strut mounts for loose
bolts or nuts.
z Check the front shock absorbers/struts for wear or damage.
Carry out a "bounce test".
z Are the front shock absorbers/struts loose or
damaged? Yes
TIGHTEN to specifications if
loose. INSTALL new front
shock absorbers/struts if
damaged. TEST the system
for normal operation.
No
GO to
H4 .
H4 CHECK THE FRONT SPRINGS
z
Check the front spring and front spring mounts/brackets for
wear or damage.
z Are the front springs or spring mounts/brackets worn
or damaged? Yes
REPAIR or INSTALL new
components as necessary.
TEST the system for normal
operation.
No
GO to
H5 .
H5 CHECK THE CONTROL ARMS/RADIUS ARMS
z
Inspect the control arm bushings for wear or damage.
z Inspect for twisted or bent control/radius arm.
z Are the control/radius arms damaged or worn? Yes
REPAIR or INSTALL new
components as necessary.
TEST the system for normal
operation.
No
GO to
H6 .
H6 CHECK THE STABILIZER BAR/TRACK BAR
z
Check the stabilizer bar/track bar bushings and links for
damage or wear.
z Check the stabilizer bar/track bar for damage.
z Check for loose or damaged stabilizer bar isolators or
brackets.
z Are the stabilizer bar/track bar components loose, worn
or damaged? Yes
REPAIR or INSTALL new
components as necessary.
TEST the system for normal
operation.
No
Suspension system OK.
CONDUCT diagnosis on
other suspect systems.
Test Step Result / Action to Take Klj . 54 ba
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PINPOINT TEST J: WHEEL AND TIRE I1 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
I2 .
No
The suspension system is
OK. Conduct a diagnosis on
other suspect systems. I2 REAR SHOCK ABSORBER/STRUT CHECK
z
WARNING: The electrical power to the air
suspension system must be shut off prior to hoisting,
jacking or towing an air suspension vehicle. This can
be accomplished by turning off the air suspension
switch. Failure to do so can result in unexpected
inflation or deflation of the air springs, which can result
in shifting of the vehicle during these operations.
z Raise and support the vehicle.
z Check the rear shock absorber/strut mounts for loose bolts
or nuts.
z Check the rear shock absorbers/struts for damage. Carry
out a shock absorber check.
z Are the rear shock absorbers/struts loose or damaged? Yes
TIGHTEN to specifications if
loose. INSTALL new rear
shock absorbers/struts if
damaged. TEST the system
for normal operation.
No
GO to
I3 .
I3 CHECK THE REAR SPRINGS
z
Check the rear springs and rear spring mounts/brackets for
wear or damage.
z Are the rear springs or spring mounts/brackets worn or
damaged? Yes
REPAIR or INSTALL new
components as necessary.
TEST the system for normal
operation.
No
GO to
I4 .
I4 CHECK THE CONTROL ARMS/TRAILING ARMS
z
Inspect the control arm/trailing arm bushings for wear or
damage. Check for loose control arm/trailing arm bolts.
z Inspect for twisted or bent control arm/trailing arms.
z Are the control arm/trailing arms loose, damaged or
worn? Yes
REPAIR or INSTALL new
components as necessary.
TEST the system for normal
operation.
No
GO to
I5 .
I5 CHECK THE STABILIZER BAR/TRACK BAR
z
Check the stabilizer bar/track bar bushings and links for
damage or wear.
z Check the stabilizer bar/track bar for damage.
z Check for loose or damaged stabilizer bar isolators or
brackets.
z Are the stabilizer bar/track bar components loose, worn
or damaged? Yes
REPAIR or INSTALL new
components as necessary.
TEST the system for normal
operation.
No
Suspension system OK.
CONDUCT diagnosis on
other suspect systems.
Test Step
Result / Action to Klj . 55 ba
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Take
J1 ROAD TEST THE VEHICLE
z
NOTE: Wheel or tire vibrations felt in the steering wheel are most
likely related to the front wheel or tire. Vibration felt through the
seat are most likely related to the rear wheel or tire. This may not
always be true, but it can help to isolate the problem to the front
or rear of the vehicle.
z Test drive the vehicle at different speed ranges.
z During the road test, if the vibration can be eliminated by placing
the vehicle in neutral or is affected by the speed of the engine,
the cause is not the wheels or tires.
z Is there a vibration and noise? Yes
GO to
J2 .
No
The wheel and tires
are OK. CONDUCT a
diagnosis on other
suspect systems. J2 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
J3 .
No
INSPECT the wheel
bearings. ADJUST or
REPAIR as necessary.
TEST the system for
normal operation. J3 INSPECT THE TIRES
z
Check the tires for missing weights.
z Check the wheels for damage.
z Inspect the tire wear pattern. Refer to the Tire Wear Patterns
chart in this section.
z Do the tires have an abnormal wear pattern? Yes
CORRECT the
condition that caused
the abnormal wear.
INSTALL new tire(s).
TEST the system for
normal operation.
No
GO to
J4 .
J4 TIRE ROTATION
z
Spin the tires slowly and watch for signs of lateral runout.
z Spin the tires slowly and watch for signs of radial runout. Yes
GO to
J5 .
No
CHECK the wheel and
tire balance.
CORRECT as
necessary. TEST the
system for normal
operation. Klj . 56 ba
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z
Are there signs of visual runout? J5 RADIAL RUNOUT CHECK ON THE TIRE
z
Measure the radial runout of the wheel and tire assembly. A
typical specification for total radial runout is 0.045 inch.
z Is the radial runout within specifications? Yes
GO to
J8 .
No
GO to J6 .
J6 RADIAL RUNOUT CHECK ON THE WHEEL
z
Measure the radial runout of the wheel. A typical specification for
total radial runout is 0.045 inch.
z Is the radial runout within specifications? Yes
INSTALL a new tire.
TEST the system for
normal operation.
No
GO to
J7 .
J7 CHECK THE HUB/BRAKE DISC OR DRUM PILOT RUNOUT OR
BOLT CIRCLE RUNOUT z
Measure the pilot or bolt circle runout. A typical specification for
radial runout is:
zPilot runout— less than 0.15 mm (0.006 inch).
z Bolt circle runout— less than 0.38 mm (0.015 inch).
z Is the radial runout within specifications? Yes
INSTALL a new wheel.
TEST the system for
normal operation.
No
REPAIR or INSTALL
new components as
necessary. REFER to
Section 204
- 01 for the
front wheels or Section 204 - 02 for the rear
wheels. J8 LATERAL RUNOUT CHECK ON THE TIRE
z
Measure the lateral runout of the wheel and tire assembly. A
typical specification for total lateral runout is 1.14 mm (0.045
inch). Yes
Wheel and tires OK.
CONDUCT diagnosis
on other suspect
systems. Klj . 57 ba
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PINPOINT TEST K: HIGH SPEED SHAKE OR SHIMMY z
Is the lateral runout within specifications? No
GO to
J9 .
J9 LATERAL RUNOUT CHECK ON THE WHEEL
z
Measure the lateral runout of the wheel. A typical specification for
total radial runout is 1.14mm (0.045 inch.
z Is the lateral runout within specifications? Yes
INSTALL a new tire.
TEST the system for
normal operation.
No
GO to
J10 .
J10 CHECK THE FLANGE FACE LATERAL RUNOUT
z
Measure the flange face lateral runout. A typical specification for
lateral runout is:
zHub/brake disc— less than 0.13 mm (0.005 inch).
z Axle shaft— less than 0.25 mm (0.010 inch).
z Is the lateral runout within specifications? Yes
INSTALL a new wheel.
TEST the system for
normal operation.
No
REPAIR or INSTALL
new components as
necessary. REFER to
Section 204
- 01 for the
front wheels or Section 204 - 02 for the rear
wheels. Test Step Result / Action to Take
K1 CHECK FOR FRONT WHEEL BEARING ROUGHNESS
z
Chock the rear wheels.
z Raise and support the front end of the vehicle so that the front
wheel and tire assemblies can spin.
z Spin the front tires by hand. Refer to Wheel Bearing Check in
this section.
z Do the wheel bearings feel rough? Yes
INSPECT the wheel
bearings. REPAIR as
necessary. TEST the
system for normal
operation.
No
GO to
K2 .
K2 CHECK THE END PLAY OF THE FRONT WHEEL BEARINGS
z
Check the end play of the front wheel bearings. Refer to
Section 204 - 01 .
z Is the end play OK? Yes
GO to
K3 .
No
ADJUST or REPAIR as
necessary. TEST the
system for normal Klj . 58 ba
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operation.
K3 MEASURE THE LATERAL RUNOUT AND THE RADIAL
RUNOUT OF THE FRONT WHEELS ON THE VEHICLE z
Measure the lateral runout and the radial runout of the front
wheels on the vehicle. Refer to Go To Pinpoint Test J .
z Are the measurements within specifications? Yes
GO to
K4 .
No
INSTALL new wheels as
necessary and BALANCE
the assembly. TEST the
system for normal
operation. K4 MEASURE THE LATERAL RUNOUT OF THE FRONT TIRES
ON THE VEHICLE z
Measure the lateral runout of the front tires on the vehicle. Go To Pinpoint Test J .
z Is the runout within specifications? Yes
GO to
K5 .
No
INSTALL new tires as
necessary and BALANCE
the assembly. TEST the
system for normal
operation. K5 MEASURE THE RADIAL RUNOUT OF THE FRONT TIRES
ON THE VEHICLE z
Measure the radial runout of the front tires on the vehicle. Go To Pinpoint Test J .
z Is the runout within specifications? Yes
BALANCE the front wheel
and tire assemblies. If any
tire cannot be balanced,
INSTALL a new tire.
TEST the system for
normal operation.
No
GO to
K6 .
K6 MATCH MOUNT THE TIRE AND WHEEL ASSEMBLY
z
Mark the high runout location on the tire and also on the
wheel. Break the assembly down and rotate the tire 180
degrees (halfway around) on the wheel. Inflate the tire and
measure the radial runout.
z Is the runout within specifications? Yes
BALANCE the assembly.
TEST the system for
normal operation.
No
If the high spot is not
within 101.6 mm (4
inches) of the first high
spot on the tire, GO to
K7
.
K7 MEASURE THE WHEEL FLANGE RUNOUT
z
Dismount the tire and mount the wheel on a wheel balancer.
Measure the runout on both wheel flanges. Go To Pinpoint Test J . Yes
LOCATE and MARK the
low spot on the wheel.
INSTALL the tire,
matching the high spot on
the tire with the low spot
on the wheel. BALANCE
the assembly. TEST the
system for normal
operation. If the condition Klj . 59 ba
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z
Is the runout within specifications? persists,GO to
K8 .
No
INSTALL a new wheel.
CHECK the runout on the
new wheel. If the new
wheel is within limits,
LOCATE and MARK the
low spot. INSTALL the
tire, matching the high
spot on the tire with the
low spot on the wheel.
BALANCE the assembly.
TEST the system for
normal operation. If the
condition persists, GO to
K8 .
K8 CHECK FOR VIBRATION FROM THE FRONT OF THE
VEHICLE WARNING: If only one drive wheel is allowed to
rotate, speed must be limited to 55 km/h (34 mph) using
the speedometer reading, since actual wheel speed will
be twice that indicated on the speedometer. Exceeding a
speed of 55 km/h (34 mph) or allowing the drive wheel to
hang unsupported can result in tire disintegration or
differential failure, which can cause serious personal
injury and extensive vehicle damage.
z Spin the front wheel and tire assemblies with a wheel
balancer while the vehicle is raised on a hoist. Feel for
vibration in the front fender or while seated in the vehicle.
z Is the vibration present? Yes
SUBSTITUTE known
good wheel and tire
assemblies as necessary.
TEST the system for
normal operation.
No
GO to
K9 .
K9 CHECK FOR VIBRATION FROM THE REAR OF THE
VEHICLE WARNING: If only one drive wheel is allowed to
rotate, speed must be limited to 55 km/h (34 mph) using
the speedometer reading, since actual wheel speed will
be twice that indicated on the speedometer. Exceeding a
speed of 55 km/h (34 mph) or allowing the drive wheel to
hang unsupported can result in tire disintegration or
differential failure, which can cause serious personal
injury and extensive vehicle damage.
z Chock the front wheels.
z Raise and support the rear end of the vehicle so that the rear
wheel and tire assemblies can spin.
z Engage the drivetrain and carefully accelerate the drive
wheels while checking for vibration.
z Is the vibration present? Yes
GO to
K10 .
No
TEST the system for
normal operation. K10 CHECK THE DRIVETRAIN
WARNING: If only one drive wheel is allowed to
rotate, speed must be limited to 55 km/h (34 mph) using
the speedometer reading, since actual wheel speed will
be twice that indicated on the speedometer. Exceeding a
speed of 55 km/h (34 mph) or allowing the drive wheel to
hang unsupported can result in tire disintegration or
differential failure, which can cause serious personal
injury and extensive vehicle damage.
z Remove the rear wheel and tire assemblies. Refer to the Yes
CHECK/TEST the
drivetrain and driveline
components. TEST the
system for normal
operation.
No
SUBSTITUTE known
good wheel and tire Klj . 60 ba
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PINPOINT TEST L: CLUTCH VIBRATION appropriate workshop manual for the service procedures.
z Secure the brake drums (if so equipped), by installing wheel
hub bolt nuts, reversed.
z Carefully accelerate the drivetrain while checking for vibration.
z Is the vibration present? assemblies as necessary.
TEST the system for
normal operation.
Test Step Result / Action to Take
L1 CHECK ENGINE COMPONENTS FOR GROUNDING
z
NOTE: Make sure the clutch is the cause of the
vibration concern. The vibration should occur during
clutch operation. The clutch can also be difficult to
engage or disengage. Eliminate all related systems
before checking the clutch components.
z NOTE: Check the driveline angles and driveshaft
runout before disassembling the clutch system. Refer
to Section 205 - 00 for the correct driveline angle
specifications.
z Check the powertrain/drivetrain mounts, exhaust
manifolds or other engine components for grounding
on the chassis.
z Are any mounts or engine components
grounded? Yes
REPAIR as necessary. TEST the
system for normal operation.
No
GO to
L2 .
L2 CHECK THE ACCESSORY DRIVE
z
Remove the accessory drive belt.
z Does the vibration stop with the accessory drive
belt removed? Yes
DIAGNOSE the accessory drive
components.
No
GO to
L3 .
L3 CHECK FOR LOOSE CLUTCH PRESSURE PLATE
BOLTS z
Check for loose clutch pressure plate bolts. Inspect
the clutch pressure plate for damage or for material
between the pressure plate and flywheel.
z Are there any loose bolts or damage? Yes
TIGHTEN the bolts to
specifications or if damaged,
INSTALL a new clutch pressure
plate. REFER to
Section 308 - 01 .
TEST the system for normal
operation.
No
GO to L4 .
L4 CHECK THE CLUTCH DISC SPRINGS
z
Check for worn, broken or loose clutch disc springs.
z Are the clutch springs worn, broken or loose? Yes
INSTALL a new clutch disc.
REFER to
Section 308 - 01 . TEST
the system for normal operation.
No
GO to L5 .
L5 CHECK THE CLUTCH DISC SPLINES
z
Inspect the clutch disc splines for damage or wear.
z Is there damage or wear? Yes
INSTALL a new clutch disc.
REFER to
Section 308 - 01 . TEST Klj . 61 ba
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PINPOINT TEST M: TRANSFER CASE VIBRATION the system for normal operation.
No
GO to
L6 .
L6 CHECK THE FLYWHEEL BOLTS
z
Check for loose flywheel bolts.
z Are the bolts loose? Yes
TIGHTEN the bolts to
specifications. REFER to
Section 308 - 01 . TEST the system for
normal operation.
No
GO to L7 .
L7 CHECK THE FLYWHEEL SURFACE
z
Inspect the flywheel surface for wear or damage.
Check the flywheel runout.
z Is there any damage or excessive wear? Yes
INSTALL a new flywheel. TEST
the system for normal operation.
No
Clutch system normal. CONDUCT
a diagnosis on other suspect
systems.
Test Step Result / Action to Take
M1 INSPECT THE TRANSFER CASE
z
WARNING: The electrical power to the air suspension
system must be shut off prior to hoisting, jacking or towing
an air suspension vehicle. This can be accomplished by
turning off the air suspension switch. Failure to do so can
result in unexpected inflation or deflation of the air springs,
which can result in shifting of the vehicle during these
operations.
z Inspect the transfer case for loose or missing mounting bolts.
Check for fluid seepage between the transfer case and the
transmission.
z Are the mounting bolts missing or loose? Yes
TIGHTEN to
specifications or
INSTALL new bolts as
necessary. TEST the
system for normal
operation.
No
GO to
M2 .
M2 INSPECT THE REAR DRIVESHAFT
z
NOTE: Verify that the driveshaft and pinion flange index marks
are aligned.
z Inspect the driveshaft for missing weights, damage or
undercoating.
z Inspect the U- joints for freedom of movement.
z Check driveshaft runout and, if necessary, check the pinion
flange runout.
z Is the driveshaft or U- joints worn or damaged or
misaligned? Yes
REPAIR or INSTALL a
new driveshaft as
necessary. TEST the
system for normal
operation.
No
GO to
M3 .
M3 CHECK THE DRIVELINE ANGLES
z
Measure the rear driveshaft and pinion angles. Refer to Section 205 - 00 .
z Measure the front driveshaft and pinion angles. Refer to Section 205 - 00 .
z Are the driveline angles incorrect? Yes
REPAIR as necessary.
TEST the system for
normal operation.
No Klj . 62 ba
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Component Tests
Idle Air Control (IAC) Valve
1. Open the hood.
2. NOTE: Key symptom is elevated idle speed while noise is occurring.
NOTE: "Snapping" the throttle can induce the noise.
Verify the condition by operating the vehicle for a short time.
3. Inspect the IAC valve. If physical evidence of contamination exists, install a new IAC valve. GO to
M4 .
M4 INSPECT THE FRONT DRIVESHAFT
z
NOTE: Verify that the driveshaft and pinion flange index marks
are aligned.
z Inspect the front driveshaft for missing weights, damage or
undercoating.
z Inspect the U- joints and slip yoke for freedom of movement.
z Check driveshaft runout and, if necessary, check the pinion
flange runout.
z Is the driveshaft or U- joints worn or damaged? Yes
REPAIR or INSTALL a
new driveshaft as
necessary. TEST the
system for normal
operation.
No
GO to
M5 .
M5 ROAD TEST WITH THE FRONT DRIVESHAFT ONLY
z
NOTE: Index mark the driveshaft to the pinion flange and to the
output shaft before removal.
z Remove the rear driveshaft.
z Plug the transfer case with an output shaft seal plug.
z NOTE: Shift the transfer case into 4WD high so the vehicle is
driven by the front driveshaft only.
z Test drive the vehicle.
z Is the vibration gone? Yes
INSTALL and BALANCE
the rear driveshaft.
TEST the system for
normal operation.
No
GO to
M6 .
M6 ROAD TEST WITH THE REAR DRIVESHAFT ONLY
z
NOTE: Index mark the front driveshaft to the pinion flange.
z Remove the front driveshaft.
z Test drive the vehicle.
z Is the vibration gone? Yes
INSTALL and BALANCE
the front driveshaft.
TEST the system for
normal operation.
No
GO to
M7 .
M7 TRANSFER CASE TAIL SHAFT INSPECTION
z
Inspect the splines of the output shaft for wear or damage.
z Inspect the splines of the driveshaft slip yoke for wear or
damage.
z Are the splines worn or damaged? Yes
REPAIR or INSTALL
new components as
necessary. TEST the
system for normal
operation.
No
The transfer case is OK.
CONDUCT a diagnosis
on other suspect
systems. Klj . 63 ba
702003 Mustang Workshop Manual
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