air condition FORD MUSTANG 2003 Owner's Manual

high idle during the
first cold start of the
day
lifter/lash
adjuster).
z A continuous, speed-
dependent rattle from
the engine — occurs
during idle or high idle
during the first cold
start of the day and
disappears as the
engine warms up z
Piston noise or
valvetrain noise
(bled down
lifter/lash
adjuster). z
Go To Pinpoint Test G .
z Idle vibration—a low-
frequency vibration (5-
20 Hz) or mild shake
that is felt through the
seat/floorpan z
Cylinder misfire. zUsing a scan tool, CHECK
the ignition system. CARRY
OUT a cylinder power test.
REFER to Section 303 - 00 .
z Engine or
torque
converter out of
balance. z
VERIFY the torque
converter to crankshaft pilot
clearance is correct,
REPAIR as necessary. RE-
INDEX the torque converter
on the flex plate by 120° on
a 3 bolt converter or 180° for
a 4 bolt converter. REFER to
Section 307 - 01 . RETEST
the vehicle.
z Idle vibration—a high-
frequency vibration
(20–80 Hz) or buzz,
that is felt through the
steering wheel or seat z
Exhaust system
mounts bound
up. z
VERIFY concern occurs at
engine firing frequency.
CHECK that the exhaust
system vibrates at the same
frequency as the engine.
ADD 9– 14 km (20–30 lb.) to
the tail pipe to test, CARRY
OUT Exhaust System Neutralizing in this section.
z Body mounts
loose. z
INSPECT the body mounts.
REPAIR as necessary.
z Power steering
lines grounded
out. z
INSPECT that the power
steering lines are not
contacting the chassis or
each other. REPAIR as
necessary. Symptom Chart—
Squeak and Rattle Condition
Possible Sources Action
z Squeak— heard
inside the vehicle
when
closing/opening
the door z
Insufficient
lubrication on
the door hinge
or check strap. z
LUBRICATE the hinge or check
strap.
z Internal door
components
loose, rubbing or
misaligned. z
CHECK the inside of the door.
TIGHTEN or ALIGN as
necessary. USE the Rotunda
Squeak and Rattle Kit to isolate
any rubbing components.
z Squeak— heard
inside the vehicle
when z
Worn or
damaged glass
run/channel. z
REPAIR or INSTALL a new
glass run/channel. REFER to
Section 501 - 11 . Klj . 31 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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misaligned.
screws. REPAIR as necessary.
z Loose interior
component or
trim. z
CARRY OUT a "touch test".
ELIMINATE the noise by
pressing or pulling on interior
trim and components. USE the
Rotunda Squeak and Rattle Kit
to isolate any rattling/squeaking
components.
z Squeak or rattle—
noise with a
vibration concern z
Damaged or
worn body
mounts. z
INSPECT the upper and lower
absorbers and washers for
damage or wear. CHECK the
body mount brackets for
damage. CHECK the nuts and
bolts are tightened to
specifications. TIGHTEN as
necessary.
z Damaged or
worn sub- frame
mounts. z
INSPECT the upper and lower
absorbers for damage or wear.
CHECK the sub- frame for
damage. CHECK the nuts and
bolts are tightened to
specifications. TIGHTEN as
necessary. Symptom Chart—
Steering Noise/Vibration Condition
Possible Sources Action
z Steering grunt or
shudder — occurs
when turning into
or out of a turn at
low speeds
(temperature
sensitive) z
Steering gear or power
steering hoses. z
GO to Steering Gear
Grunt/Shudder Test
component test in this
section.
z Steering System
clonk— hydraulic
knocking sound z
Air in the steering
hydraulic system. z
CHECK for leaks in the
system. PURGE the air
from the system.
REFER to Section 211 -
00 .
z Power steering
pump moan —
loud humming
noise occurs when
the steering wheel
is rotated to the
stop position.
Produces a 120-
600 Hz frequency
that changes with
rpm z
Power steering hose
grounded out to
chassis. z
INSPECT the power
steering hoses. REPAIR
as necessary.
z Aerated fluid. zCHECK for leaks in the
system. PURGE the air
from the system.
REFER to Section 211 -
00 .
z Steering gear isolators. zINSPECT the isolators
for wear or damage.
REPAIR as necessary.
z Low fluid. zCHECK the fluid level. Klj . 33 ba
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REFILL as necessary.
z Power steering pump
brackets loose or
misaligned. z
CHECK bolts, brackets
and bracket alignment.
TIGHTEN bolts to
specification. REPAIR
or INSTALL new
brackets as necessary.
REFER to Section 211 -
02 .
z Steering gear clunk
— occurs only
while cornering
over a bump (can
be temperature
sensitive) z
Steering gear. zINSPECT the steering
gear for loose mounting
bolts. TIGHTEN as
necessary. REFER to
Section 211 - 02 .
z Feedback (rattle,
chuckle or
knocking noise in
the steering gear)
— a condition
where roughness is
felt in the steering
wheel when the
vehicle is driven
over rough
surfaces z
Column
intermediate/flexible
shaft joints damaged or
worn. z
INSTALL a new
intermediate/flexible
shaft. REFER to Section 211 - 04 .
z Loose, damaged or
worn tie- rod ends. z
TIGHTEN the nuts to
specification or
INSTALL new tie- rod
ends as necessary.
REFER to Section 211 -
02 .
z Steering gear
insulators or mounting
bolts loose or
damaged. z
TIGHTEN the bolts or
INSTALL new bolts as
necessary. REFER to
Section 211 - 02 .
z Steering column
intermediate shaft bolts
are loose. z
TIGHTEN the bolts to
specification. REFER to
Section 211 - 04 .
z Steering column
damaged or worn. z
REPAIR or INSTALL a
new steering column as
necessary. REFER to
Section 211 - 04 .
z Loose suspension
bushings, bolts or ball
joints. z
INSPECT the
suspension system.
TIGHTEN or INSTALL
new components as
necessary. REFER to
Section 204 - 01 .
z Feedback (nibble
at the steering
wheel) — a
condition where
slight rotational
movement is felt in
the steering wheel
when the vehicle is
driven over rough
or grooved z
Lateral runout in the
tire or wheel. z
GO to Pinpoint Test H . Klj . 34 ba
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end surface of the
power steering pump
rotor.
z Damaged or worn
power steering pump
rotor splines.
z A crack on the inner
surface of the power
steering pump cam.
z Interference between
the power steering
pump rotor and cam.
z Damaged or worn
power steering pump
rotor and pressure
plates. 02 .
z Power steering
pump swish noise z
Power steering fluid
flow into the bypass
valve of the pump
valve housing with fluid
temperature below 54°
C (130°F). z
Acceptable condition.
z Power steering
pump whine noise z
Aerated fluid. zPURGE the air from the
system. REFER to
Section 211 - 00 .
CHECK for a leak in the
system.
z Damaged power
steering pump cam. z
REPAIR or INSTALL a
new power steering
pump as necessary.
REFER to Section 211 -
02 .
z Damaged valve cover
O-ring seal. z
REPAIR or INSTALL a
new power steering
pump as necessary.
REFER to Section 211 -
02 .
z Power steering
pump clicking
(mechanical) noise z
Power steering pump
rotor slippers too long,
excessive rotor slipper-
to-slot clearance or
damaged or worn rotor
assembly. z
REPAIR or INSTALL a
new power steering
pump as necessary.
REFER to Section 211 -
02 .
z Power steering
pump clatter noise z
Damaged corners on
the outside diameter or
the power steering
rotor or distorted rotor
slipper ring. z
REPAIR or INSTALL a
new power steering
pump as necessary.
REFER to Section 211 -
02 .
Symptom Chart—
Suspension Noise/Vibration Condition
Possible Sources Action
z Squeak or grunt— noise
from the front suspension,
occurs more in cold
ambient temperatures.
More noticeable over
rough roads or when
turning z
Front stabilizer
bar insulators. z
Under these conditions,
the noise is acceptable.
CHECK TSBs. Klj . 36 ba
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acceleration from a slow
speed or stop
assembly
mispositioned. and the rear suspension
for damage or wear.
REPAIR as necessary.
z Incorrect or high
CV joint
operating angle. z
CHECK vehicle ride
height is within limits.
REPAIR as necessary.
z Damaged or
worn front
suspension
components. z
CHECK for a loose
stabilizer bar, damaged
or loose strut/strut
bushings or loose or
worn ball joints.
INSPECT the steering
linkage for wear or
damage. REPAIR or
INSTALL new
components as
necessary.
z Shimmy—most
noticeable on
coast/deceleration. Also
hard steering condition z
Excessive
positive caster. z
CHECK the caster
alignment angle.
CORRECT as
necessary. REFER to
Section 204 - 00 .
Symptom Chart—
Tire Noise/Vibration Condition
Possible Sources Action
z Tire noise— hum/moan
at constant speeds z
Abnormal wear
patterns. z
SPIN the tire and CHECK
for tire wear. INSTALL a
new tire as necessary.
INSPECT for
damaged/worn suspension
components. CARRY OUT
wheel alignment.
z Tire noise— noise tone
lowers as the vehicle
speed is lowered z
Out-of- balance
tire. z
BALANCE the tire and
road test. INSTALL a new
tire as necessary. REFER
to Section 204 - 04 .
z Tire noise — ticking
noise, changes with
speed z
Nail puncture or
stone in tire
tread. z
INSPECT the tire. REPAIR
as necessary.
z Wheel and tire—
vibration and noise
concern is directly
related to vehicle
speed and is not
affected by
acceleration, coasting
or decelerating z
Damaged or
worn tire. z
Go To Pinpoint Test J .
z Tire wobble or
shudder — occurs at
lower speeds z
Damaged wheel
bearings. z
SPIN the tire and CHECK
for abnormal wheel
bearing play or roughness.
ADJUST or INSTALL new
wheel bearings as
necessary. REFER to
Section 204 - 01 .
z Damaged wheel. zINSPECT the wheel for
damage. INSTALL a new
wheel as necessary.
REFER to Section 204 -Klj . 38 ba
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Symptom Chart—
Transmission (Manual) and Transfer Case Noise/Vibration Condition
Possible Sources Action
z Clutch rattling noise—
occurs with clutch
engaged, noise
changes/disappears
with clutch pedal
depressed z
Flywheel bolts,
clutch housing bolts
or clutch pressure
plate bolts loose. z
TIGHTEN the bolts to
specifications. CHECK
the bolts for damage.
z Clutch squeaking
noise— noise is heard
when the clutch is
operated. Vehicle
moves slowly or
creeps when the clutch
is disengaged. Can
also be difficult to shift
into first and reverse
gear z
Pilot bearing seized
or damaged. z
INSTALL a new pilot
bearing. REFER to
Section 308 - 01 .
z Clutch squeaking
noise— occurs with
clutch pedal
depressed/released z
Worn clutch pedal
shaft or bushings. z
INSPECT the clutch
pedal for wear or
damage. REPAIR as
necessary. REFER to
Section 308 - 02 .
z Clutch whirring/rattle
noise— occurs when
clutch pedal is
depressed z
Worn, damaged or
misaligned clutch
release bearing. z
INSTALL a new clutch
release bearing.
REFER to Section 308 -
01 .
z Clutch grating/grinding
noise— occurs when
clutch pedal is
depressed z
Clutch pressure
plate fingers bent or
worn. z
INSPECT the clutch
pressure plate release
fingers. INSTALL a new
pressure plate as
necessary. REFER to
Section 308 - 01 .
z Contact surface of
clutch release
bearing worn or
damaged. z
INSTALL a new clutch
release bearing.
REFER to Section 308 -
01 .
z Clutch chatter— a
small amount of noise
when clutch pedal is
released at initial take-
off z
Clutch engagement. zAcceptable operating
condition.
z Clutch chatter/grabs—
in some cases a
shudder is felt. Occurs
with clutch pedal
depressed/released z
Damaged or worn
powertrain/driveline
mounts. z
INSPECT the
powertrain/drivetrain
mounts. INSTALL new
mounts as necessary.
REFER to Section 303 -
01A for 3.8L engines or
Section 303 - 01B for
4.6L (2V) engines.
z Binding or dragging
plunger of the clutch
master cylinder or
slave cylinder. z
CHECK the master and
slave cylinder
operation. INSPECT
the components for
damage or wear.
INSTALL a new master
or slave cylinder as
necessary. REFER to Klj . 40 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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z
Mismatched gear
sets. z
INSPECT the gear sets
for an uneven wear
pattern on the face of
the gear teeth. REPAIR
as necessary. REFER
to Section 308 - 03A for
T50D transmissions or
Section 308 - 03B for
TR3650 transmissions.
z Damaged or worn
transmission
bearing. z
INSPECT the
transmission bearings.
INSTALL new bearings
as necessary. REFER
to Section 308 - 03A for
T50D transmissions or
Section 308 - 03B for
TR3650 transmissions.
z Transmission
growling/humming—
noise occurs in the
forward gears. The
noise is more
prominent when the
gear is loaded. The
problem gear can be
located as the noise
occurs in a specific
gear position z
Gear is cracked,
chipped or rough. z
INSPECT the
transmission gears for
damage or wear.
INSTALL new gears as
necessary. REFER to
Section 308 - 03A for
T50D transmissions or
Section 308 - 03B for
TR3650 transmissions.
z Transmission
hissing— noise in
neutral or in forward
gears. As bearings
wear or break up, the
noise changes to a
thumping noise z
Damaged or worn
bearings. z
INSPECT the
transmission bearings.
INSTALL new bearings
as necessary. REFER
to Section 308 - 03A for
T50D transmissions or
Section 308 - 03B for
TR3650 transmissions.
z Transmission
knocking/thudding—
noise at low speeds in
forward gears z
Bearings with
damaged balls or
rollers or with pitted
and spalled races. z
INSPECT the
transmission bearings.
INSTALL new bearings
as necessary. REFER
to Section 308 - 03A for
T50D transmissions or
Section 308 - 03B for
TR3650 transmissions.
z Transmission
rumble/growl— noise at
higher speeds in
forward gears, more
pronounced in a
coast/deceleration
condition z
Incorrect driveline
angle. z
CHECK the driveline
angle. REPAIR as
necessary. REFER to
Section 205 - 00 .
z Driveshaft out of
balance or
damaged. z
CHECK the driveshaft
for damage, missing
balance weights or
undercoating. Using the
vibration analyzer (VA),
CHECK the driveshaft
balance. CARRY OUT
a driveline vibration
test. For additional Klj . 43 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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