wheel FORD MUSTANG 2003 Workshop Manual

REMOVAL AND INSTALLATION
Multifunction Switch
Removal
1. Disconnect the battery ground cable.
2. Remove the ignition switch lock cylinder. 1. Insert the ignition key into the ignition switch lock cylinder and turn to RUN position.
2. Push the ignition switch lock cylinder release tab with a punch while pulling out the ignition switch lock cylinder.
3. Remove the tilt wheel handle.
4. Remove the upper and lower steering column shrouds. 1. Remove the screws.
2. Remove the upper and lower steering column shrouds.
5. Remove the multifunction switch. 1. Remove the screws.
SECTION 211-
05: Steering Column Switches 2003 Mustang Workshop Manual Klj . 1 ba
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REMOVAL AND INSTALLATION
Key Release Button
Removal
1. Disconnect the battery ground cable.
2. Remove the ignition switch lock cylinder. 1. Insert the ignition key into the ignition switch lock cylinder and turn to RUN position.
2. Push the ignition switch lock cylinder release tab with a punch while pulling out the ignition switch lock cylinder.
3. Remove the tilt wheel handle.
4. Remove the upper and lower steering column shrouds. 1. Remove the screws.
2. Remove the upper and lower steering column shrouds.
5. Remove the key release button. 1. Remove the key release button bolt.
SECTION 211-
05: Steering Column Switches 2003 Mustang Workshop Manual Klj . 1 ba
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z
intake manifold gaskets
z cylinder head gaskets
z oil bypass filter
z oil filter adapter
z engine front cover
z oil filter adapter and filter body
z oil level indicator tube connection
z oil pressure sensor
Leakage Points— Under Engine—With Vehicle on Hoist
z oil pan gaskets (6710)
z oil pan sealer
z oil pan rear seal (6723)
z engine front cover gasket
z crankshaft front seal (6700)
z crankshaft rear oil seal (6701)
z crankshaft main bearing cap side bolts
z oil filter adapter and filter body
z oil cooler, if equipped
Leakage Points— With Transmission and Flywheel Removed
z crankshaft rear oil seal
z rear main bearing cap parting line
z rear main bearing cap and seals
z flywheel mounting bolt holes (with flywheel [6375] installed)
z camshaft rear bearing covers (6266) or pipe plugs at the end of oil passages
Oil leaks at crimped seams in sheet metal parts and cracks in cast or stamped parts can be detected
when using the dye method.
Compression Test— Compression Gauge Check
1. Make sure the oil in the crankcase is of the correct viscosity and at the correct level and that the battery (10655) is correctly charged. Operate the vehicle until the engine is at normal operating
temperature. Turn the ignition switch to the OFF position, then remove all the spark plugs
(12405).
2. Set the throttle plates in the wide- open position.
3. Install a compression gauge such as the Compression Tester in the No. 1 cylinder.
4. Install an auxiliary starter switch in the starting circuit. With the ignition switch in the OFF position, and using the auxiliary starter switch, crank the engine a minimum of five compression
strokes and record the highest reading. Note the approximate number of compression strokes Klj . 7 ba
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A/C compressor bracket-
to-cylinder head stud bolt 25 18 —
Oil level indicator tube-
to-cylinder head bolt 10 — 89
Coolant recovery reservoir bracket-to-
GOP bolts 9 — 80
Motor mount-
to-subframe nuts 115 85 —
Oil pan drain plug 26 19 —
Wire harness bracket to motor mount nut 27 20 —
Steering column pinch bolt 47 35 —
Front subframe-
to-body bolts 90 66 —
Front subframe-
to-shock tower bolts 115 85 —
Oil pan-to-
cylinder block bolts a — — —
Oil pan-to-
transmission bell housing 45 33 —
Main bearing bridge nuts 32 24
Oil pump cover-
to-engine front cover bolts 25 18 —
Oil pump cover-
to-engine front cover bolt 10 89 —
Oil pickup tube-
to-cylinder block bolts 25 18 —
Oil pickup tube-
to-oil pan baffle nut 48 35 —
Flywheel-
to-crankshaft bolts 80 59 —
Wire harness bracket-
to-motor mount stud- nut 27 20 —
Engine ground strap-
to-motor mount nut 27 20 —
Motor mount-
to-motor mount bracket bolts 70 52 —
RH motor mount-
to-motor mount bracket nut 70 52 —
Hood ground strap-
to-hood hinge bolt 12 9 —
Hood hinge nuts 12 9 —
Generator mounting bracket 25 18 —
Power steering pump bracket nuts 8 — 71
Power steering pump bolts 25 18 —
Valve tappet guide plate bolts 12 9 —
Generator positive cable nut 10 — 89
Power steering pressure tube to pump nut 40 30 —
Accelerator cable bracket-
to-intake manifold bolts 10 — 89
42-
pin connector bolt 10 — 89
Transmission oil cooler tube bracket-
to-motor mount bracket nut 27 20
Torque converter-
to-flywheel nuts 36 27 —
Engine-
to-transmission bolts 40 30 —
Engine mount bracket-
to-engine bolts 70 52 —
Engine mount bracket-
to-engine nuts 70 52 —
Water pump pulley bolts 25 18 —
Oil filter
b — — —
Upper intake manifold-
to-lower intake manifold bolts a — — —
Lower intake manifold-
to-cylinder head bolts a — — —
Rocker arm pivot-
to-cylinder head bolts a — — — Klj . 5 ba
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Cylinder Block and Lower End Components 9 18801 Radio ignition interference capacitor
10 12281 Ignition wire set —
LH 11 18696 Tube assembly
12 9424 Intake manifold (lower)
13 9439 Intake manifold gasket —
RH 14 9439 Intake manifold gasket —
LH 15 9A424 Intake manifold seal (rear)
16 6A008 Cylinder head-
to-block dowel 17 6010 Cylinder block
18 6A373 Engine rear plate (automatic transmission)
19 6375 Flywheel (automatic transmission)
20 6375 Flywheel (manual transmission)
21 6A372 Engine rear plate (manual transmission)
22 6723 Oil pan rear seal
23 6675 Oil pan
24 7120 Pilot bushing
25 9278 Oil pressure sensor
26 9B339 Oil pressure sensor fitting
27 9A424 Intake manifold seal (front)
28 18663 Heater water outlet tube
29 8255 Thermostat housing-
to-intake manifold gasket 30 8592 Water outlet connection
31 9875 Water thermostat
32 9D475 EGR valve
33 9H465 Vacuum control solenoid
34 9723 Accelerator cable bracket
35 9E936 Throttle body gasket
36 9J433 EGR transducer
37 9E498 Vacuum hose
38 12280 Ignition wire set —
RH Klj . 5 ba
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IN-
VEHICLE REPAIR
Flywheel
Removal and Installation 1. Remove the clutch. For additional information, refer to Section 308 - 01 .
2. Remove the flywheel bolts.
3. To install, reverse the removal procedure.
SECTION 303-
01A: Engine — 3.8L 2003 Mustang Workshop Manual Klj . 1 ba
22003 Mustang Workshop Manual
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IN-
VEHICLE REPAIR
Crankshaft Rear Seal
Removal 1. Remove the flywheel or the flexplate. For additional information, refer to Flexplate in this
section.
SECTION 303-
01A: Engine — 3.8L 2003 Mustang Workshop Manual Special Tool(s)
Impact Slide Hammer
100-
001 (T50T-100- A) Remover, Crankshaft Rear
Seal
303-
519 (T95P-6701- EH) Replacer, Rear Crankshaft
Seal
303-
516 (T95P-6701- BH) Spacer, Rear Crank Seal
Replacer
303-
561 (T96T-6701- B) Adapter, Crankshaft Rear Seal
(Use only the adapter retaining
bolts)
303-
518 (T95P-6701- DH) Adapter, Crankshaft Rear Seal
(Use only the adapter and the
center jack screw)
303-
S560 (T96T-6701- A)
Material Item Specification
SAE 5W-
20 Premium Synthetic
Blend Motor Oil
XO- 5W20-QSP or equivalent WSS-
M2C153-
H Klj . 1 ba
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5. Install the flywheel or the flexplate. For additional information, refer to
Flexplate in this section. Klj . 3 ba
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40. Lower the vehicle.
41. Support the transmission.
42. Install the special tool.
43. Install the special tools.
44. Using the special tool, remove the engine.
45. If necessary, remove the flywheel (6375) and the separator plate (6A372).
zRemove the bolts. Klj . 10 ba
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INSTALLATION
Engine
Installation
All vehicles
1. Install the separator plate and the flywheel.
2. Using the special tools, position the engine in the vehicle.
SECTION 303-
01A: Engine — 3.8L 2003 Mustang Workshop Manual Special Tool(s)
Heavy Duty Floor Crane
014-
00071 or equivalent Spreader Bar
303-
D089 (D93P-6001- A3) or
equivalent
Material Item Specification
SAE 5W-
20 Premium Synthetic
Blend Motor Oil
XO- 5W20-QSP or equivalent WSS-
M2C153-
H Klj . 1 ba
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