wheel FORD MUSTANG 2003 Service Manual

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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operation.
K3 MEASURE THE LATERAL RUNOUT AND THE RADIAL
RUNOUT OF THE FRONT WHEELS ON THE VEHICLE z
Measure the lateral runout and the radial runout of the front
wheels on the vehicle. Refer to Go To Pinpoint Test J .
z Are the measurements within specifications? Yes
GO to
K4 .
No
INSTALL new wheels as
necessary and BALANCE
the assembly. TEST the
system for normal
operation. K4 MEASURE THE LATERAL RUNOUT OF THE FRONT TIRES
ON THE VEHICLE z
Measure the lateral runout of the front tires on the vehicle. Go To Pinpoint Test J .
z Is the runout within specifications? Yes
GO to
K5 .
No
INSTALL new tires as
necessary and BALANCE
the assembly. TEST the
system for normal
operation. K5 MEASURE THE RADIAL RUNOUT OF THE FRONT TIRES
ON THE VEHICLE z
Measure the radial runout of the front tires on the vehicle. Go To Pinpoint Test J .
z Is the runout within specifications? Yes
BALANCE the front wheel
and tire assemblies. If any
tire cannot be balanced,
INSTALL a new tire.
TEST the system for
normal operation.
No
GO to
K6 .
K6 MATCH MOUNT THE TIRE AND WHEEL ASSEMBLY
z
Mark the high runout location on the tire and also on the
wheel. Break the assembly down and rotate the tire 180
degrees (halfway around) on the wheel. Inflate the tire and
measure the radial runout.
z Is the runout within specifications? Yes
BALANCE the assembly.
TEST the system for
normal operation.
No
If the high spot is not
within 101.6 mm (4
inches) of the first high
spot on the tire, GO to
K7
.
K7 MEASURE THE WHEEL FLANGE RUNOUT
z
Dismount the tire and mount the wheel on a wheel balancer.
Measure the runout on both wheel flanges. Go To Pinpoint Test J . Yes
LOCATE and MARK the
low spot on the wheel.
INSTALL the tire,
matching the high spot on
the tire with the low spot
on the wheel. BALANCE
the assembly. TEST the
system for normal
operation. If the condition Klj . 59 ba
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z
Is the runout within specifications? persists,GO to
K8 .
No
INSTALL a new wheel.
CHECK the runout on the
new wheel. If the new
wheel is within limits,
LOCATE and MARK the
low spot. INSTALL the
tire, matching the high
spot on the tire with the
low spot on the wheel.
BALANCE the assembly.
TEST the system for
normal operation. If the
condition persists, GO to
K8 .
K8 CHECK FOR VIBRATION FROM THE FRONT OF THE
VEHICLE WARNING: If only one drive wheel is allowed to
rotate, speed must be limited to 55 km/h (34 mph) using
the speedometer reading, since actual wheel speed will
be twice that indicated on the speedometer. Exceeding a
speed of 55 km/h (34 mph) or allowing the drive wheel to
hang unsupported can result in tire disintegration or
differential failure, which can cause serious personal
injury and extensive vehicle damage.
z Spin the front wheel and tire assemblies with a wheel
balancer while the vehicle is raised on a hoist. Feel for
vibration in the front fender or while seated in the vehicle.
z Is the vibration present? Yes
SUBSTITUTE known
good wheel and tire
assemblies as necessary.
TEST the system for
normal operation.
No
GO to
K9 .
K9 CHECK FOR VIBRATION FROM THE REAR OF THE
VEHICLE WARNING: If only one drive wheel is allowed to
rotate, speed must be limited to 55 km/h (34 mph) using
the speedometer reading, since actual wheel speed will
be twice that indicated on the speedometer. Exceeding a
speed of 55 km/h (34 mph) or allowing the drive wheel to
hang unsupported can result in tire disintegration or
differential failure, which can cause serious personal
injury and extensive vehicle damage.
z Chock the front wheels.
z Raise and support the rear end of the vehicle so that the rear
wheel and tire assemblies can spin.
z Engage the drivetrain and carefully accelerate the drive
wheels while checking for vibration.
z Is the vibration present? Yes
GO to
K10 .
No
TEST the system for
normal operation. K10 CHECK THE DRIVETRAIN
WARNING: If only one drive wheel is allowed to
rotate, speed must be limited to 55 km/h (34 mph) using
the speedometer reading, since actual wheel speed will
be twice that indicated on the speedometer. Exceeding a
speed of 55 km/h (34 mph) or allowing the drive wheel to
hang unsupported can result in tire disintegration or
differential failure, which can cause serious personal
injury and extensive vehicle damage.
z Remove the rear wheel and tire assemblies. Refer to the Yes
CHECK/TEST the
drivetrain and driveline
components. TEST the
system for normal
operation.
No
SUBSTITUTE known
good wheel and tire Klj . 60 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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PINPOINT TEST M: TRANSFER CASE VIBRATION the system for normal operation.
No
GO to
L6 .
L6 CHECK THE FLYWHEEL BOLTS
z
Check for loose flywheel bolts.
z Are the bolts loose? Yes
TIGHTEN the bolts to
specifications. REFER to
Section 308 - 01 . TEST the system for
normal operation.
No
GO to L7 .
L7 CHECK THE FLYWHEEL SURFACE
z
Inspect the flywheel surface for wear or damage.
Check the flywheel runout.
z Is there any damage or excessive wear? Yes
INSTALL a new flywheel. TEST
the system for normal operation.
No
Clutch system normal. CONDUCT
a diagnosis on other suspect
systems.
Test Step Result / Action to Take
M1 INSPECT THE TRANSFER CASE
z
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.
z Inspect the transfer case for loose or missing mounting bolts.
Check for fluid seepage between the transfer case and the
transmission.
z Are the mounting bolts missing or loose? Yes
TIGHTEN to
specifications or
INSTALL new bolts as
necessary. TEST the
system for normal
operation.
No
GO to
M2 .
M2 INSPECT THE REAR DRIVESHAFT
z
NOTE: Verify that the driveshaft and pinion flange index marks
are aligned.
z Inspect the driveshaft for missing weights, damage or
undercoating.
z Inspect the U- joints for freedom of movement.
z Check driveshaft runout and, if necessary, check the pinion
flange runout.
z Is the driveshaft or U- joints worn or damaged or
misaligned? Yes
REPAIR or INSTALL a
new driveshaft as
necessary. TEST the
system for normal
operation.
No
GO to
M3 .
M3 CHECK THE DRIVELINE ANGLES
z
Measure the rear driveshaft and pinion angles. Refer to Section 205 - 00 .
z Measure the front driveshaft and pinion angles. Refer to Section 205 - 00 .
z Are the driveline angles incorrect? Yes
REPAIR as necessary.
TEST the system for
normal operation.
No Klj . 62 ba
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4. While the noise is occurring, either place an EngineEAR probe near the IAC valve and the inlet
tube, or create a 6.35 mm (0.25 in)- 12.7 mm (0.50 in) air gap between the inlet tube and the
clean air tube. If the IAC valve is making the noise, install a new IAC valve.
5. Test the vehicle for normal operation.
Steering Gear Grunt/Shudder Test
1. Start and run the vehicle to operating temperature.
2. Set engine idle speed to 1200 rpm.
3. CAUTION: Do not hold the steering wheel against the stops for more than three to
five seconds at a time. Damage to the power steering pump will occur.
Rotate the steering wheel to the RH stop, then turn the steering wheel 90° back from that
position. Turn the steering wheel slowly in a 15° to 30° arc.
4. Turn the steering wheel another 90°. Turn the steering wheel slowly in a 15° to 30° arc.
5. Repeat the test with power steering fluid at different temperatures.
6. If a light grunt is heard or a low (50- 200 Hz) shudder is present, this is a normal steering system
condition.
7. If a loud grunt is heard, or a strong shudder is felt, fill and purge the power steering system.
Checking Tooth Contact Pattern and Condition of the Ring and Pinion
There are two basic types of conditions that will produce ring and pinion noise. The first type is a howl
or chuckle produced by broken, cracked, chipped, scored or forcibly damaged gear teeth and is
usually quite audible over the entire speed range. The second type of ring and pinion noise pertains to
the mesh pattern of the gear pattern. This gear noise can be recognized as it produces a cycling pitch
or whine. Ring and pinion noise tends to peak in a narrow speed range or ranges, and will tend to
remain constant in pitch.
1. Raise and support the vehicle. For additional information, refer to Section 100 - 02 .
2. Drain the axle lubricant. Refer to Section 205 - 02A for Ford 7.5 rear axles or
Section 205 - 02B for
Ford 8.8 integral axles.
3. Remove the carrier assembly or the axle housing cover depending on the axle type. Refer to Section 205 - 02A for Ford 7.5 rear axles or
Section 205 - 02B for Ford 8.8 integral axles.
4. Inspect the gear set for scoring or damage. Klj . 64 ba
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Wheel and tire NVH concerns are directly related to vehicle speed and are not generally affected by
acceleration, coasting or decelerating. Also, out-of-
balance wheel and tires can vibrate at more than
one speed. A vibration that is affected by the engine rpm, or is eliminated by placing the transmission
in NEUTRAL is not related to the tire and wheel. As a general rule, tire and wheel vibrations felt in the
steering wheel are related to the front tire and wheel assemblies. Vibrations felt in the seat or floor are
related to the rear tire and wheel assemblies. This can initially isolate a concern to the front or rear.
Careful attention must be paid to the tire and wheels. There are several symptoms that can be caused
by damaged or worn tire and wheels. Carry out a careful visual inspection of the tires and wheel
assemblies. Spin the tires slowly and watch for signs of lateral or radial runout. Refer to the tire wear
chart to determine the tire wear conditions and actions. Klj . 68 ba
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For a vibration concern, use the vehicle speed to determine tire/wheel frequency and rpm. Calculate
tire and wheel rpm and frequency by carrying out and following:
zMeasure the diameter of the tire.
z Record the speed at which the vibration occurs.
z Obtain the corresponding tire and wheel rpm and frequency from the Tire Speed and Frequency
Chart.
„If the vehicle speed is not listed, divide the vehicle speed at which the vibration occurs by
16 km/h (10 mph). Multiply that number by 16 km/h (10 mph) tire rpm listed for that tire
diameter in the chart. Then divide that number by 60. For example: a 40 mph vibration
with 835 mm (33 in) tires. 40 ÷ 10 = 4. Multiply 4 by 105 = 420 rpm. Divide 420 rpm by 60
seconds = 7 Hz at 40 mph.
Tire Speed and Frequency Chart Tire
Diameter Tire RPM/Hz Tire RPM/Hz Tire RPM/Hz Tire RPM/Hz
mm (inch) @ 16 km/h (10
mph) @ 80 km/h (50
mph) @ 97 km/h (60
mph) @ 113 km/h (70
mph) 483 (19) 182 910/15 1092/18 1274/21
508 (20) 173 865/14 1038/17 1211/20
533 (21) 165 825/14 990/16 1155/19
560 (22) 158 790/13 948/16 1106/18
585 (23) 151 755/13 906/15 1057/18
610 (24) 145 725/12 870/14 1015/17
635 (25) 139 695/12 834/14 973/16
660 (26) 134 670/11 804/13 938/16
685 (27) 129 645/11 774/13 903/15
710 (28) 124 620/10 744/12 868/14
735 (29) 119 595/10 714/12 833/14
760 (30) 115 575/10 690/11 805/13
785 (31) 111 555/9 666/11 777/13
810 (32) 108 540/9 648/11 756/13
835 (33) 105 525/9 630/10 735/12
864 (34) 102 510/8 612/10 714/12 Klj . 69 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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