wheel alignment FORD MUSTANG 2003 Owner's Manual

presence of the vibration. If the vibration is not evident, check the non-
driving wheels with a
wheel balancer to rule out imbalance as a possible cause. If required, balance the non- driving
wheels and repeat the road test. If the vibration is still evident, proceed to Step 2.
2. Mark the relative position of the drive wheels to the wheel nuts. Remove the wheels. Install all the nuts in the reversed position and repeat the road speed acceleration. If the vibration is gone,
refer to the tire and wheel runout procedure in Section 204 - 04 . If the vibration persists, proceed
to Step 3.
3. Inspect the driveshaft for signs of physical damage, missing balance weight, undercoating, incorrect seating, wear and binding universal joints. Clean the driveshaft and install new
universal joints or a new driveshaft if damaged. Check the index marks (paint spots) on the rear
of the driveshaft and pinion flange. If these marks are more than one- quarter turn apart,
disconnect the driveshaft and re- index to align the marks as closely as possible. After any
corrections are made, recheck for vibration at the road test speed. If the vibration is gone,
reinstall the wheels and road test. If the vibration persists, proceed to Step 4.
4. Raise the vehicle on a hoist and remove the wheels. Rotate the driveshaft by turning the axle and measure the runout at the front, the center, and the rear of the driveshaft with the indicator.
If the runout exceeds 0.89 mm (0.035 inch) at the front or center, a new driveshaft must be
installed. If the front and center are within this limit, but the rear runout is not, mark the rear
runout high point and proceed to Step 5. If the runout is within the limits at all points, proceed to
Step 7.
5. NOTE: Check the U-joints during re- indexing. If a U-joint feels stiff or gritty, install new U- joints.
Scribe alignment marks on the driveshaft and the pinion flange. Disconnect the driveshaft,
rotate it one-half turn, and reconnect it. Circular pinion flanges can be turned in one- quarter
increments to fine tune the runout condition. Check the runout at the rear of the driveshaft. If it is
still over 0.89 mm (0.035 inch), mark the high point and proceed to Step 6. If the runout is no
longer excessive, check for vibration at the road test speed. If vibration is still present, re- index
the driveshaft slip yoke on the transmission output shaft one- half turn and road test the vehicle.
If the vibration persists, proceed to Step 7.
6. Excessive driveshaft runout may originate in the driveshaft itself or in the pinion flange. To determine which, compare the two high points marked in Steps 4 and 5. If the marks are close
together, within about 25 mm (1 inch), a new shaft must be installed and the vehicle road
tested. Klj . 12 ba
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24. Connect the parking brake cable and conduit to the caliper and parking brake lever. For
additional information, refer to Section 206 - 05 .
25. Repeat the three previous steps for the brake components on the other side of the vehicle.
26. Install the exhaust system. For additional information, refer to Section 309 - 00 .
27. Install the wheels and tires. For additional information, refer to Section 204 - 04 .
28. CAUTION: If refilling the rear axle (4001), first add 118 ml (4 oz) of Additive Friction
Modifier C8AZ- 19B546-A or equivalent meeting Ford specification EST- M2C118-A.
Check the lubricant level. zIf necessary, fill the rear axle housing to the level shown with SAE 75W- 140 High
Performance Rear Axle Lubricant F1TZ-19580- B or equivalent meeting Ford
specification WSL- M2C192-A. The refill capacity is 1.23- 1.37 liters (2.6-2.9 pints).
29. Lower the vehicle.
30. Check, and adjust the wheel alignment as necessary. For additional information, refer to Section 204 - 00 . Klj . 13 ba
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16. Install the wheel and tire assembly. For additional information, refer to
Section 204 - 04 .
17. Lower the vehicle.
18. Check the wheel alignment. Adjust as necessary. For additional information, refer to Section 204 - 00 . Klj . 9 ba
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not machine a new brake disc.
7. For vehicles with a two- piece hub and brake disc assembly:
z Match-mark before disassembly.
z Remove the brake disc.
z Using a die grinder with a mild abrasive (Scotch Brite® type), remove any rust or
corrosion from the hub and brake disc mounting surfaces.
z Align the match- marks and reinstall the brake disc on the hub.
8. CAUTION: Do not use a bench lathe to machine brake discs.
NOTE: The depth of cut must be between 0.10 and 0.20 mm (0.004 and 0.008 inch). Lighter
cuts will cause heat and wear. Heavier cuts will cause poor brake disc surface finish.
Using on- vehicle brake lathe, machine the brake discs. Follow the manufacturer's instructions.
After machining, make sure the brake disc still meets the thickness specification.
9. Using a dial indicator, verify that the brake disc lateral runout is now within vehicle specification.
10. Remove any metal chips.
11. Remove the hub adapter.
12. Remove any remaining metal chips from the machining operation.
13. CAUTION: Do not carry out this step on rear drum- in-hat brake discs.
For vehicles with a two- piece hub and a non drum- in-hat brake disc assembly:
z Remove the brake disc from the hub.
z Remove any remaining metal chips from hub and brake disc mounting surfaces and from
the ABS sensor.
z Apply High Temperature Nickel Anti- Seize Lubricant F6AZ-9L494-AA to the mounting
surfaces.
z Using the match- marks, mount the brake disc on the hub.
14. Install the caliper and check brake operation.
Symptom Chart Symptom Chart
Condition
Possible Sources Action
z The Brakes Pull or
Drift z
Tire air pressure.
z Wheel alignment.
z Brake pads.
z Brake components.
z Suspension
component. z
Go To Pinpoint Test A .
z The Red Brake
Warning Indicator Is z
Instrument cluster.
z Circuit. z
Go To Pinpoint Test B . Klj . 4 ba
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PINPOINT TEST H: DTC C1233 (LF), C1234 (RF), C1235 (RR), C1236
(LR), ANTI-
LOCK BRAKE SENSOR INPUT SIGNAL MISSING Test Step Result / Action to Take
G1 CHECK THE VEHICLE
COMPONENTS z
Check for correct wheel and tire
size, front- to-rear and side- to-
side.
z Check for excessive bearing
end play.
z Check the anti- lock brake
sensor indicator for a
deformation or missing teeth.
z Are the conditions OK? Yes
GO to
G2 .
No
REPAIR as necessary. CLEAR the DTCs. REPEAT the
self- test. G2 TEST DRIVE THE VEHICLE
z
Enter the following diagnostic
mode on the diagnostic tool:
CLEAR the DTCs.
z Key in OFF position.
z Key in ON position.
z Test drive the vehicle over 24
kph (15 mph).
z Enter the following diagnostic
mode on the diagnostic tool:
Retrieve DTCs.
z Is DTC C1222 retrieved? Yes
INSTALL a new anti-
lock brake control module; REFER
to Module . REPEAT the self-
test.
No
If another DTC is retrieved, GO to the Anti- Lock Brake
Control Module Diagnostic Trouble Code (DTC) index.
If no DTCs are retrieved, the system is OK. Test Step Result / Action to Take
H1 CHECK THE SUSPECT ANTI-
LOCK BRAKE
SENSOR z
Check the suspect anti- lock brake sensor
mounting.
z Check the suspect anti- lock brake sensor for
excessive dirt build up, obstructions, and
damage.
z Is the suspect anti- lock brake sensor and
mounting OK? Yes
GO to
H2 .
No
REPAIR as necessary. CLEAR the
DTCs. REPEAT the self-test. H2 CHECK THE SUSPECT ANTI-
LOCK BRAKE
SENSOR INDICATOR z
Check the suspect anti- lock brake sensor
indicator for corrosion, nicks, bridged teeth,
damaged teeth, correct mounting, and alignment
with the anti- lock brake sensor.
z Check the air gap and bearing end play.
z Is the suspect anti- lock brake sensor
indicator OK? Yes
GO to
H3 .
No
INSTALL a new anti- lock brake sensor
indicator; REFER to Sensor — Front or
Sensor — Rear . CLEAR the DTCs.
REPEAT the self- test. H3 CHECK THE ANTI-
LOCK BRAKE SENSOR
OUTPUT z
Key in ON position.
z Enter the following diagnostic mode on the
diagnostic tool: CLEAR the DTCs..
z Key in OFF position.
z Key in ON position. Yes
INSTALL a new anti-
lock brake control
module; REFER to Module . REPEAT
the self- test. Klj . 12 ba
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column bearing(s).
bearing(s). REFER to
Section 211 - 04 .
z Loose, worn or
damaged lower
steering column shaft
U-joint(s). z
INSTALL a new lower
steering column shaft.
REFER to Section 211 - 04 .
z Wander zUnevenly loaded or
overloaded vehicle. z
INFORM the
customer of incorrect
vehicle loading.
z Loose, worn or
damaged front wheel
spindle tie- rod. z
GO to the Tie- Rod
Articulation Torque
Component Test.
z Loose, worn or
damaged tie- rod ends. z
GO to the Steering
Linkage Component
Test.
z Loose or damaged
steering gear mounting
bolts. z
INSTALL new or
TIGHTEN bolts.
REFER to Section 211 - 02 .
z Loose lower steering
column shaft U- joint
bolts. z
TIGHTEN the bolts.
REFER to Section 211 - 04 .
z Loose, worn or
damaged lower
steering column shaft
U-joints. z
INSTALL a new lower
steering column shaft.
REFER to Section 211 - 04 .
z Loose, worn or
damaged steering
column bearing(s). z
INSTALL new
steering column
bearings. REFER to
Section 211 - 04 .
z Suspension
components. z
REFER to Section 204 - 00 for suspension
system diagnosis and
testing.
z Drift/Pull zUnevenly loaded or
overloaded vehicle. z
INFORM the
customer of incorrect
vehicle loading.
z Wheel alignment. zCHECK the wheel
alignment. ADJUST
as required. REFER
to Section 204 - 00 .
z Loose, worn or
damaged front wheel
spindle tie- rod. z
GO to the Tie- Rod
Articulation Torque
Component Test.
z Loose, worn or
damaged tie- rod ends. z
GO to the Steering
Linkage Component
Test.
z Suspension
components. z
REFER to Section 204 - 00 for suspension
system diagnosis and
testing.
z The steering gear valve
effort out of balance. z
GO to Steering Gear
Valve Component
Test in this section.
z Check the brake
system for proper z
REFER to Section 206 - 00 . Klj . 6 ba
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operation.
z Incorrect
frame/underbody
alignment. z
CORRECT as
required. REFER to
Frame Dimension
Manual.
z Feedback zLoose, worn or
damaged front wheel
spindle tie- rod. z
GO to the Tie- Rod
Articulation Torque
Component Test.
z Loose, worn or
damaged tie- rod ends. z
GO to the Steering
Linkage Component
Test.
z Loose or damaged
steering gear insulators
or bolts. z
INSTALL new or
TIGHTEN the
retaining bolts.
REFER to Section 211 - 02 .
z Loose lower steering
column shaft U- joint
bolts. z
TIGHTEN the bolts.
REFER to Section 211 - 04 .
z Loose suspension
bushings, fasteners or
ball joints. z
INSTALL new
suspension
components as
necessary. REFER to
Section 204 - 01 .
z Worn or damaged
steering column
bearing(s). z
INSTALL new
steering column
bearing(s). REFER to
Section 211 - 04 .
z Poor
Returnability/Sticky
Steering z
Binding lower steering
column shaft U- joints. z
INSTALL a new lower
steering column shaft.
REFER to Section 211 - 04 .
z Loose, worn or
damaged front wheel
spindle tie- rod. z
GO to the Tie- Rod
Articulation Torque
Component Test.
z Loose, worn or
damaged tie- rod ends. z
GO to the Steering
Linkage Component
Test.
z Suspension
components. z
REFER to Section 204 - 00 for suspension
system diagnosis and
testing.
z Binding steering
column bearing(s). z
INSTALL new
steering column
bearing(s). REFER to
Section 211 - 04 .
z Shimmy zLoose, worn or
damaged tie- rod end. z
GO to the Steering
Linkage Component
Test.
z Loose, worn or
damaged front wheel
spindle tie- rod. z
GO to the Tie- Rod
Articulation Torque
Component Test.
z Suspension
components. z
REFER to Section 204 - 00 for suspension
system diagnosis and
testing. Klj . 7 ba
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11. Turn (or have an assistant turn) the steering wheel slightly in both directions and release quickly
while watching the pressure gauge.
zThe pressure reading should move from the normal back pressure reading and snap
back as the steering wheel is released.
z If the pressure returns slowly or sticks, the rotary valve in the steering gear is sticking or
the steering column is binding. Check the steering column and linkages before servicing
the steering gear.
Tie- Rod Articulation Torque
1. NOTE: This check may be done with the steering gear on or off the vehicle.
Disconnect the tie- rod end from the front wheel spindle. For additional information, refer to
Section 211 - 02 .
2. Move the front wheel spindle tie- rod back and forth three times.
3. Hook the special tool 211- 034 (T74P-3504-Y) over the tie-rod end or the threaded portion of the
front wheel spindle tie- rod and measure the force required to move the front wheel spindle tie-
rod. Refer to Tie- Rod Articulation Torque in General Specifications in this section.
4. If the force required to move the front wheel spindle tie- rod does not meet the specifications,
install a new front wheel spindle tie- rod. For additional information, refer to Section 211 - 02 .
Steering Gear Valve 1. With the vehicle in motion, place the transmission in NEUTRAL and turn the engine OFF. zIf the vehicle does not pull with the engine OFF, install a new steering gear. For
additional information, refer to Section 211 - 02 .
2. If the vehicle pulls with the engine OFF, cross- switch the front wheels.
3. If the vehicle pulls to the opposite side, cross- switch the front and rear wheels on the same side.
4. If the vehicle pull direction does not change, check the front suspension components, wheel alignment and frame alignment. For additional information, refer to Section 204 - 00 or frame
dimensions manual. Klj . 10 ba
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2. Install the steering gear into the special tools.
3. Clean the exterior of the steering gear with solvent. If necessary, drain any excess power
steering fluid.
4. Inspect the steering gear housing for cracks and other damage. If necessary, install a new steering gear.
5. Verify the power steering gear input shaft bearing rotates freely. If necessary, install a new steering gear.
6. Place an alignment mark on the tie- rod ends, nuts and front wheel spindle tie- rods. Remove the
tie- rod ends and nuts.
7. CAUTION: Use care not to damage the front suspension steering ball stud dust
seals. If the front suspension steering ball stud dust seals are damaged, this will allow
contamination into the steering gear and cause leakage.
Remove the clamps and the two front suspension steering ball stud dust seals.
zDiscard any clamps that are damaged or excessively corroded.
z Discard any front suspension steering ball stud dust seals that are damaged. Klj . 2 ba
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PINPOINT TEST E: CLUTCH RELATED VIBRATIONS z
Inspect the flywheel for damage and
runout. Refer to Flywheel Runout Check .
z Is flywheel OK? Yes
GO to
D6 .
No
TIGHTEN, RESURFACE or INSTALL a new
flywheel as necessary. REFER to Section 308 -
01 . TEST the system for normal operation.
D6 INSPECT RELEASE LEVER
INTERFACE TO PIVOT STUD z
Inspect the release lever and the pivot
stud for damage or misalignment.
z Are there any signs of damage
present or misalignment between the
release lever and pivot stud? Yes
INSTALL a new pivot stud and release lever.
REFER to
Section 308 - 01 . TEST the system
for normal operation.
No
VERIFY customer concern. GO to Symptom Chart if necessary.
Test Step Result / Action to Take
E1 CHECK FOR ENGINE COMPONENT
GROUNDING z
Raise the vehicle on a hoist. Refer to
Section 100 - 02 .
z Check the engine and transmission
mounts for grounding.
z Check for exhaust manifolds or other
engine component grounding on the
body or frame.
z Is there evidence of grounding on
the body or frame? Yes
REPAIR the components as necessary. TEST the
system for normal operation.
No
GO to
E2 .
E2 CHECK FOR ACCESSORY DRIVE
VIBRATIONS z
Key in START position.
z Remove the accessory drive belt.
z Does the vibration stop when the
accessory drive belt is removed
from the engine? Yes
REFER to
Section 303 - 05 to diagnose the
accessory drive belt components.
No
STOP the engine and INSTALL the drive belt. GO
to E3 .
E3 CHECK FOR RELEASE BEARING
NOISE z
Key in START position.
z Depress and hold the clutch pedal.
z Is a whirring, grating, or grinding
noise present only when pedal is
pushed? Yes
INSTALL a new clutch release hub and bearing.
REFER to
Section 308 - 01 .
No
GO to E4 .
E4 INSPECT THE FLYWHEEL
z
Key in OFF position.
z Remove the transmission. Refer to
Section 308 - 03A or
Section 308 - 03B .
z Carry out a flywheel check. Refer to
Flywheel Runout Check . Yes
VERIFY customer concern. GO to
Symptom Chart if necessary.
No Klj . 10 ba
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