brake FORD MUSTANG 2003 Owner's Guide

PINPOINT TEST K: HIGH SPEED SHAKE OR SHIMMY z
Is the lateral runout within specifications? No
GO to
J9 .
J9 LATERAL RUNOUT CHECK ON THE WHEEL
z
Measure the lateral runout of the wheel. A typical specification for
total radial runout is 1.14mm (0.045 inch.
z Is the lateral runout within specifications? Yes
INSTALL a new tire.
TEST the system for
normal operation.
No
GO to
J10 .
J10 CHECK THE FLANGE FACE LATERAL RUNOUT
z
Measure the flange face lateral runout. A typical specification for
lateral runout is:
zHub/brake disc— less than 0.13 mm (0.005 inch).
z Axle shaft— less than 0.25 mm (0.010 inch).
z Is the lateral runout within specifications? Yes
INSTALL a new wheel.
TEST the system for
normal operation.
No
REPAIR or INSTALL
new components as
necessary. REFER to
Section 204
- 01 for the
front wheels or Section 204 - 02 for the rear
wheels. Test Step Result / Action to Take
K1 CHECK FOR FRONT WHEEL BEARING ROUGHNESS
z
Chock the rear wheels.
z Raise and support the front end of the vehicle so that the front
wheel and tire assemblies can spin.
z Spin the front tires by hand. Refer to Wheel Bearing Check in
this section.
z Do the wheel bearings feel rough? Yes
INSPECT the wheel
bearings. REPAIR as
necessary. TEST the
system for normal
operation.
No
GO to
K2 .
K2 CHECK THE END PLAY OF THE FRONT WHEEL BEARINGS
z
Check the end play of the front wheel bearings. Refer to
Section 204 - 01 .
z Is the end play OK? Yes
GO to
K3 .
No
ADJUST or REPAIR as
necessary. TEST the
system for normal Klj . 58 ba
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PINPOINT TEST L: CLUTCH VIBRATION appropriate workshop manual for the service procedures.
z Secure the brake drums (if so equipped), by installing wheel
hub bolt nuts, reversed.
z Carefully accelerate the drivetrain while checking for vibration.
z Is the vibration present? assemblies as necessary.
TEST the system for
normal operation.
Test Step Result / Action to Take
L1 CHECK ENGINE COMPONENTS FOR GROUNDING
z
NOTE: Make sure the clutch is the cause of the
vibration concern. The vibration should occur during
clutch operation. The clutch can also be difficult to
engage or disengage. Eliminate all related systems
before checking the clutch components.
z NOTE: Check the driveline angles and driveshaft
runout before disassembling the clutch system. Refer
to Section 205 - 00 for the correct driveline angle
specifications.
z Check the powertrain/drivetrain mounts, exhaust
manifolds or other engine components for grounding
on the chassis.
z Are any mounts or engine components
grounded? Yes
REPAIR as necessary. TEST the
system for normal operation.
No
GO to
L2 .
L2 CHECK THE ACCESSORY DRIVE
z
Remove the accessory drive belt.
z Does the vibration stop with the accessory drive
belt removed? Yes
DIAGNOSE the accessory drive
components.
No
GO to
L3 .
L3 CHECK FOR LOOSE CLUTCH PRESSURE PLATE
BOLTS z
Check for loose clutch pressure plate bolts. Inspect
the clutch pressure plate for damage or for material
between the pressure plate and flywheel.
z Are there any loose bolts or damage? Yes
TIGHTEN the bolts to
specifications or if damaged,
INSTALL a new clutch pressure
plate. REFER to
Section 308 - 01 .
TEST the system for normal
operation.
No
GO to L4 .
L4 CHECK THE CLUTCH DISC SPRINGS
z
Check for worn, broken or loose clutch disc springs.
z Are the clutch springs worn, broken or loose? Yes
INSTALL a new clutch disc.
REFER to
Section 308 - 01 . TEST
the system for normal operation.
No
GO to L5 .
L5 CHECK THE CLUTCH DISC SPLINES
z
Inspect the clutch disc splines for damage or wear.
z Is there damage or wear? Yes
INSTALL a new clutch disc.
REFER to
Section 308 - 01 . TEST Klj . 61 ba
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GENERAL PROCEDURES
Brake Disc Machining
WARNING: The electrical power to the air suspension system must be shut off prior to
hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off
the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the
air springs, which can result in shifting of the vehicle during these operations.
CAUTION: Do not install brake discs that are less than the minimum thickness specified.
Do not machine a brake disc below the minimum thickness specification.
1. Check wheel bearing end- play and correct as necessary.
2. NOTE: Begin at the front of the vehicle unless the vibration has been isolated to the rear.
Remove the tire and wheel assembly.
3. Remove the brake caliper and the brake caliper anchor plate. Refer to the appropriate section in Group 206 for the procedure.
4. Inspect the brake linings. Install new brake linings if below specification. For additional information, refer to the appropriate brake section.
5. Measure and record the brake disc thickness. Install a new brake disc if the thickness after machining will be at or below specification. The specification is molded into the brake disc.
zDo not machine a new brake disc.
SECTION 100-
04: Noise, Vibration and Harshness 2003 Mustang Workshop Manual Special Tool(s)
Gauge, Clutch Housing
308-
021 (T75L-4201- A) Dial Indicator Gauge with
Holding Fixture
100-
002 (TOOL- 4201-C) or
equivalent
Material Item Specification
Metal Surface Cleaner
F4AZ-
19A536- RA or equivalent WSE-
M5B392-
A High Temperature Nickel Anti-
Seize Lubricant
F6AZ-
9L494- AA or equivalent ESE-
M12A4-A Klj . 1 ba
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6. For vehicles with a two-
piece hub and brake disc assembly:
z Match-mark before disassembly.
z Remove the brake disc.
z Clean the hub and brake disc mounting surfaces with metal surface cleaner.
z Using a die grinder with a mild abrasive (Scotch Brite® type), remove any rust or
corrosion from the hub and brake disc mounting surfaces.
z Align the match- marks and reinstall the brake disc on the hub.
7. CAUTION: Do not use a bench lathe to machine brake discs.
NOTE: The depth of cut must be between 0.10 and 0.20 mm (0.004 and 0.008 inch). Lighter
cuts will cause heat and wear. Heavier cuts will cause poor brake disc surface finish.
Using an on- car brake lathe, machine the brake discs. Follow the manufacturer's instructions.
After machining, make sure the brake disc still meets the thickness specification.
8. Using the special tools, verify that the brake disc lateral runout is now within specification. For additional information, refer to Section 206 - 00 .
9. Remove the special tool hub adapter.
10. Remove any remaining metal chips from the machining operation.
11. For vehicles with a two- piece hub and brake disc assembly:
z Remove the brake disc from the hub.
z Remove any remaining metal chips from hub and brake disc mounting surfaces and from
the ABS sensor.
z Apply a liberal amount of lubricant to the hub flange, pilot area and to the brake disc- to-
hub mounting surface.
z Using the match marks, mount the brake disc on the hub.
12. Install the brake caliper anchor plate and the brake caliper.
13. Install the tire and wheel assembly.
14. Test the system for normal operation. Klj . 2 ba
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GENERAL PROCEDURES
Wheel Bearing Check
1. WARNING: The electrical power to the air suspension system must be shut off prior
to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by
turning off the air suspension switch. Failure to do so can result in unexpected inflation
or deflation of the air springs, which can result in shifting of the vehicle during these
operations.
Raise the vehicle until the front tires are off the floor.
zMake sure the wheels are in a straight forward position.
2. NOTE: Make sure the wheel rotates freely and that the brake pads are retraced sufficiently to
allow free movement of the tire and wheel assembly.
Spin the tire by hand to check the wheel bearings for roughness.
3. Grip each front tire at the top and bottom and move the wheel inward and outward while lifting the weight of the tire off the front wheel bearing.
4. If the tire and wheel (hub) is loose on the spindle, does not rotate freely, or has a rough feeling when spun, carry out one of the following:
1. On vehicles with inner and outer bearings, inspect the bearings and cups for wear or damage. Adjust or install new bearings and cups as necessary.
2. On vehicles with one sealed bearing, install a new wheel hub.
SECTION 100-
04: Noise, Vibration and Harshness 2003 Mustang Workshop Manual Klj . 1 ba
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6. If an obvious cause for an observed or reported condition is found, correct the cause (if
possible) before proceeding to the next step.
7. If the fault is not visually evident, determine the symptom and GO to Symptom Chart .
Symptom Chart z
Front wheel bearing(s)
z Loose or damaged front or rear suspension components
z Loose, damaged or missing suspension fastener(s)
z Damaged spring(s)
z Damaged or leaking strut and spring assemblies
z Damaged or leaking shock absorber(s)
z Worn or damaged suspension bushing(s)
z Loose, worn or damaged steering system components
z Damaged axle components
Symptom Chart Condition
Possible Sources Action
z Dogtracking zExcessive rear
thrust angle. z
CHECK the wheel alignment.
ADJUST as necessary.
z Front or rear
suspension
components. z
INSPECT the front and rear
suspension system. REPAIR
or INSTALL new suspension
components as necessary.
REFER to Section 204 - 01 or
Section 204 - 02 .
z Drive axle
damaged. z
REPAIR as necessary. Refer
to the appropriate section in
Group 205 for the procedure..
z Drift/pull zUnequal tire
pressure. z
ADJUST tire pressure.
z Excessive side-to-
side difference in
caster or camber. z
CHECK the wheel alignment.
ADJUST as necessary.
z Tire forces. zROTATE tires front to rear.
z Unevenly loaded or
overloaded vehicle. z
NOTIFY the customer of
incorrect vehicle loading.
z Steering
components. z
REFER to Section 211 - 00 .
z Brake drag. zREFER to Section 206 - 00 .
z Front bottoming
or riding low z
Strut(s). zINSTALL new strut(s) as
necessary. REFER to Section 204 - 01 .
z Front coil springs
(5310). z
CHECK ride height. INSTALL
new springs as necessary.
REFER to Section 204 - 01 .
z Incorrect tire
wear z
Incorrect tire
pressure (rapid
center rib or inner
and outer edge
wear). z
ADJUST tire pressure. Klj . 2 ba
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REFER to
Section 204 - 04 .
z Strut(s). zINSTALL new strut(s) as
necessary. REFER to Section 204 - 01 .
z Shock absorber(s). zINSTALL new shock absorber
(s) as necessary.
z Loose front
stabilizer bar (5482)
or rear stabilizer
bar (5A772). z
TIGHTEN to specification.
REFER to Section 204 - 01 or
Section 204 - 02 .
z Worn stabilizer
assembly bushing
(s). z
INSTALL new bushing(s) as
necessary. REFER to Section 204 - 01 or
Section 204 - 02 .
z Front coil spring(s)
or rear spring(s). z
INSTALL new front coil
springs or rear springs as
necessary. REFER to Section 204 - 01 or
Section 204 - 02 .
z Vehicle leans to
one side z
Unevenly loaded or
overloaded vehicle. z
NOTIFY the customer of
incorrect vehicle loading.
z Front or rear
suspension
components. z
INSPECT the front and rear
suspension system. REPAIR
or INSTALL new suspension
components as necessary.
REFER to Section 204 - 01 or
Section 204 - 02 .
z Front coil springs or
rear springs. z
INSTALL new front coil
springs or rear springs as
necessary. REFER to Section 204 - 01 or
Section 204 - 02 .
z Incorrect ride
height. Lateral tilt
out of specification. z
CHECK ride height. INSTALL
new front coil springs or rear
springs as necessary. REFER
to Section 204 - 01 or
Section 204 - 02 .
z Vibration/noise zTire or wheel
runout.
z Tire flatspotting.
z Wheel bearings.
z Wheel hubs.
z Brake components.
z Suspension
components.
z Steering
components. z
REFER to Section 100 - 04 .
z Wander zUnevenly loaded or
overloaded vehicle. z
NOTIFY the customer of
incorrect vehicle loading.
z Ball joint(s). zGO to the Ball Joint Inspection
component test in this section.
z Front wheel bearing
(s). z
REFER to Wheel Bearing Inspection in this section.
z Loose, worn or
damaged
suspension
components(s). z
INSTALL new suspension
components as necessary.
REFER to Section 204 - 01 or
Section 204 - 02 .
z Loose suspension
fasteners. z
TIGHTEN to specification.
REFER to Section 204 - 01 or
Section 204 - 02 . Klj . 4 ba
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GENERAL PROCEDURES
Wheel Bearing Inspection
1. Raise the vehicle until the tire is off the floor. For additional information, refer to Section 100 - 02 .
2. NOTE: Make sure the wheel rotates freely and the brake pads are retracted sufficiently to allow
movement of the tire and wheel assembly.
Grasp each tire at the top and bottom and move the wheel inward and outward while lifting the
weight of the tire off the wheel bearing.
3. If the tire and wheel (hub) is loose on the wheel spindle or does not rotate freely, install a new front wheel hub (1104) as necessary. For additional information, refer to Section 204 - 01 .
SECTION 204-
00: Suspension System — General Information 2003 Mustang Workshop Manual Klj . 1 ba
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SPECIFICATIONS
SECTION 204-
01: Front Suspension 2003 Mustang Workshop Manual Torque Specifications
Description Nm lb-
ft lb-
in Front shock absorber upper nut 100 74 —
Front shock absorber-
to-spindle nuts 200 148 —
Shock absorber upper mount-
to-body nuts 40 30 —
Shock absorber upper mount-
to-body bolt 40 30 —
Wheel hub and bearing retainer nut 350 258 —
Stabilizer bar bracket nuts 70 52 —
Stabilizer bar link nuts 19 14 —
Anti-
lock brake sensor bolt 6 — 53
Anti-
lock brake sensor wire bracket nut 28 21 —
Ball joint-
to-front wheel spindle nut 175 129 —
Front suspension lower arm-
to-body nuts 200 148 —
Tie-
rod- to-spindle nuts 55 41 —
Steering gear-
to-crossmember nuts 70 52 —
Wheel nuts 129 95 — Klj . 1 ba
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REMOVAL AND INSTALLATION
Wheel Hub and Bearing
Removal
CAUTION: Suspension fasteners are critical parts because they affect performance of vital
components and systems and their failure can result in major service expense. A new part with
the same part number or an equivalent part must be installed, if installation is necessary. Do
not use a part of lesser quality or substitute design. Torque values must be used as specified
during reassembly to ensure correct retention of these parts.
1. Raise the vehicle on a hoist. For additional information, refer to Section 100 - 02 .
2. Remove the wheel and tire assembly. For additional information, refer to Section 204 - 04 .
3. Remove the front brake disc. For additional information, refer to Section 206 - 03 .
4. Remove and discard the front hub cap grease seal (1N135).
5. CAUTION: The wheel hub retainer (3B477) is a one time use item and must be
replaced with a new retainer when removed. Failure to do so can cause the retainer to
come loose during vehicle operation resulting in loss of vehicle control.
Remove and discard the front axle wheel hub retainer.
6. Remove the front wheel hub and bearing (1104).
SECTION 204-
01: Front Suspension 2003 Mustang Workshop Manual Klj . 1 ba
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