FORD MUSTANG 2003 Service Manual

Lateral runout means measuring the movement or "wobble" of a wheel or tire at the sidewall. Radial
runout means measuring the out-of-
round at the tread surface.
Rustling
Intermittent sound of varying frequency (100- 2000 Hz), sounds similar to shuffling through leaves.
Shake
A low- frequency vibration (5-20 Hz), usually with visible component movement. Usually relates to tires,
wheels, brake drums or brake discs if it is vehicle speed sensitive, or engine if it is engine speed
sensitive. Also referred to as a shimmy or wobble.
Shimmy
An abnormal vibration or wobbling, felt as a side- to-side motion of the steering wheel in the driveshaft
rotation. Also described as waddle.
Shudder
A low- frequency vibration that is felt through the steering wheel or seat during light brake application.
Slap
A resonance from flat surfaces, such as safety belt webbing or door trim panels.
Slip Yoke/Slip Spline
The driveshaft coupling that allows length changes to occur while the suspension articulates and while
the driveshaft rotates.
Squeak
A high- pitched transient sound, similar to rubbing fingers against a clean window.
Squeal
A long- duration, high- pitched noise.
Static Balance
The equal distribution of weight around the wheel. Statically unbalanced wheel and tire assemblies can
cause a bouncing action called wheel tramp. This condition will eventually cause uneven tire wear.
Tap
A light, rhythmic, or intermittent hammering sound, similar to tapping a pencil on a table edge.
Thump
A dull beat caused by two items striking together. Tick Klj . 9 ba
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A rhythmic tap, similar to a clock noise.
Tip-
In Moan
A light moaning noise heard during light vehicle acceleration, usually between 40- 100 km/h (25-65
mph).
TIR
The acronym for total indicated runout is TIR.
Tire Deflection
The change in tire diameter in the area where the tire contacts the ground.
Tire Flat Spots
A condition commonly caused by letting the vehicle stand while the tires cool off. This condition can be
corrected by driving the vehicle until the tires are warm. Also, irregular tire wear patterns in the tire
tread resulting from wheel- locked skids.
Tire Force Vibration
A tire vibration caused by variations in the construction of the tire that is noticeable when the tire
rotates against the pavement. This condition can be present on perfectly round tires because of
variations in the inner tire construction. This condition can occur at wheel rotation frequency or twice
rotation frequency.
Transient
A noise or vibration that is momentary, a short duration.
Two- Plane Balance
Radial and lateral balance.
Vibration
Any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up
and down.
Whine
A constant, high- pitched noise. Also described as a screech.
Whistle
High- pitched noise (above 500 Hz) with a very narrow frequency band. Examples of whistle noises are
a turbocharger or airflow around an antenna.
Wind Noise
Any noise caused by air movement in, out or around the vehicle. Klj . 10 ba
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WOT
The acronym for wide open throttle is WOT.
Tools and Techniques
Electronic Vibration Analyzer (EVA)
The EVA is a hand-
held electronic diagnostic tool which will assist in locating the source of
unacceptable vibrations. The vibration sensor can be remotely mounted anywhere in the vehicle for
testing purposes. The unit displays the three most common vibration frequencies and their
corresponding amplitudes simultaneously. A bar graph provides a visual reference of the relative
signal strength (amplitude) of each vibration being displayed and its relative G force. The keypad is
arranged to make the EVA simple to program and use. Some of the functions include the ability to
average readings as well as record, play back and freeze readings. The EVA has a strobe balancing
function that can be used to detect imbalance on rotating components such as a driveshaft or engine
accessories.
The EVA allows for a systematic collection of information that is necessary to accurately diagnose and
repair NVH problems. For the best results, carry out the test as follows:
a. Test drive the vehicle with the vibration sensor inside the vehicle.
b. Place the sensor in the vehicle according to feel. „If the condition is felt through the steering wheel, the source is most likely in the front of
the vehicle.
„ A vibration that is felt in the seat or floor only will most likely be found in the driveline,
drive axle or rear wheels and tires.
c. Record the readings. Also note when the condition begins, when it reaches maximum intensity, and if it tends to diminish above/below a certain speed.
„Frequencies should be read in the "average" mode. Item Description
1 EVA screen
2 Frequency mode displayed in rpm or Hz
3 Active sensor input (A or B)
4 Current active mode
5 G force indicators or the strongest frequencies in descending strength of each vibration
6 Strength of each vibration
7 Frequency in rpm/Hz of each vibration Klj . 11 ba
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„
Frequencies have a range of plus or minus 2. A reading of 10 Hz can be displayed as an
8 Hz through 12 Hz.
d. Place the vibration sensor on or near the suspect area outside the vehicle.
e. Continue the road test, driving the vehicle at the speed the symptom occurs, and take another reading.
f. Compare the readings.
„A match in frequency indicates the problem component or area.
„ An unmatched test could indicate the concern is caused by the engine, torque converter,
or engine accessory. Use the EVA in the rpm mode and check if concern is rpm related.
„ Example: A vibration is felt in the seat. Place the sensor on the console. Record the
readings. Place the vibration sensor on the rear axle. Compare the readings. If the
frequencies are the same, the axle is the problem component.
Vibrate Software®
Vibrate Software® ( Rotunda tool number 215- 00003) is a diagnostic aid which will assist in pinpointing
the source of unacceptable vibrations. The engine's crankshaft is the point of reference for vibration
diagnosis. Every rotating component will have an angular velocity that is faster, slower, or the same as
the engine's crankshaft. Vibrate Software® calculates the angular velocity of each component and
graphically represents these velocities on a computer screen and on a printed vibration worksheet.
The following steps outline how Vibrate Software® helps diagnose a vibration concern:
zEnter the vehicle information. Vibrate will do all the calculations and display a graph showing
tire, driveshaft and engine vibrations.
z Print a Vibration Worksheet graph. The printed graph is to be used during the road test.
z Road test the vehicle at the speed where the vibration is most noticeable. Record the vibration
frequency (rpm) and the engine rpm on the worksheet graph. The point on the graph where the
vibration frequency (rpm) reading and the engine rpm reading intersect indicates the specific
component group causing the concern.
„An EVA or equivalent tool capable of measuring vibration frequency and engine rpm will
be needed.
z Provide pictures of diagnostic procedures to aid in testing components.
Combination EngineEAR/ChassisEAR
An electronic listening device used to quickly identify noise and the location under the chassis while
the vehicle is being road tested. The ChassisEARs can identify the noise and location of
damaged/worn wheel bearings, CV joints, brakes, springs, axle bearings or driveshaft carrier bearings.
EngineEAR Basic Unit
An electronic listening device used to detect even the faintest noises. The EngineEARs can detect the
noise of damaged/worn bearings in generators, water pumps, A/C compressors and power steering
pumps. They are also used to identify noisy lifters, exhaust manifold leaks, chipped gear teeth and for
detecting wind noise. The EngineEAR has a sensing tip, amplifier, and headphones. The directional
sensing tip is used to listen to the various components. Point the sensing tip at the suspect component
and adjust the volume with the amplifier. Placing the tip in direct contact with a component will reveal
structure-borne noise and vibrations, generated by or passing through, the component. Various
volume levels can reveal different sounds.
Ultrasonic Leak Detector
The Ultrasonic Leak Detector is used to detect wind noises caused by leaks and gaps in areas where
there is weather- stripping or other sealing material. It is also used to identify A/C leaks, vacuum leaks Klj . 12 ba
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and evaporative emission noises. The Ultrasonic Leak Detector includes a multi-
directional transmitter
(operating in the ultrasonic range) and a hand- held detector. The transmitter is placed inside the
vehicle. On the outside of the vehicle, the hand- held detector is used to sweep the area of the
suspected leak. As the source of the leak is approached, a beeping sound is produced which
increases in both speed and frequency.
Squeak and Rattle Repair Kit
The squeak and rattle repair kit (Rotunda tool number 164- R4900) contains lubricants and self-
adhesive materials that can be used to eliminate interior and exterior squeaks and rattles. The kit
consists of the following materials:
zPVC (soft foam) tape
z Urethane (hard foam) tape
z Flocked (black fuzzy) tape
z UHMW (frosted) tape
z Squeak and rattle oil tube
z Squeak and rattle grease tube
Tracing Powder
Tracing powder is used to check both the uniformity of contact and the tension of a seal against its
sealing surface. These tests are usually done when a suspected air leak/noise appears to originate
from the seal area or during the alignment and adjustment of a component to a weatherstrip. Tracing
powder can be ordered from Crest Industries as ATR Leak Trace. Carry out the tracing powder test as
follows:
a. Clean the weatherstrip.
b. Spray the tracing powder on the mating surface only. c. Close the door completely. Do not slam the door.
d. Open the door. An imprint is made where the weatherstrip contacted the mating surface seal. Gaps or a faint imprint will show where there is poor contact with the weatherstrip. Klj . 13 ba
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Index Card
Place an index card or a piece of paper between the weatherstrip and the sealing surface, then close
the door. Slowly withdraw the index card or paper after the door is closed and check the amount of
pressure on the weatherstrip. There should be a medium amount of resistance as it is withdrawn.
Continue around the entire seal area. If there is little or no resistance, this indicates insufficient contact
to form a good seal. At these points, the door, the glass, or the weatherstrip is out of alignment. Klj . 14 ba
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DIAGNOSIS AND TESTING
Noise, Vibration and Harshness (NVH)
To assist the service advisor and the technician, a Write-
up Job Aid and an NVH Diagnostic Guide are
included with this material. The Write- up Job Aid serves as a place to record all important symptom
information. The NVH Diagnostic Guide serves as a place to record information reported on the Write-
up Job Aid as well as data from the testing to be carried out.
To begin a successful diagnosis, fill out the NVH Diagnostic Guide, record the reported findings, then
proceed to each of the numbered process steps to complete the diagnosis. SECTION 100-
04: Noise, Vibration and Harshness 2003 Mustang Workshop Manual Special Tool(s)
ChassisEAR
107-
R2102 or equivalent Electronic Vibration Analyzer
100-
F027 (014- 00344) or
equivalent EngineEAR
107-
R2100 or equivalent Ultrasonic Leak Detector
134-
R0135 or equivalent Klj . 1 ba
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