brake FORD MUSTANG 2003 Workshop Manual

6. Disconnect the brake pedal-
to-power brake booster push rod.
1. Remove the self- locking pin.
2. Remove the BPP switch from the brake master cylinder push rod.
3. Remove the brake master cylinder push rod spacers (2B129).
4. Remove the brake master cylinder push rod bushing (2474).
7. Disconnect the clutch pedal position (CPP) switch electrical connector.
8. Disconnect the deactivation switch connector from the wiring harness. Klj . 2 ba
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13. Remove the self-
adjusting mechanism.
14. Remove the self- adjusting mechanism shaft bushings.
Installation 1. NOTE: Before the installation of the clutch pedal shaft or clutch pedal, remove and inspect the
brake and clutch pedal bushings. Clean and lubricate with a light film of engine oil meeting Ford
specification WSS- M2C153-G and replace the brake and clutch pedal bushing if excessive wear
is evident.
To install, reverse the removal procedure. Klj . 4 ba
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4. Remove the front seat. For additional information, refer to
Section 501 - 10 .
5. Unhook the clutch release lever cable (7K553) from the clutch pedal adjuster quadrant (7L583).
6. Open the hood, remove the screws and the clutch release cable (7K553).
7. NOTE: On 4.6L vehicles only
Remove the bolt and the clutch release lever cable bracket from the brake master cylinder
(2140).
8. Raise the vehicle. For additional information, refer to Section 100 - 02 .
9. Remove the screw from the clutch release lever cable clamp. Klj . 2 ba
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9 7N232 Gear shift plate
10 7K201 Gear selector interlock sleeve
11 305078-
S Pin
12 7302 Selector body
13 7230 Gear shifter fork 3-
4 shift 14 7160 Output shaft bearing snap ring
15 7117 Second speed synchronizer thrust washer
16 7175 First and second gear synchronizer inner cone
17 7174 First and second gear synchronizer outer cone
18 7107 Synchronizer blocking ring
19 7A044 Synchronizer hub insert (also part of 7124)
20 7K218 First and second speed synchronizer hub ball
21 7061 Output shaft assembly
22 7109 Synchronizer hub insert spring (also part of
7124)
23 7124 Sleeve (also part of 7061)
24 7173 First gear bearing spacer
25 7127 First gear bearing
26 7100 First gear
27 7065 Output shaft rear bearing
28 7D234 Thrust bearing
29 7D235 Thrust washer
30 — Synchronizer hub (part of 7124)
31 7124 Synchronizer assembly
32 7B340 Third gear
33 7B369 Third speed bearing
34 7B320 Third speed gear bearing spacer
35 7064 Snap ring
36 7119 Thrust washer
37 7102 Second gear
38 7728 Second speed gear bearing spacer
39 7693 Countershaft front bearing seal
40 7F431 Countershaft bearing assembly
41 7113 Countershaft cluster gear
42 7L172 Countershaft rear bearing adjustment shim
43 7195 Countershaft rear bearing retainer
44 7C210 Bolt
45 7144 Fifth speed cluster gear
46 7M000 Reverse brake ring
47 7G042 Thrust washer
48 7059 Fifth speed synchronizer retaining snap ring
49 7L276 Oil pick-
up funnel Klj . 3 ba
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14. Remove the fifth speed synchronizer retaining snap ring, the thrust washer (7G042), the reverse
brake ring (7M000), and the synchronizer blocking ring (7107).
15. Remove the fifth speed cluster gear (7144), the synchronizer blocking ring (7107), the synchronizer assembly (7124), and the fifth gear shifter fork (7230) as an assembly.
16. Remove the reverse gearshift lever retaining clip.
17. NOTE: Do not remove the reverse gearshift lever (7K002) at this time.
Using a TORX® bit driver, remove the shift lever reverse pin (7K024). Klj . 5 ba
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21.
NOTE: If not done so previously, soak the blocking ring in transmission fluid for ten minutes.
Install the fifth speed cluster gear, the synchronizer blocking ring, the synchronizer assembly,
and the fifth gear shifter fork as an assembly.
22. CAUTION: To prevent component damage when installing the extension housing
(7A039), the alignment tab on the reverse brake ring (7M000) must engage the alignment
slot in the extension housing.
NOTE: If not done so previously, soak the blocking ring in transmission fluid for ten minutes.
Install the synchronizer blocking ring, the reverse brake ring, the thrust washer, and the fifth
speed synchronizer retaining snap ring.
23. Apply pipe sealant to the reversing lamp switch threads and install the switch.
24. Install the reverse gearshift lever retaining clip. Klj . 8 ba
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29. Apply a 3.2-
mm (1/8-in) bead of silicone rubber to the sealing surface on the extension housing.
30. Install the detent ball, the shifter detent spring, and the gearshift offset lever. 1. Coat the shifter detent spring with petroleum jelly and install it in the gearshift offset lever.
2. Lubricate the detent plate and install the detent ball in the neutral position on the plate.
3. Position the gearshift offset lever in the extension housing with the gear shift interlock
spring over the detent ball.
31. CAUTION: To prevent component damage, the alignment tab on the reverse brake
ring must align with the alignment slot in the extension housing.
NOTE: Verify that the oil pick- up funnel engages the fifth gear synchronizer.
Slide the gearshift offset lever and the extension housing into place as an assembly. Press
downward on the gearshift offset lever to compress the shifter interlock spring and push the
gearshift offset lever and extension housing into place. Klj . 10 ba
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DESCRIPTION AND OPERATION
Speed Control
The speed control system consists of the following components:
zspeed control actuator cable (9A825)
z deactivator switch
z output shaft sensor (OSS)
z speed control actuator switches (9C888)
z brake pedal position (BPP) switch (13480)
z speed control servo (9C735)
z clutch pedal position switch (manual transmission only)
SECTION 310-
03: Speed Control 2003 Mustang Workshop Manual Klj . 1 ba
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DIAGNOSIS AND TESTING
Speed Control
Refer to Wiring Diagrams Cell
31 , Speed Control for schematic and connector information.
Principles of Operation
The speed control system is designed to maintain vehicle speed above 48 km/h (30 mph). After the
ON switch is depressed, depressing the SET/ACCEL switch will activate the speed control servo. To
increase a set speed, either depress and hold for continuous acceleration, or momentarily tap the
SET/ACCEL switch for 1.6 km/h (1 mph) acceleration increments. To decrease a set speed, depress
and hold the COAST switch until the target speed is reached, or momentarily tap the COAST switch
for 1.6 km/h (1 mph) deceleration increments. When the speed control system has been disabled by
tapping the brake pedal, the RESUME switch can be depressed and the vehicle will return to the
original set speed if the vehicle is traveling over 48 km/h (30 mph) and the OFF switch has not been
depressed.
NOTE: The deactivator switch is provided as an additional safety feature. Normally, when the brake
pedal is depressed, an electrical signal from the brake lamp circuit to the speed control servo will
deactivate the system. Under increased brake pedal effort, the deactivator switch will open and
remove power to the speed control servo, releasing the throttle independent of the speed control
servo.
NOTE: The air bag sliding contract provides the electrical interface between the steering column wiring
and the speed control actuator switches in the steering wheel.
The inputs to the speed control servo are the:
zvehicle speed signal.
SECTION 310-
03: Speed Control 2003 Mustang Workshop Manual Special Tool(s)
Worldwide Diagnostic System
(WDS)
418-
F224,
New Generation STAR (NGS)
Tester
418- F052, or equivalent
diagnostic tool 73 Digital Multimeter or
equivalent
105-
R0051 Breakout Box, EEC-V Control
System 418-049, or equivalent
014- 00950 Klj . 1 ba
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z
speed control actuator switches.
z brake pedal position (BPP) switch.
z clutch pedal position (CPP) switch.
z deactivator switch.
The output of the speed control servo is the:
zspeed control actuator cable controlling the throttle position.
Inspection and Verification
NOTE: If any concerns are noted with the speedometer, stoplamps, or horn, address those concerns
by referring to their associated sections before continuing speed control diagnosis.
1. Verify the customer concern by operating the speed control system.
2. Visually inspect for obvious signs of mechanical and electrical damage.
3. If the fault is not visually evident, verify the symptom and GO to the Symptom chart.
Symptom Chart
NOTE: New speed control diagnostic software is available in Version 12 or higher for the diagnostic
tool. When using this software, it is necessary to use Next Generation Speed Control Adapter 007-
00586 with the diagnostic tool.
NOTE: Refer to the Wiring Diagrams for connector numbers stated in the Pinpoint Test.
Visual Inspection Chart Mechanical Electrical
z
Deactivator switch
z Speed control actuator cable not attached to throttle
z Speed control actuator cable not fully seated to the
engine bracket z
Central junction box (CJB)
Fuse:
„15 (15A)
„ 33 (15A)
„ 35 (15A)
z Battery junction box (BJB)
fuse:
„HORN (20A)
z Wiring harness
z Loose or corroded
connections
z Speed control actuator
switches
Symptom Chart Condition
Possible Sources Action
z The speed control is zCentral junction zGo To Pinpoint Test A . Klj . 2 ba
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