oil FORD MUSTANG 2003 User Guide

occurs on first
(morning) brake
application
pads.
Caused by humidity and
low disc brake pad
temperature.
z Squealing noise— a
continuous squeal z
Disc brake pads
or linings worn
below minimum
thickness. z
INSTALL new disc brake
pads. REFER to Section 206 - 03 for front disc brake
pads or Section 206 - 04 for
rear disc brake pads.
z Squealing noise— an
intermittent squeal
brought on by cold,
heat, water, mud or
snow z
Disc brake pad. zAcceptable condition.
z Groaning noise—
occurs at low speeds
with brake lightly
applied (creeping) z
Disc brake
pads. z
Acceptable condition.
z Grinding noise—
continuous z
Disc brake pads
or linings worn
below minimum
thickness. z
INSPECT the disc brake
pads, brake discs and
attaching hardware for
damage. REPAIR or
INSTALL new components
as necessary. REFER to
Section 206 - 03 for front
disc brakes and Section 206 - 04 for rear disc brakes.
z Moaning noise zBrake linings
contaminated
with grease or
oil. z
INSPECT the brake pads
and shoes for
contamination. REPAIR or
INSTALL new components
as necessary. REFER to
Section 206 - 03 for front
disc brakes or Section 206 -
04 for rear disc brakes.
z Brake
vibration/shudder—
occurs when brakes
are applied z
Uneven disc or
drum wear.
z Uneven disc
brake pad or
lining transfer.
z Suspension
components. z
Go To Pinpoint Test A .
z Brake
vibration/shudder—
occurs when the brake
pedal is released z
Brake drag. zINSPECT the disc brake
pads or linings for
premature wear. REPAIR
or INSTALL a new caliper
or wheel cylinder as
necessary. REFER to
Section 206 - 03 for front
disc brakes and Section 206 - 04 for rear disc brakes.
Symptom Chart—
Driveline Noise/Vibration Condition
Possible Sources Action
z Axle howling or
whine— front or rear
axle z
Axle lubricant
low. z
CHECK the lubricant level.
FILL the axle to
specification.
z Axle housing zINSPECT the axle housing Klj . 17 ba
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CARRY OUT a driveline
vibration test. REFER to
Section 205
- 00 . REPAIR as
necessary.
z Binding or
damaged
splines on the
driveshaft slip-
yoke. z
CLEAN and INSPECT the
splines of the slip- yoke,
driveshaft and coupling
shaft for wear or damage.
INSTALL a new slip- yoke or
driveshaft assembly as
necessary. REFER to
Section 205 - 01 . REPAIR as
necessary.
z Driveshaft
runout. z
CARRY OUT a Runout
Check. REFER to Section 205 - 00 . REPAIR as
necessary.
z Incorrect lateral
and radial
tire/wheel
runout. z
INSPECT the tire and
wheels. MEASURE tire
runouts. REPAIR or
INSTALL new components
as necessary. REFER to
Section 204 - 04 .
z Driveline angles
out of
specification. z
CHECK for correct driveline
angles. REPAIR as
necessary. REFER to
Section 205 - 00 .
z Incorrectly
seated CV joint
in the front
wheel hub. z
CHECK the outer CV joint
for correct seating into the
hub. REPAIR as necessary. Symptom Chart —
Engine Noise/Vibration Condition
Possible Sources Action
z Grinding noise—
occurs during
engine cranking z
Incorrect starter
motor mounting. z
INSPECT the starter motor
for correct mounting.
REPAIR as necessary.
REFER to Section 303 - 06 .
z Starter motor. zCHECK the starter motor.
REPAIR or INSTALL a new
starter motor as necessary.
REFER to Section 303 - 06 .
z Incorrect starter
motor drive
engagement. z
INSPECT the starter motor
drive and flexplate/flywheel
for wear or damage.
INSTALL a new starter
motor drive or flywheel as
necessary. REFER to
Section 303 - 06 .
z Engine ticking
noise z
Fuel injector.
z Fuel line.
z Oil pump.
z Valve lifter.
z Belt tensioner.
z Water pump.
z Obstruction of cooling
fan. z
Go To Pinpoint Test B .
z Engine drumming zPowertrain mount. zCARRY OUT Klj . 23 ba
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z
Generator electrical
field or bearings. z
CARRY OUT generator
load test. REPAIR or
INSTALL a new generator
as necessary. REFER to
Section 414 - 02 .
z Drone type noise zExhaust system. zCARRY OUT the Exhaust System Neutralizing in this
section. REPAIR as
necessary.
z A/C compressor. zCHECK for noise with
vehicle at constant speeds.
CYCLE the compressor on
and off and listen for a
change in pitch. REPAIR as
necessary. REFER to
Section 412 - 03 .
z Powertrain mounts. zCARRY OUT the
Powertrain/Drivetrain Mount Neutralizing in this
section.
z Sputter type
noise— noise
worse when cold,
lessens or
disappears when
vehicle is at
operating
temperature z
Damaged or worn
exhaust system
components. z
INSPECT the exhaust
system for leaks or
damage. REPAIR as
necessary. REFER to
Section 309 - 00 .
z Rattling noise—
noise from the
upper engine
(valve train).
Worse when
engine is cold z
Low oil level. zCHECK oil level. FILL as
necessary.
z Thin or diluted oil. zINSPECT the oil for
contamination. If oil is
contaminated, CHECK for
the source. REPAIR as
necessary. CHANGE the oil
and filter.
z Low oil pressure. zCARRY OUT an oil
pressure test. If not within
specifications, REPAIR as
necessary. REFER to
Section 303 - 00 .
z Worn rocker
arms/fulcrums or
followers. z
CARRY OUT a valve train
analysis. INSTALL new
valve train components as
necessary. REFER to
Section 303 - 01A for 3.8L
engines or Section 303 - 01B
for 4.6L (2V) engines.
z Worn valve guides. zCARRY OUT a valve train
analysis. INSTALL new
valve guides as necessary.
REFER to Section 303 - 01A
for 3.8L engines or
Section 303 - 01B for 4.6L (2V)
engines. Klj . 26 ba
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as necessary.
z Accelerator pedal
vibration— felt
through the pedal
as a buzz z
Throttle cable loose
or misrouted. z
INSPECT the throttle cable.
REPAIR as necessary.
REFER to Section 310 - 02 .
z Engine
vibration— mostly
at coast/neutral
coast. Condition
improves with
vehicle
accelerating z
Combustion
instability. z
CHECK the ignition system.
INSTALL new components
as necessary.
z Engine vibration
or shudder—
occurs with light
to medium
acceleration
above 56 km/h
(35 mph) z
Worn or damaged
spark plugs. z
INSPECT the spark plugs
for cracks, high resistance
or broken insulator.
INSTALL a new spark plug
(s) as necessary.
z Plugged fuel injector. zREPAIR or INSTALL a new
injector as necessary.
REFER to Section 303 - 04A
for 3.8L engines or
Section 303 - 04B for 4.6L (2V)
engines.
z Damaged spark plug
wire. z
INSPECT the spark plug
wires for damage. INSTALL
a new spark plug wire(s) as
necessary.
z Contaminated fuel. zINSPECT the fuel for
contamination. DRAIN the
fuel system and refill.
z Worn or damaged
torque converter. z
CHECK the torque
converter. INSTALL a new
torque converter as
necessary. REFER to
Section 307 - 01 .
Symptom Chart—
Idle Noise/Vibration Condition
Possible Sources Action
z Idle air control (IAC)
valve moan — occurs
on throttle tip- out z
IAC valve is
contaminated
with oil. z
GO to Component Tests in
this section.
z Accessory drive belt
chirp — occurs at idle
or high idle, cold or
hot. Most common
occurrence is during
humid weather z
Accessory drive
belt worn, or
pulley is
misaligned or
loose. z
INSPECT for loose or
misaligned pulleys. CHECK
the drive belt for wear or
damage. INSTALL new
pulley(s)/drive belt, or
accessory drive components
as necessary. REFER to
Section 303 - 05 .
z Accessory drive
bearing hoot —
occurs at idle or high
idle in cold
temperatures of
approximately +4°C z
Accessory drive
idler or
tensioner pulley
bearing is
experiencing
stick/slip z
Go To Pinpoint Test C . Klj . 28 ba
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closing/opening
the window
z Squeak— heard
outside of vehicle
when
closing/opening
the door z
Exhaust shield
rubbing against
the chassis or
exhaust pipe. z
CHECK the exhaust system.
REPAIR as necessary. REFER
to Section 309 - 00 .
z Squeak— occurs
with initial brake
pedal application z
Disc brake pads. zUnder certain conditions,
asbestos free pads can
generate a squeak noise. This
noise is normal and does not
indicate a concern.
z Squeak— a
constant noise
that occurs with
brake pedal
applications z
Damaged or
worn disc brake
pads. z
INSPECT the pads for oil,
grease or brake fluid
contamination. CHECK for
glazed linings. A brake disc with
hard spots will also cause a
squeak type noise. REPAIR or
INSTALL new pads as
necessary. REFER to Section 206 - 03 for front disc brakes and
Section 206 - 04 for rear disc
brakes.
z Squeak— noise
occurs over
bumps or when
turning z
Worn control
arm bushings. z
INSPECT the control arm
bushings. Spray with lubricant
and CARRY OUT a "bounce
test" to determine which
bushing. REPAIR as necessary.
REFER to Section 204 - 01 .
z Worn or
damaged shock
absorber/strut. z
INSPECT the shock absorber
for damage. CARRY OUT a
"bounce test" to isolate the
noise. INSTALL a new shock
absorber/strut as necessary.
REFER to Section 204 - 01 for
the front shock absorber/strut or
Section 204 - 02 for the rear
shock absorber/strut.
z Rattle— heard
when
closing/opening
the door or
window z
Loose internal
door
mechanism,
bracket or
attachment. z
REPEAT the motion or CARRY
OUT a "tap test" to duplicate the
noise. INSPECT the door for
loose components. TIGHTEN
loose components or USE the
Rotunda Squeak and Rattle Kit
to isolate any rattling
components.
z Rattle — GT
models only,
noise occurs from
the rear of the
vehicle z
A loose or under
torqued shock
damper
attaching nut. z
VERIFY the torque on the
shock damper- to-axle nuts is 63
Nm (46 lb- ft). VERIFY the
torque for the shock damper- to-
rail bracket nuts is 90 Nm (66
lb- ft). Do not over torque.
TIGHTEN as necessary.
z Squeak or rattle—
heard inside the
vehicle over rough
roads/bumps z
Misaligned glove
compartment
door/hinge. z
ALIGN the glove compartment
door.
z Instrument panel
trim loose or z
INSPECT the instrument panel
trim for missing or loose clips or Klj . 32 ba
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Section 308 - 02 .
z Grease or oil on the
clutch disc facing. z
CHECK the input shaft
seal and rear main oil
seal. REPAIR as
necessary. INSTALL a
new clutch disc.
REFER to Section 308 -
03A for T50D
transmissions or
Section 308 - 03B for
TR3650 transmissions.
z Clutch disc surface
glazed or damaged. z
INSPECT the clutch
disc surface for a
glazed, hardened or
damage condition.
CARRY OUT a disc
check. INSTALL a new
clutch disc as
necessary. REFER to
Section 308 - 01 .
z Damaged or worn
clutch pressure
plate. z
INSPECT the clutch
pressure plate for wear
or damage. INSTALL a
new clutch pressure
plate as necessary.
REFER to Section 308 -
01 .
z Flywheel surface
damaged or glazed. z
INSPECT the flywheel
for damage or wear.
CARRY OUT a
flywheel runout check.
INSTALL a new
flywheel as necessary.
REFER to Section 303 -
01A for 3.8L engines or
Section 303 - 01B for
4.6L (2V) engines.
z Clutch chatter noise—
noise when clutch
pedal is released at
initial take- off. Clutch is
hard to engage and
disengage z
Pilot bearing worn,
damaged or not
correctly aligned in
bore. z
INSPECT the clutch
pressure plate release
fingers for uneven
wear, clutch
components burnt or a
seized pilot bearing.
INSTALL a new pilot
bearing as necessary.
REFER to Section 308 -
01 .
z Clutch vibration zLoose flywheel
bolts.
z Damaged or loose
clutch pressure
plate.
z Excessive flywheel
runout. z
Go To Pinpoint Test L .
z Transmission
rattling/clattering
noise— noise at idle or
on light acceleration
from a stop. Gear
selection difficult z
Gearshift lever joint
worn or damaged. z
INSTALL a new
gearshift lever. REFER
to Section 308 - 03A for
T50D transmissions or
Section 308 - 03B for
TR3650 transmissions. Klj . 41 ba
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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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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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DIAGNOSIS AND TESTING
Suspension System
Inspection and Verification
1. Road test. zVerify the customer's concern by performing a road test on a smooth road.
2. Inspect tires. zCheck the tire pressure with all normal loads in the vehicle and the tires cold. For
additional information, refer to the vehicle certification (VC) label.
z Verify that all tires are sized to specification.
z Inspect the tires for incorrect wear and damage.
3. Inspect chassis and underbody. zRemove any excessive accumulation of mud, dirt or road deposits from the chassis and
underbody.
4. Inspect for aftermarket equipment. zCheck for aftermarket changes to the steering, suspension, wheel and tire components
(such as competition, heavy duty, etc.) The specifications shown in this manual do not
apply to vehicles equipped with aftermarket equipment.
5. Inspect shock absorbers. All vehicles are equipped with gas- pressurized hydraulic shock absorbers. These shock
absorbers are not adjustable or refillable and cannot be repaired.
zOil Leak: A light film of oil (weepage) on the upper portion of the shock absorber is
permissible and is a result or correct shock lubrication. Weepage is a condition in which a
film of oil accumulates on the thin tube (body) and is normally noticed due to the
collection of dust in this area. If shock absorbers exhibit this weepage condition, they are
functional units and new shock absorbers should not be installed. Leakage is a condition
in which the entire shock absorber body is covered with oil and the oil will drip from the
shock absorber onto the pavement. If condition exists:
„Make sure fluid observed is not from sources other than the shock absorber.
„ Install a new shock absorber, if necessary.
z Vehicle Sag: Many times new shock absorbers are installed in an effort to solve a vehicle
sag concern. Shock absorbers by design are hydraulic damping units only and, unlike
suspension springs, do not support any suspension loads. Therefore, installing a new
shock absorber will not correct a vehicle sag concern.
z Installment in Pairs: In the past it was recommended that new shock absorbers be
installed in pairs if one unit became unrepairable. New shock absorbers no longer need
to be installed in pairs when only one unit is not repairable.
SECTION 204-
00: Suspension System — General Information 2003 Mustang Workshop Manual Visual Inspection Chart
Mechanical Klj . 1 ba
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6. If an obvious cause for an observed or reported condition is found, correct the cause (if
possible) before proceeding to the next step.
7. If the fault is not visually evident, determine the symptom and GO to Symptom Chart .
Symptom Chart z
Front wheel bearing(s)
z Loose or damaged front or rear suspension components
z Loose, damaged or missing suspension fastener(s)
z Damaged spring(s)
z Damaged or leaking strut and spring assemblies
z Damaged or leaking shock absorber(s)
z Worn or damaged suspension bushing(s)
z Loose, worn or damaged steering system components
z Damaged axle components
Symptom Chart Condition
Possible Sources Action
z Dogtracking zExcessive rear
thrust angle. z
CHECK the wheel alignment.
ADJUST as necessary.
z Front or rear
suspension
components. z
INSPECT the front and rear
suspension system. REPAIR
or INSTALL new suspension
components as necessary.
REFER to Section 204 - 01 or
Section 204 - 02 .
z Drive axle
damaged. z
REPAIR as necessary. Refer
to the appropriate section in
Group 205 for the procedure..
z Drift/pull zUnequal tire
pressure. z
ADJUST tire pressure.
z Excessive side-to-
side difference in
caster or camber. z
CHECK the wheel alignment.
ADJUST as necessary.
z Tire forces. zROTATE tires front to rear.
z Unevenly loaded or
overloaded vehicle. z
NOTIFY the customer of
incorrect vehicle loading.
z Steering
components. z
REFER to Section 211 - 00 .
z Brake drag. zREFER to Section 206 - 00 .
z Front bottoming
or riding low z
Strut(s). zINSTALL new strut(s) as
necessary. REFER to Section 204 - 01 .
z Front coil springs
(5310). z
CHECK ride height. INSTALL
new springs as necessary.
REFER to Section 204 - 01 .
z Incorrect tire
wear z
Incorrect tire
pressure (rapid
center rib or inner
and outer edge
wear). z
ADJUST tire pressure. Klj . 2 ba
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