sensor 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 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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REMOVAL AND INSTALLATION
Cable and Bracket
Removal
1. Raise the vehicle on a hoist. For additional information, refer to Section 100 - 02 .
2. Remove the cable shift from the shifter lever and bracket and discard the clip.
3. Remove the bolt from the cable.
4. Remove the bolt from the cable.
5. Disconnect the transmission range selector lever cable from the TR sensor lever.
SECTION 307-
05: Automatic Transaxle/Transmission External Controls 2003 Mustang Workshop Manual Klj . 1 ba
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SPECIFICATIONS
SECTION 308-
00: Manual Transaxle/Transmission and Clutch — General
Information 2003 Mustang Workshop
Manual General Specifications
Item Specification
Pressure plate
Pressure spring Belleville
Sensor spring Belleville
Clutch Disc (3.8L)
Clutch diameter 280 mm (11.0 inches)
Number of springs 5
Color identification none
Clutch Disc (4.6L 2V)
Clutch diameter 280 mm (11.0 inches)
Number of springs 4
Color identification none
Lubricants (Spec and Capacity) Fluid
T50D-
MERCON® Multi- Purpose ATF Transmission Fluid XT -2-QDX 2.6L (2.8 qt)
TR3650-
Synthetic MERCON® ( ATF) Transmission Fluid E6AZ-19582- B 3.6L (7.5 pt) Klj . 1 ba
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IN-
VEHICLE REPAIR
Output Shaft Speed (OSS) Sensor
Removal and Installation 1. With the vehicle in NEUTRAL, raise and support the vehicle. For additional information, refer to Section 100 - 02 .
2. Disconnect the electrical connector.
3. Remove the output shaft speed (OSS) sensor.
4. To install, reverse the removal procedure.
SECTION 308-
03A: Manual Transaxle/Transmission — T5OD 2003 Mustang Workshop Manual Klj . 1 ba
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REMOVAL
Transmission
1. Disconnect the battery ground cable. For additional information, refer to Section 414 - 01 .
2. Lift up on the clutch pedal and secure it in place.
3. Remove the gearshift lever knob (7213).
4. Remove the console panel gearshift plate. Lift the gearshift lever boot over the gearshift lever (7210).
5. Remove the bolts and the shift lever.
6. Raise and support the vehicle. For additional information, refer to Section 100 - 02 .
7. Disconnect the heated oxygen sensor electrical connectors. SECTION 308-
03A: Manual Transaxle/Transmission — T5OD 2003 Mustang Workshop Manual Klj . 1 ba
62003 Mustang Workshop Manual
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13. Disconnect the reversing lamp switch electrical connector. Disconnect the wiring harness from
the transmission.
14. Remove the starter motor (11001). For additional information, refer to Section 303 - 06 .
15. Disconnect the output shaft speed sensor (OSS) electrical connector. Disconnect the wiring harness from the transmission.
16. Remove the bolt and the clutch release lever cover. Klj . 3 ba
62003 Mustang Workshop Manual
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Transmission Case and Shift Components — Disassembled View 45 — Selector gate
46 7025 Mainshaft rear bearing and cup
47 7K316 Mainshaft fifth gear
48 — Retaining ring
49 7H150 Output shaft speed (OSS) sensor
50 — Retaining ring
51 7L172 Shim
52 7025 Countershaft front bearing and cup
53 7113 Countershaft
54 7025 Countershaft rear bearing and cup
55 — Thrust bearing
56 7144 Countershaft fifth gear
57 — Countershaft fifth gear needle bearing
58 — Countershaft fifth gear bearing spacer
59 — Retaining ring
60 7124 Fifth gear synchronizer assembly
61 7107 Fifth gear synchronizer blocking ring
62 — Fifth gear synchronizer spring (part of 7124)
63 — Fifth gear synchronizer hub (part of 7124)
64 — Fifth gear synchronizer insert (part of 7124)
65 — Fifth gear synchronizer sleeve (part of 7124)
66 — Fifth gear clutch cone
67 — Retaining ring
68 — Reverse idler gear support
69 7140 Reverse idler gear shaft
70 7141 Reverse idler gear
71 7E169 Reverse idler gear needle bearing
72 — Reverse idler gear bearing spacer Klj . 4 ba
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Transmission Identification
The transmission identification tag is located under the lower bolt that retains the extension housing to
the main case.
The five speed overdrive (TR3650) transmission is available for the Mustang 4.6L (2V).
Transmission Identification 16 7240 Main shift rail
17 7F018 Gearshift offset lever
18 — Spacer
19 — Bearing
20 7210 Gearshift lever
21 — Gearshift plate and spring
22 — Shipping seal
23 7052 Output shaft seal
24 — Extension housing bushing
25 7A039 Extension housing
26 7034 Vent
27 — Vehicle speed sensor (VSS)
28 — Fifth/reverse gear lockout
29 7L027 Magnet
30 7K201 Shift interlock plate
31 7005 Transmission main case
32 — Interlock pins
33 7A010 Drain plug
34 15520 Reverse lamp switch
35 — Detent plug
36 — Detent spring
37 — Detent
38 6392 Clutch housing
39 7B602 Ball stud
40 — Bearing
Part Klj . 6 ba
72003 Mustang Workshop Manual
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IN-
VEHICLE REPAIR
Output Shaft Speed (OSS) Sensor
Removal and Installation 1. With the vehicle in NEUTRAL, raise and support the vehicle. For additional information, refer to Section 100 - 02 .
2. Disconnect the electrical connector.
3. Remove the output shaft speed (OSS) sensor.
4. To install, reverse the removal procedure.
SECTION 308-
03B: Manual Transaxle/Transmission — TR3650 2003 Mustang Workshop Manual Klj . 1 ba
22003 Mustang Workshop Manual
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