manual transmission FORD MUSTANG 2003 Workshop Manual

Possible Component Reference/Action
250 —
ELECTRICAL ROUTINE ·
No Electrical Concerns 350 —
HYDRAULIC/MECHANICAL ROUTINE Shift Linkage
·
Damaged or incorrectly
adjusted ·
Inspect and repair as required. Verify transmission shift cable
adjustment; refer to Section 307 - 05 . Adjust transmission shift
cable as necessary. After repairing transmission shift cable,
verify that the digital TR sensor is correctly adjusted. Adjust
the digital TR sensor as necessary. Main Controls
·
3- 4 shift valve, 1- 2 and 2-3
shift valve, gaskets, 3-4
capacity modulator valve,
stuck or damaged or
assembled incorrectly ·
Inspect for damage. Repair as required. ·
OD servo assembly damaged
or stuck in manual 2nd only. ·
Inspect cover, piston and seal for damage. Repair as required. ·
Low/Reverse servo assembly
damaged or stuck in manual
1st only ·
Inspect cover, piston and seal for damage. Repair as required. Overdrive
·
Reverse band, manual 1st
(only) damaged ·
Inspect for damage. Repair as required. ·
OD band, reverse clutch drum
assembly worn or damaged
(manual 2nd only) ·
Inspect for damage. Repair as required. Reverse Band (Manual 1st Only)
·
Damaged or incorrectly
adjusted ·
Inspect for damage. Repair as required.
Other Concerns: Shift Lever Efforts High Possible Component Reference/Action
251 —
ELECTRICAL ROUTINE ·
No Electrical Concerns 351 —
HYDRAULIC/MECHANICAL ROUTINE Shift Linkage, Digital TR
Sensor
·
Damaged or incorrectly
adjusted ·
Inspect and repair as required. Verify transmission shift cable
adjustment; refer to Section 307 - 05 . Adjust transmission shift
cable as necessary. After repairing transmission shift cable, verify
that the digital TR sensor is correctly adjusted. Adjust the digital
TR sensor as necessary. ·
Brake shift interlock
system, solenoid damaged ·
Refer to the appropriate brake section in the workshop manual. Manual Lever
·
Retaining pin damaged, nut
loose, detent spring bent or
damaged or Park ·
Inspect for damage. Repair as required. Klj . 26 ba
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mechanism damaged
Main Controls
·
Manual valve stuck or
damaged ·
Inspect for damage. Repair as required. ·
Bolts not tightened to
specifications ·
Tighten bolts to specifications.
Other Concerns: External Leaks Possible Component Reference/Action
252 —
ELECTRICAL ROUTINE Powertrain Control System
·
Electrical inputs/outputs, sensor
seals leaking (digital TR, OSS,
vehicle speed sensor VSS, if
equipped, or transmission connector) ·
Inspect for leakage and repair as required. 352 —
HYDRAULIC/MECHANICAL ROUTINE Case
·
Case vent, case porosity, case
cracked ·
Check the vent for free breathing. Check the fluid level.
Check the transmission for overheat conditions. Repair
as required. Seals/Gaskets
·
Leakage at gaskets, seals, etc. (refer
to external sealing illustration for
potential leak locations) ·
Remove all traces of lubricant on exposed surfaces of
the transmission. Check the vent for free breathing.
Operate the transmission at normal temperatures and
perform fluid leakage check. Repair as required. Other
·
Cooler fitting, cooler lines pressure
tap, converter drain plug, band
anchor pins ·
Locate the source of the leak. Repair as required.
Other Concerns: Poor Vehicle Performance Possible Component Reference/Action
253 —
ELECTRICAL ROUTINE Powertrain Control System
·
Electrical inputs/outputs, vehicle
wiring harnesses, shift solenoids,
digital TR sensor, torque
converter clutch (TCC) solenoid,
transmission fluid temperature
(TFT) sensor ·
Carry out Self-Test. Refer to the Powertrain
Control/Emissions Diagnosis (PC/ED) manual for diagnosis
and testing of the Powertrain Control System. Go To Pinpoint Test A ,
Go To Pinpoint Test B or
Go To Pinpoint Test C . Repair as required. Clear codes, road test and
repeat Self- Test. Also refer to Routines 241/341 Torque
Converter Operation Concern: Always Applied. ·
Engine driveability concerns ·
Inspect air intake/air filter system. Check the fuel system
and fuel pressure. Refer to the Powertrain
Control/Emissions Diagnosis (PC/ED) manual. Inspect the
exhaust system for restriction. Refer to Section 309 - 00 .
353 —
HYDRAULIC/MECHANICAL ROUTINE Shift Linkage, Digital TR Sensor Klj . 27 ba
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·
Damaged or incorrectly adjusted ·
Inspect and repair as required. Verify transmission shift
cable adjustment; refer to Section 307 - 05 . Adjust
transmission shift cable as necessary. After repairing
transmission shift cable, verify that the digital TR sensor is
correctly adjusted. Adjust the digital TR sensor as
necessary. Verify Correct Shift Scheduling
and Engagements
·
See Reference/Action ·
Go to the appropriate diagnostic routines. Torque Converter Clutch Always
Applied
·
See Reference/Action ·
Go to Hydraulic/Mechanical Routine 241/341. Torque Converter Clutch
·
Damaged ·
Inspect torque converter. Install a new converter as outlined.
Other Concerns: Noise/Vibration — Forward Or Reverse Possible Component Reference/Action
254 —
ELECTRICAL ROUTINE ·
No Electrical Concerns 354 —
HYDRAULIC/MECHANICAL ROUTINE For Noises/Vibrations That Change With Engine
Speed
·
Converter components/balance weight ·
Locate source of disturbance. Repair as
required. ·
Fluid level (low) pump cavitation ·
Pump assembly ·
Engine drive accessories ·
Cooler lines grounding out ·
Flexplate For Noises/Vibrations That Change With Vehicle
Speed
·
Engine mounts loose or damaged ·
Locate source of disturbance and repair as
required. ·
Driveline concerns:
„ U-joints
„ Rear axle
„ Suspension
„ Modifications
1st Gear: „Low one- way clutch
„ Gearset
„ Friction elements ·
Refer to the following shift routine(s) for
further diagnosis:
„ Shift 1- 2, Routine 320
„ Shift 2- 3, Routine 321
„ Shift 3- 4, Routine 322
„ Shift 4- 3, Routine 323
„ Shift 3- 2, Routine 324
„ Shift 2- 1, Routine 325
„ Torque Converter Cycling 242/342 ·
2nd Gear:
„ Intermediate one- way clutch
„ Intermediate clutch piston bleed hole out of Klj . 28 ba
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12 o'clock position
„ Friction elements ·
3rd Gear:
„ Torque converter
„ Case to planet support spring
„ Friction elements ·
4th Gear:
„ Gear set
„ Friction elements
„ Torque converter ·
Reverse:
„ Gear set
„ Friction elements ·
Output shaft splines worn or damaged Other Noises/Vibrations
·
Main controls, valve resonance ·
Shift cable:
„ Vibration
„ Grounding
„ Cooler lines
„ Grounding ·
Locate source of disturbance and repair as
required.
Other Concerns: Engine Will Not Crank Possible Component Reference/Action
255 —
ELECTRICAL ROUTINE Powertrain Control System
·
Electrical inputs/outputs,
vehicle wiring harnesses,
engine starting system
hardware, digital TR sensor ·
Carry out Self- Test. Refer to the Powertrain Control/Emissions
Diagnosis (PC/ED) manual for diagnosis and testing of the
Powertrain Control System. Go To Pinpoint Test C . Repair and
adjust as required. 355 —
HYDRAULIC/MECHANICAL ROUTINE Shift Linkage, Digital TR
Sensor
·
Damaged or incorrectly
adjusted ·
Inspect and repair as required. Verify transmission shift cable
adjustment; refer to Section 307 - 05 . Adjust transmission shift
cable as necessary. After repairing transmission shift cable,
verify that the digital TR sensor is correctly adjusted. Adjust the
digital TR sensor as necessary.
Other Concerns: No Park (P) Range Possible Component Reference/Action
256 —
ELECTRICAL ROUTINE ·
No Electrical Concerns 356 —
HYDRAULIC/MECHANICAL ROUTINE Klj . 29 ba
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Shift Linkage, Digital TR Sensor
·
Damaged or incorrectly adjusted ·
Inspect and repair as required. Verify transmission shift
cable adjustment; refer to Section 307 - 05 . Adjust
transmission shift cable as necessary. After repairing
transmission shift cable, verify that the digital TR sensor
is correctly adjusted. Adjust the digital TR sensor as
necessary. Park Mechanism
·
Output shaft ring, parking brake pawl,
parking pawl return spring, park rod
guide cup, parking pawl shaft,
parking pawl actuating rod, manual
lever detent spring damaged or
assembled incorrectly ·
Inspect for damage or incorrect assembly and repair as
required.
Other Concerns: Overheating Possible Component Reference/Action
257 —
ELECTRICAL ROUTINE Refer to Routine 240/340, Torque Converter Operation Concern: No Apply
357 —
HYDRAULIC/MECHANICAL ROUTINE Fluid
·
Incorrect level ·
Adjust fluid to correct level. ·
Condition ·
Inspect condition of fluid. Other
·
Damaged, blocked or reversed cooler lines or
restriction in the transmission oil cooler ·
Inspect for damage and correct
installation. Repair as required. Vehicle Concerns Causing Engine Overheating
·
Refer to the appropriate engine
cooling section. Main Controls
·
Drain back valve, torque clutch control valve, converter
limit valve stuck, damaged or assembled incorrectly ·
Inspect for damage and repair as
required. Torque Converter Clutch
·
No apply ·
Refer to Routine 240/340. Klj . 30 ba
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GENERAL PROCEDURES
Transmission Fluid Cooler —
Backflushing and Cleaning
1. CAUTION: Do not use any supplemental transmission fluid additives or cleaning
agents. The use of these products could cause internal transmission components to fail;
this will effect the operation of the transmission.
Conduct backflushing with a suitable torque converter/fluid cooler cleaner. Test your equipment
to make sure that a vigorous fluid flow is present before proceeding. Install a new filter in the
flush equipment if flow is weak or contaminated.
2. To aid in attaching the cleaner to the transmission steel cooler lines, connect two additional rubber hoses to the transmission end of the steel transmission cooler lines as described below.
zConnect the cleaner tank pressure line to the steel transmission cooler return line
(longest line).
z Connect a tank return hose to the steel transmission cooler pressure line (shorter line).
Place the outlet end of this hose in the solvent tank reservoir.
3. Turn on solvent pump and allow the solvent to circulate a minimum of 5 minutes (cycling switch on and off will help dislodge contaminants in cooler system).
4. Switch off the solvent pump and disconnect the solvent pressure hose from the transmission cooler return line.
5. Use compressed air to blow out the cooler(s) and lines (blow air into the transmission cooler return line) until all solvent is removed.
6. Remove the rubber return hose from the remaining steel cooler line.
SECTION 307-
01: Automatic Transaxle/Transmission 2003 Mustang Workshop Manual Klj . 1 ba
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GENERAL PROCEDURES
Transmission Fluid Drain and Refill
Draining
CAUTION: Always refer to the instructions supplied with the flush and fill machine.
NOTE: Draining fluid from the transmission by removing only the fluid pan is acceptable for vehicles
that do not have a torque converter drain plug, for normal or severe duty fluid maintenance.
NOTE: A new procedure for draining and adding transmission fluid using a suitable transmission flush
and fill machine has been added. The following procedure has different methods for draining and
refilling the listed vehicles:
zAll vehicles using a suitable flush and fill machine.
z Vehicles equipped with a torque converter drain plug.
z Vehicles without a torque converter drain plug.
Use the method that is applicable to your vehicle.
All vehicles using a suitable flush and fill machine 1. With the vehicle in NEUTRAL, position on a hoist. For additional information, refer to Section 100 - 02 .
2. Use a suitable flush and fill machine to change the fluid.
3. When connecting the flush and fill machine, connect the machine to the fluid cooler tube after the fluid cooler on the cooler return line. This will help remove any foreign material trapped in
the fluid coolers. Refill SECTION 307-
01: Automatic Transaxle/Transmission 2003 Mustang Workshop Manual Special Tool(s)
Automatic Transmission Flush
and Fill Machine
211-
00018
Automatic Transmission Flush
and Fill Machine
199- 00010 or equivalent
Material Item Specification
MERCON® V Automatic
Transmission Fluid
XT
-5-QM MERCON®
V Klj . 1 ba
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4. Use only clean automatic transmission fluid.
5. Once the fluid exchange has been completed, disconnect the flush and fill machine. Reconnect
any disconnected fluid cooler tubes.
6. With the engine running and the transmission at normal operating temperature 66- 77°C (150-
170°F), check and adjust the transmission fluid level, and check for any leaks. If fluid is needed,
add fluid in increments of 0.24- liter (0.5-pint) until the correct level is achieved (fluid should be in
the cross- hatched area of the fluid level indicator).
Draining
Vehicles equipped with a torque converter drain plug 1. With the vehicle in NEUTRAL, position on a hoist. For additional information, refer to Section 100 - 02 .
2. Loosen the transmission fluid pan bolts and allow the fluid to drain.
3. After the fluid has drained, remove the transmission fluid pan.
4. Do not remove the fluid filter. It is not necessary to change the fluid filter during a normal maintenance fluid change.
5. Remove the torque converter drain plug cover. Klj . 2 ba
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6. Remove the torque converter drain plug and discard.
7. Clean and inspect the transmission fluid pan, transmission fluid pan gasket and magnet.
8. Thoroughly flush the cooler tubes. For additional information, refer to
Transmission Fluid Cooler — Backflushing and Cleaning in this section.
Refill 9. After the torque converter has drained, install a new drain plug. Klj . 3 ba
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10. Install the torque converter drain plug cover.
11. Position the magnet into the transmission fluid pan.
12.
NOTE: The fluid pan gasket is reusable, clean and inspect for damage. If not damaged, the
gasket should be reused.
Install the fluid pan and gasket. 1. Position the fluid pan with the gasket in place.
2. Install the bolts.
13. CAUTION: The use of any other transmission fluid can result in the transmission
failing to operate in a normal manner or transmission failure.
Fill the transmission.
zAdd 4.7 liters (5 qts) of clean automatic transmission fluid to the transmission through the
fluid filler tube.
14. Start the engine. Move the transmission range selector lever through all the gear ranges, checking for engagements.
15. With the engine running and the transmission at normal operating temperature 66- 77°C (150- Klj . 4 ba
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