FORD MUSTANG 2003 Workshop Manual

z
Are the resistances greater than 10,000 ohms? A9 CHECK FOR PARKING BRAKE GROUND
z
Measure the resistance between raise relay C4063 pin 86, circuit
977 (VT/WH), harness side and ground; and between lower relay
C4064 pin 86, circuit 977 (VT/WH), harness side and ground.
z Are the resistances less than 5 ohms? Yes
GO to
A11 .
Yes
GO to A10 .
A10 CHECK THE PARKING BRAKE SWITCH
z
Disconnect: Parking Brake Switch C306.
z Measure the resistance between raise relay C4063 pin 86, circuit
977 (VT/WH), harness side and parking brake switch C306, circuit
22 (LB/BK), harness side; and between lower relay C4064 pin 86,
circuit 977 (VT/WH), harness side and parking brake switch C306,
circuit 22 (LB/BK), harness side.
z Are the resistances less than 5 ohms? Yes
INSTALL a new
parking brake switch.
REFER to
Section 206 - 05 . TEST the
system for normal
operation.
No
REPAIR the circuit in
question. TEST the
system for normal
operation. A11 CHECK THE CONVERTIBLE TOP MOTOR LOWER CIRCUIT
z
Connect: Raise Relay C4063.
z Connect: Lower Relay C4064.
z Disconnect: Convertible Top Motor C4062.
z Measure the resistance between convertible top motor C4062,
circuit 902 (YE), harness side and ground. Yes
GO to
A13 .
No
GO to A12 . Klj . 5 ba
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z
Is the resistance less than 5 ohms? A12 CHECK CIRCUIT 902 (YE) FOR AN OPEN
z
Disconnect: Lower Relay C4064.
z Measure the resistance between lower relay C4064 pin 30, circuit
902 (YE), harness side and convertible top motor C4062, circuit
902 (YE), harness side.
z Is the resistance less than 5 ohms? Yes
INSTALL a new lower
relay. TEST the
system for normal
operation.
No
REPAIR the circuit.
TEST the system for
normal operation.
A13 CHECK THE LOWER INPUT TO THE MOTOR
z
Key in ON position.
z Measure the voltage between convertible top motor C4062, circuit
902 (YE), harness side and ground.
z Depress and hold the convertible top switch in the LOWER
position.
z Is the voltage greater than 10 volts? Yes
GO to
A14 .
No
INSTALL a new lower
relay. TEST the
system for normal
operation. A14 CHECK THE CONVERTIBLE TOP MOTOR RAISE CIRCUIT
z
Key in OFF position.
z Measure the resistance between convertible top motor C4062,
circuit 903 (RD), harness side and ground. Yes
GO to
A16 .
No
GO to A15 . Klj . 6 ba
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PINPOINT TEST B: THE CONVERTIBLE TOP HESITATES/COMES UP
UNEVEN z
Is the resistance less than 5 ohms? A15 CHECK CIRCUIT 903 (RD) FOR AN OPEN
z
Disconnect: Raise Relay C4063.
z Measure the resistance between raise relay C4063 pin 30, circuit
903 (RD), harness side and convertible top motor C4062, circuit
903 (RD), harness side.
z Is the resistance less than 5 ohms? Yes
INSTALL a new raise
relay. TEST the
system for normal
operation.
No
REPAIR the circuit.
TEST the system for
normal operation.
A16 CHECK THE RAISE INPUT TO THE MOTOR
z
Key in ON position.
z Depress and hold the convertible top switch in the RAISE position.
z Measure the voltage between convertible top motor C4062, circuit
903 (RD), harness side and ground.
z Is the voltage greater than 10 volts? Yes
INSTALL a new
convertible top motor;
REFER to
Hydraulic System, Lift Cylinder
and Motor in this
section. TEST the
system for normal
operation.
No
INSTALL a new raise
relay. TEST the
system for normal
operation. Test Step Result / Action to Take
B1 CHECK THE CONVERTIBLE TOP UP/DOWN
OPERATION NOTE:
The parking brake must be applied for the Yes Klj . 7 ba
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PINPOINT TEST C: THE CONVERTIBLE TOP DOES NOT RAISE OR
DOES NOT GO UP ALL THE WAY
PINPOINT TEST D: THE CONVERTIBLE TOP HYDRAULIC SYSTEM convertible top system to operate.
z Key in ON position.
z Actuate the convertible top switch to the LOWER
and RAISE positions.
z Did the convertible top operate to the full down
and full up position without hesitating? ADJUST the convertible top linkage.
TEST the system for normal
operation.
No
GO to
B2 .
B2 CHECK THE MOTOR OPERATION
z
Gain access to the convertible top motor/pump
assembly.
z Operate the convertible top to the LOWER and
RAISE positions while listening to the motor.
z Did the motor stop and then continue at any
time? Yes
Go To Pinpoint Test A
.
No
GO to B3 .
B3 CHECK THE CONVERTIBLE TOP LINKAGE
z
Operate the convertible top to the LOWER and
RAISE positions while observing the convertible
top linkage.
z Did the linkage operate smoothly without
binding? Yes
Go To Pinpoint Test D
.
No
ADJUST the convertible top linkage.
TEST the system for normal
operation. Test Step Result / Action to Take
C1 CHECK THE CONVERTIBLE TOP OPERATION
NOTE:
The parking brake must be applied for the
convertible top system to operate.
z Key in ON position.
z Actuate the convertible top switch to the RAISE
position.
z Did the motor operate? Yes
GO to
C2 .
No
Go To Pinpoint Test A .
C2 CHECK THE CONVERTIBLE TOP LINKAGE
z
Operate the convertible top to the LOWER and
RAISE positions while observing the convertible
top linkage.
z Did the linkage bind and prevent the
convertible top from raising? Yes
ADJUST the convertible top linkage.
TEST the system for normal
operation.
No
Go To Pinpoint Test D
.
Test Step Result / Action to Take
D1 CHECK THE FLUID LEVEL
NOTE:
The fluid level should be even
with the bottom of the filler plug hole.
NOTE: Place an absorbent cloth
below the filler plug when checking
the fluid level.
z Remove the filler plug and check the Yes
GO to
D3 .
No
GO to D2 . Klj . 8 ba
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fluid level.
z Is the fluid level OK? D2 CHECK THE HYDRAULIC SYSTEM
FOR LEAKS z
Inspect all fittings and hoses for leaks.
z Are any leaks noticed? Yes
REPAIR the leaking fittings or INSTALL new
hoses as necessary. TEST the system for normal
operation.
No
GO to
D3 .
D3 BLEED THE HYDRAULIC SYSTEM
z
Bleed the hydraulic system. Refer to
System Bleeding in this section.
z Does the system operate correctly
after bleeding? Yes
OPERATE the convertible top up and down three
times. INSPECT the hydraulic system for leaks or
loss of fluid. REPAIR as necessary if loss of fluid
is detected.
No
GO to
D4 .
D4 CHECK THE CONVERTIBLE TOP
z
Remove the hydraulic system from
the vehicle. Refer to Hydraulic System, Lift Cylinder and Motor in this
section.
z Operate the convertible top assembly
up and down manually.
z Does the convertible top bind? Yes
ADJUST the convertible top. INSTALL the
hydraulic system; REFER to
Hydraulic System, Lift Cylinder and Motor in this section. TEST the
system for normal operation.
No
GO to D5 .
D5 CHECK THE HYDRAULIC SYSTEM
OUT OF THE VEHICLE z
Bleed the hydraulic system. Refer to
System Bleeding in this section.
z Does the system operate correctly
after bleeding? Yes
CHECK all fittings and hoses for leaks. REPAIR
as necessary if loss of fluid is detected. INSTALL
the hydraulic system; REFER to
Hydraulic System, Lift Cylinder and Motor in this section.
TEST the system for normal operation.
No
GO to D6 .
D6 CHECK THE LIFT CYLINDERS
z
Operate the hydraulic system using a
12 volt power source.
z Did the lift cylinders extend and
retract? Yes
INSTALL a new motor/pump assembly. REFER to
Hydraulic System, Lift Cylinder and Motor
in this
section. TEST the system for normal operation.
No
INSTALL a new lift cylinder. REFER to Hydraulic System, Lift Cylinder and Motor in this section.
TEST the system for normal operation. Klj . 9 ba
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Klj . 10 ba
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GENERAL PROCEDURES
System Bleeding
1. If required, remove the hydraulic system from the vehicle. Refer to Hydraulic System, Lift Cylinder and Motor in this section.
2. Remove the fill plug at the end of the hydraulic pump.
3. Fill the pump with Mercon® Multi- Purpose Automatic Transmission Fluid XT -2-QDX or
equivalent to the bottom of the fill hole and install the fill plug.
4. NOTE: Some noise squeal may be noticed due to the air in the system.
Connect a 12- volt power source to the motor connector and operate the motor until the
cylinders are fully extended. Reverse the 12- volt connection to fully retract the cylinders. Repeat
this procedure three times.
5. Remove the fill plug and check the fluid level. Fill the pump with MERCON® Multi- Purpose
Automatic Transmission Fluid XT -2-QDX or equivalent to the bottom of the fill hole.
SECTION 501-
18: Convertible Top 2003 Mustang Workshop Manual Klj . 1 ba
22003 Mustang Workshop Manual
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6. Install a fill plug.
7. Install the hydraulic system in the vehicle. Refer to
Hydraulic System, Lift Cylinder and Motor in
this section. Klj . 2 ba
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GENERAL PROCEDURES
Linkage Adjustment
NOTE:
Before starting the adjustment process, inspect the top for damage, make sure that the door
window glass and rear quarter glass are correctly adjusted then completely lower all window glass.
NOTE: After each adjustment make sure the convertible top operates correctly.
The Convertible Top Dowel Pins Fall Forward (Overshoot) or Rearward (Undershoot). The
Receiver Cups — Cam Bolt Adjustment.
1. Remove the quarter trim panel. For additional information, refer to Section 501 - 05 .
2. Close the convertible top and examine the position of the dowel pins relative to the receiver cups.
3. Move the convertible top to the half- open position to access the cam bolt.
4. NOTE: Rotating the top of the cam bolt toward the front of the vehicle will lengthen the top, increase the tension on the top and increase pull - down effort. Rotating the cam bolt in the SECTION 501-
18: Convertible Top 2003 Mustang Workshop Manual Material
Item Specification
Threadlock and
Sealer
E0AZ-
19554- AA WSK-
M2G351- A5 (type
II) Shoulder Bolt Kit
F5ZZ-
76539A04- A — Klj . 1 ba
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opposite direction will have the opposite effect.
NOTE:
Turn the adjusting cam one notch at a time.
Adjust the adjusting cam as needed. 1. Remove the cam stop set screw.
2. Rotate the adjusting cam.
3. Install the cam stop set screw.
5. Make sure the convertible top operate correctly.
6. Install the quarter trim panel. For additional information, refer to Section 501 - 05 .
7. Close the convertible top.
Convertible Top Lifts Up Unevenly — Lift Cylinder and C-pivot Inspection
8. Remove the quarter trim panel. For additional information, refer to Section 501 - 05 .
9. NOTE: This step applies to vehicles equipped with the Mach sound system.
Remove the screws and disconnect the electrical connectors.
10. Remove the screws. Klj . 2 ba
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