Test G FORD MUSTANG 2003 Workshop Manual

Pinpoint Tests
PINPOINT TEST A: THE SHIFT INTERLOCK SYSTEM DOES NOT
RELEASE/LOCK CORRECTLY z
The shift control is
out of correct gear
relationship z
Transmission shift
cable and bracket.
z Retainer bracket.
z Shift control linkage
out of adjustment. z
Go To Pinpoint Test B .
z Transmission range
indicator does not
correspond to the
gear z
Transmission shift
cable bracket. z
TIGHTEN the bolts
holding transmission
shift cable bracket.
z Transmission shift
cable loose from the
transmission
retainer bracket. z
TIGHTEN the bolts.
z Shift linkage. zVERIFY digital
transmission range
(DTR) sensor range for
correct adjustment.
REFER to Section 307 -
01 .
z The Transmission
Control Switch (TCS)
Is Inoperative z
CJB Fuse 28 (15A).
z TCS.
z TCS not cycled
during self- test.
z Powertrain control
module (PCM).
z Circuitry. z
Go To Pinpoint Test C .
z The Transmission
Control Indicator
Lamp (TCIL) Is Not
Operating Correctly z
Bulb.
z Instrument cluster.
z Powertrain control
module. z
REFER to Section 413 -
01 .
z Excessive Shift Effort zTransmission shift
cable. z
INSTALL a new
transmission shift cable.
z Cable bracket. zADJUST the cable.
TIGHTEN the screws.
z Transmission Range
Selector Lever Will
Not Shift z
Transmission shift
cable. z
INSTALL a new
transmission shift cable.
z Broken transmission
shift cable. z
INSTALL a new
transmission shift cable. Test Step Result / Action to Take
A1 TEST THE BRAKE LIGHTS
z
Key in ON position.
z Apply the brake pedal and observe the stoplamps.
z Do the stoplamps illuminate? Yes
GO to
A2 .
No
REFER to Section 417 -Klj . 2 ba
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PINPOINT TEST B: THE SHIFT CONTROL IS OUT OF CORRECT
GEAR RELATIONSHIP 01 .
A2 CHECK CIRCUIT 511 (LG) FOR AN OPEN
z
Key in OFF position.
z Disconnect: Shift Lock Actuator C2127.
z Measure the voltage between the shift lock actuator C2127- 3,
Circuit 511 (LG), harness side and ground while depressing
and releasing the brake pedal.
z Is the voltage greater than 10 volts with the brake pedal
depressed and 0 volts with the brake pedal released? Yes
GO to
A3 .
No
REPAIR the circuit. TEST
the system for normal
operation. A3 CHECK CIRCUIT 294 (WH/LB) FOR AN OPEN
z
Key in ON position.
z Measure the voltage between shift lock actuator C2127- 1,
Circuit 294 (WH/LB), harness side and ground.
z Is the voltage greater than 10 volts? Yes
GO to
A4 .
No
REPAIR the circuit. TEST
the system for normal
operation. A4 TEST CIRCUIT 1205 (BK) FOR AN OPEN
z
Measure the resistance between shift lock actuator C2127- 2,
Circuit 1205 (BK), harness side and ground.
z Is the resistance less than 5 ohms? Yes
INSTALL a new shift lock
actuator. REFER to
Brake Shift Interlock Actuator .
TEST the system for
normal operation.
No
REPAIR the circuit. TEST
the system for normal
operation. Klj . 3 ba
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PINPOINT TEST C: THE TRANSMISSION CONTROL SWITCH (TCS)
IS INOPERATIVE Test Step Result / Action to Take
B1 CHECK THE SHIFT
CONTROL LINKAGE z
Key in ON position.
z Apply the brake pedal.
z Actuate the transmission
range selector lever in all
ranges.
z Observe the shift control
linkage during operation.
z Is the shift control linkage
OK? Yes
GO to
B2 .
No
REPAIR as necessary. TEST the system for normal
operation. B2 CHECK THE TRANSMISSION
SHIFT CABLE z
Check the transmission shift
cable and bracket installation
and tightness.
z Is the transmission shift
cable correctly installed
and adjusted? Yes
GO to
B3 .
No
REPAIR as necessary. TEST the system for normal
operation. B3 CHECK THE
LINKAGE/CABLE FOR CORRECT
GEAR RELATIONSHIP z
Apply the brake pedal.
z Actuate the transmission
range selector lever in all
ranges.
z Does the indicator match
the gear selection? Yes
VERIFY the correct adjustment of the digital transmission
range (DTR) sensor. REFER to
Section 307 - 01 . Adjust the
digital DTR sensor if necessary. TEST the system for
normal operation.
No
ADJUST the transmission shift cable. REFER to Cable Adjustment . TEST the system for normal operation.
Test Step Result / Action to Take
C1 CHECK THE VOLTAGE TO THE TRANSMISSION CONTROL
SWITCH z
Key in OFF position.
z Disconnect: Transmission Control Switch C279.
z Key in ON position.
z Measure the voltage between TCS C279- 3, Circuit 911
(WH/LG), harness side and ground. Yes
GO to
C2 .
No
REPAIR the circuit. TEST
the system for normal
operation. Klj . 4 ba
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z
Is the voltage greater than 10 volts? C2 CHECK THE TCS
z
Measure the resistance between TCS Pin 3 (component
side), and TCS Pin 4 (component side), while depressing and
releasing the TCS.
z Is the resistance less than 5 ohms with the TCS
depressed and greater than 10,000 ohms with the TCS
released? Yes
GO to
C3 .
No
INSTALL a new TCS. Test
the system for normal
operation. C3 CHECK CIRCUIT 224 (TN/WH) FOR AN OPEN
z
Key in OFF position.
z Disconnect: PCM C175.
z Measure the resistance between TCS C279- 4, Circuit 224
(TN/WH), harness side and PCM C175- 29, Circuit 224
(TN/WH), harness side.
z Is the resistance less than 5 ohms? Yes
REFER to Powertrain
Control/Emissions
Diagnosis (PC/ED)
manual.
No
REPAIR the circuit. TEST
the system for normal
operation. Klj . 5 ba
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DIAGNOSIS AND TESTING
Manual Transmission and Clutch
Inspection and Verification
It is important to get an accurate description of the concern before any diagnosis can be carried out.
Ask questions as to whether it occurs when hot or cold, during shifting, driving at a particular speed or
in a particular gear. If possible, have the customer demonstrate the concern.
zWith the vehicle at a complete stop, shift through all the gears and evaluate the noise at
different engine rpm. Check for any noises in NEUTRAL at different engine rpm.
Symptom Chart SECTION 308-
00: Manual Transaxle/Transmission and Clutch — General
Information 2003 Mustang Workshop
Manual Symptom Chart
Condition
Possible Sources Action
z Clutch slippage zClutch pedal
sticking.
z Pressure plate
diaphragm
spring damaged
or weakened.
z Clutch pressure
plate damaged.
z Clutch disc
facing damaged
or worn
excessively.
z Clutch disc
facing surface
hardened or oil-
coated.
z Clutch release
hub and bearing
binding.
z Flywheel glazed
or damaged.
z loose pressure
plate to flywheel
bolts z
Go To Pinpoint Test A .
z Clutch chatter or shudder zLoose or worn
engine mount.
z Loose pressure
plate to flywheel
bolts
z Oil on clutch
disc facing.
z Clutch pressure
plate damaged z
Go To Pinpoint Test B . Klj . 1 ba
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or excessive
runout.
z Clutch disc
facing surface
hardened or
damaged.
z Flywheel
surface glazed
or damaged.
z Transmission
input shaft
eccentric or not
perpendicular.
z Clutch drag zClutch drag.
z Cable release
linkage outside
the flywheel
housing worn,
cracked, bent.
z Excessive
runout or
damaged clutch
disc.
z Clutch disc
splines rusted or
worn.
z Loose pressure
plate to flywheel
bolts. z
Go To Pinpoint Test C .
z Clutch pedal pulsation zClutch disc
damaged or
worn.
z Excessive
flywheel runout.
z Loose pressure
plate to flywheel
bolts.
z Improperly
assembled
release lever to
pivot stud. z
Go To Pinpoint Test D .
z Clutch related vibrations zEngine
component
grounding
against frame.
z Loose flywheel
bolts.
z Excessive
flywheel runout.
z Imbalanced
clutch pressure
plate.
z Accessory drive
belt loose or
damaged. z
Go To Pinpoint Test E .
z Hard shifting zManual
transmission
concern.
z Loose pressure
plate to flywheel
bolts. z
Go To Pinpoint Test F . Klj . 2 ba
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z
Excessive noise zPilot bearing
worn or
damaged.
z Excessive
crankshaft end
play. z
Go To Pinpoint Test G .
z Transmission difficult to
shift z
Lubricant. zADD or DRAIN AND
FILL with specified
lubricant.
z Internal shift
mechanism. z
CHECK the internal shift
mechanism for smooth
operation. REPAIR or
INSTALL a new
mechanism as
necessary.
z Sliding gears,
synchronizers. z
CHECK for free
movement of gears and
synchronizers. REPAIR
or INSTALL new
components as
necessary.
z Housings, shaft. zCHECK for binding
condition between the
input shaft and the
engine crankshaft pilot
bearing or bushing.
REPAIR or INSTALL
new components as
necessary. REFER to
Section 308 - 03A or
Section 308 - 03B .
z Loose pressure
plate to flywheel
bolts. z
CHECK for loose bolts
at the pressure plate.
INSTALL new
components as
necessary. REFER to
Section 308 - 01 .
z NOTE: While verifying
the condition, determine
whether the noise is gear
rollover noise, release
bearing rub or some
other transmission-
related noise. Gear
rollover noise, inherent in
manual transmissions, is
caused by the constant
mesh gears turning at the
engine idle speed while
the clutch is engaged and
the transmission is in
NEUTRAL. Release
bearing rub is sometimes
mistaken for mainshaft
bearing noise. Gear
rollover noise will
disappear when the
clutch is disengaged or
when the transmission is
engaged in gear. z
Lubricant. zADD or DRAIN AND
FILL with specified
lubricant. Klj . 3 ba
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Pinpoint Tests
PINPOINT TEST A: CLUTCH SLIPPAGE
PINPOINT TEST B: CLUTCH CHATTER OR SHUDDER z
Shafts or bore.
z Overloading of
vehicle.
z Incorrect
preload.
z Input shaft oil
dam. z
Install new components
as necessary and verify
the oil dam installation is
correct. REFER to
Section 308 - 03A or
Section 308 - 03B .
CHECK for correct
installation of the snap
ring on the mainshaft
next to the oil dam.
z Oil baffle in the
input bearing
shim pack. z
INSTALL a new oil
baffle, making sure it is
not damaged during
assembly. REFER to
Section 308 - 03A or
Section 308 - 03B .
Test Step Result / Action to Take
A1 INSPECT THE CLUTCH LINKAGE
z
Key in OFF position.
z Block the wheels and apply the parking brake.
z Depress and slowly release the clutch pedal.
z Does the clutch pedal release without
binding? Yes
GO to
A2 .
No
INSPECT the clutch pedal. REFER to
Section 308 - 02 .
A2 CARRY OUT A STALL TEST
z
Key in START position.
z Block the wheels and apply the parking brake.
z Place the transmission in fourth gear.
z Increase the engine speed to 2000 rpm and
slowly release the clutch pedal.
z Does the engine stall within five seconds? Yes
The clutch is not slipping. VERIFY the
customer concern.
No
INSPECT the clutch components for
damage.
Test Step Result / Action to Take
B1 CHECK ENGINE OR TRANSMISSION MOUNTS
z
Inspect all the engine and transmission mounts
for looseness or damage. Refer to Section 303 -
01A or
Section 303 - 01B and
Section 308 - 03A or
Section 308 - 03B .
z Are any of the engine or transmission mounts Yes
TIGHTEN or INSTALL new engine
mounts or transmission mounts. TEST
the system for normal operation. Klj . 7 ba
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PINPOINT TEST C: CLUTCH DRAG loose or damaged? No
GO to
B2 .
B2 INSPECT PRESSURE PLATE BOLTS
z
Inspect the pressure plate- to-flywheel bolts.
z Are any of the pressure plate- to-flywheel bolts
loose? Yes
TIGHTEN or INSTALL new bolts.
REFER to
Section 308 - 01 . TEST the
system for normal operation.
No
GO to B3 .
B3 INSPECT PRESSURE PLATE
z
Remove the clutch pressure plate. Refer to
Section 308 - 01 .
z Inspect the clutch pressure plate. Refer to
Pressure Plate Check .
z Are any signs of damage present on the clutch
pressure plate? Yes
INSTALL a new clutch pressure plate.
REFER to
Section 308 - 01 . TEST the
system for normal operation.
No
GO to B4 .
B4 CHECK CLUTCH DISC
z
Carry out the clutch disc inspection procedure.
Refer to Disc Check .
z Is the clutch disc OK? Yes
GO to
B5 .
No
INSTALL a new clutch disc. REFER to
Section 308 - 01 . TEST the system for
normal operation. B5 INSPECT THE FLYWHEEL
z
Inspect the flywheel for damage and runout. Refer
to Flywheel Runout Check .
z Is the flywheel OK? Yes
GO to
B6 .
No
REPAIR or INSTALL a new flywheel
as necessary. REFER to Section 308 -
01 . TEST the system for normal
operation. B6 INSPECT THE INPUT SHAFT
z
INSPECT the input shaft for signs of wear or
damage.
z Are any signs of wear or damage present on
the input shaft? Yes
INSTALL a new input shaft. REFER to
Section 308
- 03A or
Section 308 - 03B .
No
VERIFY the customer concerns. GO
to Symptom Chart if necessary.
Test Step Result / Action to Take
C1 CHECK HIGH SHIFTING EFFORTS
z
Key in START position.
z Set parking brake.
z With the shift control selector in REVERSE, Yes
Clutch system OK.
No Klj . 8 ba
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PINPOINT TEST D: CLUTCH PEDAL PULSATION clutch disengaged and engine idling, move
the shift lever to a position halfway between
REVERSE and NEUTRAL.
z Slowly engage clutch. The transmission will
behave as if it is in NEUTRAL.
z Gear clash can now be heard if an attempt
is made to shift into REVERSE with the
clutch engaged. Reserve can now be
measured.
z While maintaining light pressure on the shift
selector, slowly press the clutch pedal to the
floor. The gear clash will stop and the shift
selector will slide into the REVERSE
position.
z Is there a minimum 19.05 mm (0.750 inch)
clutch pedal reserve? CHECK the clutch pressure plate and clutch
disc. INSTALL a new clutch pressure plate
or clutch disc if necessary. REFER to
Section 308
- 01 . TEST the system for
normal operation. Test Step Result / Action to Take
D1 CHECK THE CLUTCH PEDAL
PULSATION z
Key in START position.
z With the transmission in NEUTRAL,
slowly press the clutch pedal.
z Does the clutch pedal pulsate while
being pressed? Yes
GO to
D2 .
No
VERIFY customer concern. GO to Symptom Chart if necessary.
D2 INSPECT PRESSURE PLATE BOLTS
z
Inspect the pressure plate- to-flywheel
bolts.
z Are any of the pressure plate- to-
flywheel bolts loose? Yes
TIGHTEN or INSTALL new bolts. REFER to
Section 308
- 01 . TEST the system for normal
operation.
No
GO to D3 .
D3 INSPECT THE CLUTCH PRESSURE
PLATE z
Remove the clutch pressure plate.
Refer to Section 308 - 01 .
z INSPECT the clutch pressure plate for
damage. Refer to Pressure Plate Check .
z Are there any signs of damage
present on the clutch pressure plate? Yes
INSTALL a new clutch pressure plate. REFER
to
Section 308 - 01 . TEST the system for normal
operation.
No
GO to D4 .
D4 INSPECT THE CLUTCH DISC
z
Carry out the clutch disc inspection
procedure. Refer to Disc Check .
z Is the clutch disc OK? Yes
GO to
D5 .
No
INSTALL a new clutch disc. REFER to Section 308 - 01 . TEST the system for normal operation.
D5 INSPECT THE FLYWHEEL Klj . 9 ba
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