transmission fluid FORD MUSTANG 2003 User Guide

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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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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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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Lower the rear end of the driveshaft to clear the rear axle housing. Pull the driveshaft rearward
until the driveshaft slip yoke clears the transmission extension housing.
zPlace a paint index mark on the driveshaft slip yoke and the transmission output shaft.
z Place a commercially available plug in the extension housing to prevent fluid leakage.
5. CAUTION: Install the driveshaft with new bolts. If new bolts are not available, apply
threadlock and sealer to the threads of the original bolts.
CAUTION: Do not allow the slip yoke to bottom on the transmission output shaft.
CAUTION: The driveshaft centering socket yoke fits tightly on the rear axle pinion
flange pilot. To make sure that the yoke seats squarely on the flange, tighten the bolts
evenly in a cross pattern as shown.
NOTE: Clean all foreign material from the yoke areas of the driveshaft.
To install, reverse the removal procedure. Klj . 2 ba
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2. Remove the four bolts.
6. CAUTION: The driveshaft centering socket yoke fits tightly on the rear axle pinion
flange pilot. Never hammer on the driveshaft or any of its components to disconnect the
yoke from the flange. Pry only in the area shown, with a suitable tool, to disconnect the
yoke from the flange.
Using a suitable tool as shown, disconnect the driveshaft centering socket yoke from the rear
axle pinion flange.
7. CAUTION: Do not allow the slip yoke to bottom on the transmission output shaft.
Lower the rear end of the driveshaft to clear the rear axle housing. Pull the driveshaft rearward
until the driveshaft slip yoke clears the transmission extension housing. zPlace a paint index mark on the driveshaft slip yoke and the transmission output shaft.
z Place a commercially available plug in the extension housing to prevent fluid leakage.
8. CAUTION: Install the driveshaft with new bolts. If new bolts are not available, apply
threadlock and sealer to the threads of the original bolts.
CAUTION: Do not allow the slip yoke to bottom on the transmission output shaft.
CAUTION: The driveshaft centering socket yoke fits tightly on the rear axle pinion
flange pilot. To make sure that the yoke seats squarely on the flange, tighten the bolts
evenly in a cross pattern as shown.
NOTE: Clean all foreign material from the yoke areas of the driveshaft.
To install, reverse the removal procedure. Klj . 2 ba
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Component Tests
Brake Booster
1. Check the hydraulic brake system for leaks or insufficient fluid.
2. With the transmission (7003) in NEUTRAL, stop the engine (6007) and apply the parking brake control (2780). Apply the brake pedal several times to exhaust all vacuum in the system.
3. Apply the brake pedal and hold it in the applied position. Start the engine. If the vacuum system is operating, the brake pedal will tend to move downward under constant foot pressure. If no
motion is felt, the power brake booster system is not functioning. Continue with the following
steps.
4. Remove the vacuum booster hose from the check valve connection. Manifold vacuum must be available at the check valve end of the vacuum booster hose with the engine at idle speed and
the transmission in NEUTRAL. If the manifold vacuum is available to the power brake booster,
connect the vacuum booster hose to the power brake booster check valve and repeat Steps 2
and 3.
5. If no downward movement of the brake pedal is felt, install a new power brake booster.
6. Operate the engine a minimum of 10 seconds at fast idle. Stop the engine, and let the vehicle stand for 10 minutes. Then apply the brake pedal with approximately 89 N (20 lb) of force. The
brake pedal feel should be the same as that noted with the engine operating. If the brake pedal
feels hard (no power assist), install a new power brake booster check valve and retest. If the
brake pedal feels spongy, bleed the hydraulic system to remove air. For additional information,
refer to Bleeding — System in this section. Check Valve z
Engine running at idle speed.
z CAUTION: Do not hold the brake pedal at 444 Nm
(100 lb) force for more than 5 seconds at a time.
z Apply brake pedal with approximately 444 Nm (100 lb)
force and hold.
z Check hydro-boost unit input seal, housing seal,
accumulator seal, piston seal and spool plug seal for
leakage.
z Is hydro- boost unit free of leaks? Yes
GO to
G6 .
No
INSTALL a new hydro- boost
unit. G6 CHECK RESERVE RETENTION
z
Engine running at idle speed.
z CAUTION: Do not hold the brake pedal at 444 Nm
(100 lb) force for more than 5 seconds at a time.
z Charge system to pressure by holding the steering wheel at
stop or by pressing the brake pedal with approximately 444
Nm (100 lb) force.
z Key in OFF position.
z Wait five seconds.
z Press brake pedal and observe if there is any power brake
reserve.
z Is there any power brake reserve? Yes
Hydro-
boost unit is OK.
No
INSTALL a new hydro- boost
unit. Klj . 13 ba
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SPECIFICATIONS
SECTION 211-
00: Steering System — General Information 2003 Mustang Workshop Manual General Specifications
Item Specification
Lubricants
Motorcraft MERCON® Multi-Purpose (ATF) Transmission Fluid XT-
2- QDX MERCON®
Power Steering Gear
Turning effort 2.27 Kg (5.0 lb)
Turns lock-to-
lock 2.38
Power Steering Purge Vacuum
Vacuum 68-
85 kPa (20- 25 in/hg) Power Steering Pump —
CII Flow 9.8 liters/minute
(2.6 gpm)
Fluid @ 74°- 80° C (165°-175°
F)
Engine at 1,500 rpm Pressure 1,034 kPa
(150 psi)
Fluid @ 74°- 80° C (165°-175°
F)
Engine at 1,500 rpm Minimum capacity 3.4 liters/minute
(0.9 gpm)
Fluid @ 74°- 80° C (165°-175°
F)
Engine at idle
Pressure at 5,102 kPa (750
psi) Relief pressure 7,240-8,400 kPa
(1,050-1,230 psi) Power Steering Pump —
CIII Flow 9.8 liters/minute
(2.6 gpm)
Fluid @ 74°- 80° C (165°-175°
F)
Engine at 1,500 rpm Pressure 1,034 kPa
(150 psi)
Fluid @ 74°- 80° C (165°-175°
F)
Engine at 1,500 rpm Minimum capacity 4.7 liters/minute
(1.25 gpm)
Fluid @ 74°- 80° C (165°-175°
F)
Engine at idle
Pressure at 5,171 kPa (750 psi) Klj . 1 ba
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z
On some vehicles, the power steering pump high pressure port is inaccessible and the
special tool should then be installed either at the steering gear or at a point in the high
pressure line between the power steering pump and the steering gear.
2. Place a dial thermometer in the power steering pump reservoir.
3. Check the power steering fluid level. If necessary, add power steering fluid. zUse Motorcraft MERCON® Multi-Purpose ATF XT -2-QDX or MERCON® equivalent.
4. Install a digital tachometer.
5. CAUTION: Do not hold the steering wheel against the stops for more than three to
five seconds at a time. Damage to the power steering pump will occur.
Start the engine. Place the transmission in neutral. Set the parking brake. Raise the power
steering fluid temperature to 74- 80°C (165-175°F) by rotating the steering wheel fully to the left
and right several times.
6. Set the engine speed to 1500 rpm. Record the flow rate and pressure readings. zIf the flow rate is below the flow rate specification, a new power steering pump may need
to be installed. Continue with the test procedure.
z If the pressure reading is above the maximum pressure specification, then check power
steering hoses for kinks and restrictions.
7. Partially close the gate valve to obtain 750 psi. Set the engine speed at idle. Record the flow rate.
zIf the flow is less than the specified flow rate, then install a new power steering pump. For
additional information, refer to Section 211 - 02 .
8. CAUTION: Do not allow the gate valve to remain closed for more than 5 seconds.
Completely close and partially open the gate valve 3 times. Record the pressure relief valve
actuation pressure reading. zIf the pressure does not meet the relief pressure specification, install a new power
steering pump. For additional information, refer to Section 211 - 02 .
9. Set engine speed to 1500 rpm. Record the flow rate. zIf the flow rate varies more than 3.785 liters/minute (1 gallon/minute) from the initial flow
rate reading, install a new power steering pump. For additional information, refer to
Section 211 - 02 .
10. CAUTION: Do not hold the steering wheel against the stops for more than three to
five seconds at a time. Damage to the power steering pump will occur.
Set the engine speed at idle. Turn (or have an assistant turn) the steering wheel to the left and
right stops. Record flow rate and pressure readings at the stops.
zThe pressure reading at both stops should be nearly the same as the maximum pump
relief pressure.
z The flow rate should drop below 1.9 liters/minute (0.5 gallons/minute).
z If the pressure does not reach the maximum pump relief pressure or the flow rate does
not drop below the specified value, excessive internal leakage is occurring. Install a new
steering gear as necessary. For additional information, refer to Section 211 - 02 . Klj . 9 ba
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SPECIFICATIONS
a
Once torque is reached, continue turning to align slot in nut with cotter pin hole in tie- rod.
SECTION 211-
02: Power Steering 2003 Mustang Workshop Manual General Specifications
Item Specification
Lubricants
Motorcraft Multi-Purpose (ATF) Transmission Fluid XT
-2-QDX MERCON®
Silicone Dielectric Compound D7AZ-
19A331-A ESE-
M1C171- A Steering Gear Grease C3AZ-19578-
A ESW-
M1C87- A
Torque Specifications Description Nm lb-
ft lb-
in Front wheel spindle tie-
rod 100 74 —
Power steering pump mounting bolts (CII pump) 51 38 —
Power steering pump mounting bolts
(CIII pump) 25 18 —
Pressure line fitting
(CII pump) 40 30 —
Pressure line fitting
(CIII pump) 65 48 —
Pressure line fitting 30 22 —
Return line fitting
(steering gear) 30 22 —
Steering gear mounting nut 48 35 —
Steering intermediate shaft coupling pinch bolt 34 25 —
Tie-
rod end castellated nut 56
a 11
a —
Tie-
rod end jam nut 55 41 — Klj . 1 ba
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