lock FORD MUSTANG 2003 Workshop Manual

REMOVAL AND INSTALLATION
Brake Shift Interlock Actuator
Removal
1. Remove the shifter top control panel.
2. Disconnect the electrical connectors.
3. Remove the shifter bezel. 4. Remove the bulb from the bezel. SECTION 307-
05: Automatic Transaxle/Transmission External Controls 2003 Mustang Workshop Manual Klj . 1 ba
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5. Disconnect the electrical connector.
6.
CAUTION: Extra force may be needed to lift up on the handle. Do not to pull too far
or damage to the overdrive cancel button may result, as the wires may be pulled out of
the switch.
Remove the screw and the handle.
7. Remove the clip and bolt from the brake shift interlock cable. Klj . 2 ba
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8. Disconnect the shift interlock cable.
9. Remove the instrument panel steering column cover.
1. Remove the screws.
2. Remove the instrument panel steering column cover.
10. Remove the instrument panel reinforcement. 1. Remove the screws.
2. Remove the instrument panel reinforcement.
11. Remove the nuts and lower the steering column. Klj . 3 ba
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12. Remove the screws from the brake shift interlock cable.
13. Remove the brake shift cable interlock actuator.
Installation 1. To install, reverse the removal procedure. Klj . 4 ba
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DESCRIPTION AND OPERATION
Manual Transmission and Clutch
The primary function of the clutch is to couple and uncouple engine power to the transmission upon
driver command. For additional information, refer to
Section 308 - 01 .
Clutch Disc and Clutch Pressure Plate — 3.8L
SECTION 308-
00: Manual Transaxle/Transmission and Clutch — General
Information 2003 Mustang Workshop
Manual Item Part Number Description
1 6397 Flywheel housing to block dowel (2 req'd)
2 — Rear face of block and flywheel (part of 6010)
3 6397 Flywheel to clutch pressure plate dowel (3 req'd)
4 7600 Pilot bearing
5 7550 Clutch disc
6 7563 Clutch pressure plate Klj . 1 ba
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Clutch Disc and Clutch Pressure Plate —
4.6L (4V)
z The clutch is a single plate, dry friction clutch disc. The clutch disc has a splined hub with
integral torsional springs. The clutch disc hub attaches to the input shaft.
z Engine output is coupled to the transmission input shaft by friction existing between the clutch
disc facings and the flywheel/clutch pressure plate assembly. The extent of this friction is directly related to the composition of the facing material and the magnitude of the clamping 12 7548 Clutch release hub and bearing
13 N808969-
S100 Bolt
14 N808969-
S100 Bolt (6 req'd)
15 — Rear face of block and flywheel (part of 6010)
16 — Bolt (3 req'd)
17 6397 Flywheel housing to block dowel (2 req'd)
Item Part Number Description
1 6375 Flywheel
2 7600 Pilot bearing
3 7550 Clutch disc
4 7563 Clutch pressure plate
5 7548 Clutch release hub and bearing
6 7515 Clutch release lever
7 7B602 Clutch release lever stud
8 6392 Flywheel housing
9 N808969-S100 Clutch pressure plate bolt (6 req'd) Klj . 3 ba
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Release bearing rub will
disappear when the
clutch is engaged. In the
event that a bearing is
damaged, the noise is
more pronounced while
engaged in gear under
load or coast than in
NEUTRAL.
Noisy in forward gears
zComponents
grounding out
on the
transmission. z
CHECK for screws,
bolts, etc., of body or
other components
grounding out.
CORRECT as
necessary.
z Components
housing bolts. z
CHECK the torque on
the transmission-to-
flywheel housing bolts
and the flywheel
housing- to-engine block
bolts. TIGHTEN the
bolts to specification.
REFER to Section 308 -
01 .
z Bearings or
gears. z
INSPECT the bearings.
INSPECT the gears and
gear teeth for wear or
damage. INSTALL new
components as
necessary. REFER to
Section 308 - 01 .
z Gears clash when
shifting from one forward
gear to another z
Pilot bearing. zCHECK for a binding
condition between the
input shaft and the
engine crankshaft pilot
bearing. INSTALL new
components as
necessary. REFER to
Section 308 - 01 .
z Gear teeth
and/or
synchronizer. z
REPAIR or INSTALL
new components as
necessary. REFER to
Section 308 - 03A or
Section 308 - 03B .
z Engine idle
speed too high. z
REFER to the
Powertrain
Control/Emissions
Diagnosis (PC/ED)
manual.
z Transmission jumps out
of gear z
Transmission
range selector
lever boot. z
INSTALL a new boot if
exceptionally stiff.
REFER to Section 308 -
03A or
Section 308 -
03B .
z Transmission-to-
engine mounting
bolts. z
TIGHTEN the bolts to
specification. Klj . 4 ba
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z
Crankshaft pilot
bearing. z
INSTALL a new bearing.
z Internal
damage. z
INSPECT the
synchronizer sleeves for
free movement on their
hubs. INSPECT the
synchronizer blocking
rings for widened index
slots, rounded clutch
teeth and smooth
internal surface. CHECK
countershaft cluster gear
for excessive end play.
CHECK shift forks for
worn or loose mounting
on shift rails. INSPECT
the synchronizer sliding
sleeve and the gear
clutch teeth for wear or
damage. REPAIR or
INSTALL a new
component as
necessary.
z Gear teeth. zIf worn or damaged,
INSTALL new gears.
REFER to Section 308 -
03A or
Section 308 -
03B .
z Transmission will not shift
into one gear— all others
OK z
Manual shift
linkage. z
REPAIR or INSTALL
new components as
necessary.
z Backup switch
ball. z
If REVERSE is the
problem, CHECK
backup switch for ball
frozen in extended
position.
z Internal
components. z
INSPECT the shift rail
and fork system,
synchronizer system and
the gear clutch teeth for
restricted travel.
REPAIR or INSTALL
new components as
necessary.
z Transmission is locked in
one gear and cannot be
shifted out of that gear z
Internal
components. z
INSPECT the problem
gears, shift rails, forks
and the synchronizer for
wear or damage.
REPAIR as necessary.
REFER to Section 308 -
03A or
Section 308 -
03B .
z Fork on rail. zCHECK the shift rail
interlock system.
REFER to Section 308 -
03A or
Section 308 -
03B .
z Transmission leaks zLubricant. zCHECK the level and
type. Klj . 5 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 G: EXCESSIVE NOISE contamination, REPAIR as
necessary. TEST the
system for normal
operation. If the
transmission is still hard to
shift, GO to
F9 .
No
TIGHTEN the bolts to 80
Nm (59 lb- ft). TEST the
system for normal
operation. If the
transmission is still hard to
shift, GO to F9 .
F9 INSPECT THE TRANSMISSION
z
Remove the transmission.
z Disassemble the transmission. Refer to Section 308 - 03B .
z Carry out the following:
zinspect all the shift rails for excessive scuffing or
wear.
z check the interlock pins on the shift rail.
z make sure the interlock bolts are tighten to 31 Nm (23
lb-ft).
z inspect the shift pads for wear or cracking.
z inspect the shift forks for wear or damage.
z check the synchronizer rings (of the affected gear[s])
for wear or damage.
z check the synchronizer hubs (of the affected gear[s])
for wear or damage.
z inspect the clutching teeth of the affected gear.
z Are there any internal components worn or damaged? Yes
INSTALL new components
or REPAIR as necessary.
TEST the system for
normal operation.
No
ASSEMBLE and INSTALL
the transmission. TEST the
system for normal
operation.
Test Step Result / Action to Take
G1 TRANSMISSION NEUTRAL GEAR ROLLOVER TEST
z
Start the engine and let it idle with the transmission in
neutral and the clutch engaged (pedal up). If noise is
excessive, depress the clutch pedal to stop the
transmission input shaft from rotating.
z Does the noise stop when the clutch pedal is
depressed? Yes
INSPECT the clutch component
for damage. REFER to General
Procedures in this section.
No
GO to
G2 .
G2 CHECK THE PILOT BEARING
z
Inspect the pilot bearing for damage. Refer to Bearing .
z Is the pilot bearing OK? Yes
GO to
G3 .
No
INSTALL a new pilot bearing.
REFER to Section 308 - 01 .
G3 CHECK TORSION SPRINGS
z
Inspect the torsion springs for fatigue or breakage.
z Are there any signs of fatigue or breakage? Yes
INSTALL a new clutch disc.
REFER to
Section 308 - 01 .
TEST the system for normal
operation. Klj . 14 ba
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