AC system FORD MUSTANG 2003 Workshop Manual

·
No end clearance ·
Inspect converter and install a new or remanufactured torque
converter as required. ·
Piston plate damaged or stuck
to cover ·
If cover is heat- stained, install a new converter and determine
the cause of the overheat condition.
Torque Converter Clutch Operation Concerns: Cycling/Shudder/Chatter Possible Component Reference/Action
242 —
ELECTRICAL ROUTINE Powertrain Control System
·
Electrical inputs/outputs, vehicle
wiring harnesses, PCM, torque
converter clutch (TCC) solenoid,
OSS ·
Carry out Self-Test. Refer to the Powertrain
Control/Emissions Diagnosis (PC/ED) manual for
diagnosis and testing of the Powertrain Control System.
Go To Pinpoint Test E . Repair as required. Clear
DTCs, road test and repeat Self- Test. ·
Speed control equipped vehicles ·
Evaluate with speed control off. 342 —
HYDRAULIC/MECHANICAL ROUTINE Fluid
·
Condition ·
Inspect fluid condition. If burnt, drain fluid and converter.
Install a new fluid and filter assembly. Bring vehicle to
normal operating temperature. Carry out Transmission
Drive Cycle Test. Carry out Transmission Self- Test. If
condition still exists, continue diagnostics. Main Controls
·
Solenoid pressure regulator valve,
No. 7 check ball, bypass clutch
control valve and plunger, converter
pressure limit valve stuck, damaged
or assembled incorrectly ·
Inspect for damage. Repair as required. ·
Bolts not tightened to specifications ·
Tighten bolts to specifications. ·
Solenoid screen blocked or damaged ·
Clean or install a new screen. ·
TCC solenoid malfunction ·
Activate solenoid using scan tool. If solenoid operation
cannot be felt when placing hand on solenoid, install a
new solenoid. Inspect O- rings for damage. Repair as
required. ·
Gaskets damaged ·
Inspect for damage and install a new gasket. Pump Assembly
·
Bolts not tightened to specification ·
Tighten bolts to specification. ·
Porosity/cross leaks, missing balls or
leaking ·
Inspect for porosity/leaks or missing balls. Install a new
pump as required. ·
Gaskets damaged ·
Inspect for damage and install a new gasket. Input Shaft
·
Seals damaged ·
Inspect for damage. Repair as required. Torque Converter
·
Excessive end clearance ·
Inspect converter. Install a new or re- manufactured
torque converter as required.
Other Concerns: No Engine Braking In Manual 2nd Or Manual 1st Position Klj . 25 ba
312003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2748/S3B~us~en~ ...

Possible Component Reference/Action
250 —
ELECTRICAL ROUTINE ·
No Electrical Concerns 350 —
HYDRAULIC/MECHANICAL ROUTINE Shift Linkage
·
Damaged or incorrectly
adjusted ·
Inspect and repair as required. Verify transmission shift cable
adjustment; refer to Section 307 - 05 . Adjust transmission shift
cable as necessary. After repairing transmission shift cable,
verify that the digital TR sensor is correctly adjusted. Adjust
the digital TR sensor as necessary. Main Controls
·
3- 4 shift valve, 1- 2 and 2-3
shift valve, gaskets, 3-4
capacity modulator valve,
stuck or damaged or
assembled incorrectly ·
Inspect for damage. Repair as required. ·
OD servo assembly damaged
or stuck in manual 2nd only. ·
Inspect cover, piston and seal for damage. Repair as required. ·
Low/Reverse servo assembly
damaged or stuck in manual
1st only ·
Inspect cover, piston and seal for damage. Repair as required. Overdrive
·
Reverse band, manual 1st
(only) damaged ·
Inspect for damage. Repair as required. ·
OD band, reverse clutch drum
assembly worn or damaged
(manual 2nd only) ·
Inspect for damage. Repair as required. Reverse Band (Manual 1st Only)
·
Damaged or incorrectly
adjusted ·
Inspect for damage. Repair as required.
Other Concerns: Shift Lever Efforts High Possible Component Reference/Action
251 —
ELECTRICAL ROUTINE ·
No Electrical Concerns 351 —
HYDRAULIC/MECHANICAL ROUTINE Shift Linkage, Digital TR
Sensor
·
Damaged or incorrectly
adjusted ·
Inspect and repair as required. Verify transmission shift cable
adjustment; refer to Section 307 - 05 . Adjust transmission shift
cable as necessary. After repairing transmission shift cable, verify
that the digital TR sensor is correctly adjusted. Adjust the digital
TR sensor as necessary. ·
Brake shift interlock
system, solenoid damaged ·
Refer to the appropriate brake section in the workshop manual. Manual Lever
·
Retaining pin damaged, nut
loose, detent spring bent or
damaged or Park ·
Inspect for damage. Repair as required. Klj . 26 ba
312003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2748/S3B~us~en~ ...

mechanism damaged
Main Controls
·
Manual valve stuck or
damaged ·
Inspect for damage. Repair as required. ·
Bolts not tightened to
specifications ·
Tighten bolts to specifications.
Other Concerns: External Leaks Possible Component Reference/Action
252 —
ELECTRICAL ROUTINE Powertrain Control System
·
Electrical inputs/outputs, sensor
seals leaking (digital TR, OSS,
vehicle speed sensor VSS, if
equipped, or transmission connector) ·
Inspect for leakage and repair as required. 352 —
HYDRAULIC/MECHANICAL ROUTINE Case
·
Case vent, case porosity, case
cracked ·
Check the vent for free breathing. Check the fluid level.
Check the transmission for overheat conditions. Repair
as required. Seals/Gaskets
·
Leakage at gaskets, seals, etc. (refer
to external sealing illustration for
potential leak locations) ·
Remove all traces of lubricant on exposed surfaces of
the transmission. Check the vent for free breathing.
Operate the transmission at normal temperatures and
perform fluid leakage check. Repair as required. Other
·
Cooler fitting, cooler lines pressure
tap, converter drain plug, band
anchor pins ·
Locate the source of the leak. Repair as required.
Other Concerns: Poor Vehicle Performance Possible Component Reference/Action
253 —
ELECTRICAL ROUTINE Powertrain Control System
·
Electrical inputs/outputs, vehicle
wiring harnesses, shift solenoids,
digital TR sensor, torque
converter clutch (TCC) solenoid,
transmission fluid temperature
(TFT) sensor ·
Carry out Self-Test. Refer to the Powertrain
Control/Emissions Diagnosis (PC/ED) manual for diagnosis
and testing of the Powertrain Control System. Go To Pinpoint Test A ,
Go To Pinpoint Test B or
Go To Pinpoint Test C . Repair as required. Clear codes, road test and
repeat Self- Test. Also refer to Routines 241/341 Torque
Converter Operation Concern: Always Applied. ·
Engine driveability concerns ·
Inspect air intake/air filter system. Check the fuel system
and fuel pressure. Refer to the Powertrain
Control/Emissions Diagnosis (PC/ED) manual. Inspect the
exhaust system for restriction. Refer to Section 309 - 00 .
353 —
HYDRAULIC/MECHANICAL ROUTINE Shift Linkage, Digital TR Sensor Klj . 27 ba
312003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2748/S3B~us~en~ ...

12 o'clock position
„ Friction elements ·
3rd Gear:
„ Torque converter
„ Case to planet support spring
„ Friction elements ·
4th Gear:
„ Gear set
„ Friction elements
„ Torque converter ·
Reverse:
„ Gear set
„ Friction elements ·
Output shaft splines worn or damaged Other Noises/Vibrations
·
Main controls, valve resonance ·
Shift cable:
„ Vibration
„ Grounding
„ Cooler lines
„ Grounding ·
Locate source of disturbance and repair as
required.
Other Concerns: Engine Will Not Crank Possible Component Reference/Action
255 —
ELECTRICAL ROUTINE Powertrain Control System
·
Electrical inputs/outputs,
vehicle wiring harnesses,
engine starting system
hardware, digital TR sensor ·
Carry out Self- Test. Refer to the Powertrain Control/Emissions
Diagnosis (PC/ED) manual for diagnosis and testing of the
Powertrain Control System. Go To Pinpoint Test C . Repair and
adjust as required. 355 —
HYDRAULIC/MECHANICAL ROUTINE Shift Linkage, Digital TR
Sensor
·
Damaged or incorrectly
adjusted ·
Inspect and repair as required. Verify transmission shift cable
adjustment; refer to Section 307 - 05 . Adjust transmission shift
cable as necessary. After repairing transmission shift cable,
verify that the digital TR sensor is correctly adjusted. Adjust the
digital TR sensor as necessary.
Other Concerns: No Park (P) Range Possible Component Reference/Action
256 —
ELECTRICAL ROUTINE ·
No Electrical Concerns 356 —
HYDRAULIC/MECHANICAL ROUTINE Klj . 29 ba
312003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2748/S3B~us~en~ ...

GENERAL PROCEDURES
Transmission Fluid Cooler —
Backflushing and Cleaning
1. CAUTION: Do not use any supplemental transmission fluid additives or cleaning
agents. The use of these products could cause internal transmission components to fail;
this will effect the operation of the transmission.
Conduct backflushing with a suitable torque converter/fluid cooler cleaner. Test your equipment
to make sure that a vigorous fluid flow is present before proceeding. Install a new filter in the
flush equipment if flow is weak or contaminated.
2. To aid in attaching the cleaner to the transmission steel cooler lines, connect two additional rubber hoses to the transmission end of the steel transmission cooler lines as described below.
zConnect the cleaner tank pressure line to the steel transmission cooler return line
(longest line).
z Connect a tank return hose to the steel transmission cooler pressure line (shorter line).
Place the outlet end of this hose in the solvent tank reservoir.
3. Turn on solvent pump and allow the solvent to circulate a minimum of 5 minutes (cycling switch on and off will help dislodge contaminants in cooler system).
4. Switch off the solvent pump and disconnect the solvent pressure hose from the transmission cooler return line.
5. Use compressed air to blow out the cooler(s) and lines (blow air into the transmission cooler return line) until all solvent is removed.
6. Remove the rubber return hose from the remaining steel cooler line.
SECTION 307-
01: Automatic Transaxle/Transmission 2003 Mustang Workshop Manual Klj . 1 ba
12003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2748/S3B~us~en~ ...

REMOVAL
Transmission
CAUTION: Whenever a transmission has been disassembled to install new parts the
transmission fluid cooler tubes must be cleaned and backflushed. Use a suitable torque
converter/fluid cooler cleaner. If equipped a new oil- to-air cooler must also be installed.
When internal wear or damage has occurred in the transmission, metal particles, clutch plate
material or band material may have been carried into the torque converter and fluid cooler.
These contaminants are a major cause of recurring transmission troubles and must be
removed from the system before the transmission is put back into use.
CAUTION: After transmission is removed for a major overhaul, it is important to
completely clean all transmission components, including torque converter, oil- to-air cooler if
equipped, cooler inlet tube, main control valve body, clutches and all coasting booster valve
shuttle balls after any transmission repair that generates contamination. These contaminants
are a major cause for recurring transmission concerns and must be removed from the system
before the transmission is returned to use.
The cleaning of foreign material from the direct clutch check ball is often omitted. This
omission can lead to repeat repair of the transmission.
If equipped a new oil- to-air cooler must be installed under the following conditions; for
installation refer to Section 307 - 02 .
z Evidence of transmission assembly or fluid contamination is found due to the following
transmission or converter failure modes:
„major metallic failure
„ multiple clutches or clutch plate failures
„ sufficient component wear which results in metallic contamination.
1. Place the transmission range selector lever in NEUTRAL.
2. Disconnect the battery ground cable. For additional information, refer to Section 414 - 01 .
3. Raise and support the vehicle. For additional information, refer to Section 100 - 02 .
4. Remove the dual converter Y pipe. For additional information, refer to Section 309 - 00 .
5. Disconnect the transmission harness electrical connector.
SECTION 307-
01: Automatic Transaxle/Transmission 2003 Mustang Workshop Manual Special Tool(s)
Retainer, Torque Converter
307-
346 (T97T-7902- A) Klj . 1 ba
72003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2748/S3B~us~en~ ...

DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES
Torque Converter Cleaning And Inspection
1. If a new torque converter is being installed, continue with Substep 2 of Step 2.
2. If a new torque converter is not being installed, the following procedures must be performed: 1. The torque converter must be thoroughly cleaned.
„Torque converters with drain plugs can be cleaned by using a suitable torque
converter/fluid cooler cleaner.
„ Torque converters without drain plugs can be cleaned by hand. Partially fill the
torque converter using only recommended transmission fluid for the applicable
transmission. Hand agitate the torque converter and then thoroughly drain the
fluid. Refill the torque converter with clean automatic transmission fluid specified
for transmission, and reinstall.
2. All in- tank and auxiliary coolers must be thoroughly cleaned by forward and backward
flushing. For additional information, refer to Transmission Fluid Cooler — Backflushing
and Cleaning in this section.
3. All cooler lines must be thoroughly cleaned by backward and forward flushing. For additional information, refer to Transmission Fluid Cooler — Backflushing and Cleaning
in this section.
4. All Cooler Bypass Valves (CBV), if equipped, must be thoroughly cleaned.
5. Carry out the Transmission Fluid Cooler Flow Test. For additional information, refer to
Transmission Fluid Cooler — Backflushing and Cleaning in this section.
6. If the transmission cooling system fails the Transmission Fluid Cooler Flow Test, a new fluid cooler, cooler bypass valve, and/or cooler lines must be installed. For additional
information, refer to Section 307 - 02 .
7. If new coolers are to be installed, use only factory approved service parts.
SECTION 307-
01: Automatic Transaxle/Transmission 2003 Mustang Workshop Manual Material
Item Specification
MERCON® V Automatic
Transmission Fluid
XT
-5-QM, XT -5-DM MERCON® V Klj . 1 ba
22003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2748/S3B~us~en~ ...

DIAGNOSIS AND TESTING
Transmission Cooling
Inspection and Verification
WARNING: Never remove the radiator cap under any conditions while the engine is
operating. Failure to follow these instructions could result in personal injury and/or damage to
the cooling system or engine. To avoid having scalding hot coolant or steam blow out of the
radiator, use extreme care when removing the radiator cap from a hot radiator. Wait until the
engine has cooled, then wrap a thick cloth around the radiator cap and turn it slowly to the first
stop. Step back while the pressure is released from the cooling system. When you are certain
all the pressure has been released, press down on the radiator cap (with a cloth), turn and
remove.
The transmission fluid cooler is integral to the radiator (8005). Whenever leaks or damage to the
radiator are found, install an entire new radiator. For additional information, refer to Section 303 - 03A or
Section 303 - 03B .
Symptom Chart SECTION 307-
02: Transaxle/Transmission Cooling 2003 Mustang Workshop Manual SYMPTOM CHART
Condition
Possible Sources Action
z Transmission
Overheating z
Damaged radiator. zREPAIR or install a new
radiator. For additional
information, REFER to
Section 303 - 03A or
Section 303 - 03B .
z System leaks. zINSPECT for leaks. REPAIR
as necessary.
z Incorrect fluid level. zADJUST to proper level.
z Fluid condition. zINSPECT according to
instructions under Fluid
Condition Check. REFER to
Section 307 - 01 .
z Damaged, blocked,
reversed, leaking or
restricted cooler lines
or cooler tubes. z
INSPECT cooler lines and
tubes. REPAIR or flush as
necessary.
z Engine concerns
causing transmission
to overheat. z
INSPECT engine cooling
system. For additional
information, REFER to
Section 303 - 03A or
Section 303 - 03B .
z Excessive towing
loads. z
CHECK gross vehicle weight.
z Incorrect idle or
performance. z
REFER to the Powertrain
Control/Emissions Diagnosis
(PC/ED) manual. Klj . 1 ba
22003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2748/S3B~us~en~ ...

DESCRIPTION AND OPERATION
External Controls
The transmission shift cable transfers the transmission operating mode from the gearshift lever to the
automatic transmission (7003). The indicated position of the transmission floor mounted selector lever
is transferred to the transmission through the cable and down to the manual control lever on the
transmission.
Shift Interlock System
The brake/shift interlock mechanism is used on vehicles equipped with an automatic transmission.
This system is used to prevent shifting from PARK unless the brake pedal is depressed. The
brake/shift interlock system consists of an actuator attached to the key interlock assembly and
necessary wiring. The shift lock actuator is energized when the ignition switch is turned to the run
position, locking the floor mounted transmission range selector lever in the PARK position. When the
brake pedal is depressed, the shift lock actuator is deactivated and the floor mounted transmission
range selector lever can be moved out of the PARK position.
Transmission Control Switch (TCS)
The transmission control switch (TCS) is a momentary contact switch that is located on the floor
mounted transmission range selector lever. Pushing the TCS will either disengage or engage the
overdrive function of the automatic transmission. If the OVERDRIVE is disengaged, the word O/D OFF
will illuminate on the instrument cluster.
SECTION 307-
05: Automatic Transaxle/Transmission External Controls 2003 Mustang Workshop Manual Klj . 1 ba
12003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2748/S3B~us~en~ ...

DIAGNOSIS AND TESTING
External Controls
Refer to Wiring Diagrams Cell
37 , Shift Lock for schematic and connector information.
Refer to Wiring Diagrams Cell 29 , Transmission Control for schematic and connector information.
Inspection and Verification 1. Verify the customer concern by operating the transmission external control.
2. Visually inspect for obvious signs of mechanical and electrical damage; refer to the following chart:
3. If the concern is not visually evident, determine the symptom. GO to Symptom Chart .
Symptom Chart SECTION 307-
05: Automatic Transaxle/Transmission External Controls 2003 Mustang Workshop Manual Special Tool(s)
73 Digital Multimeter
105-
R0051 or equivalent
Visual Inspection Chart Mechanical Electrical
z
Shift control linkage binding.
z Shift lock actuator.
z Shift control cable.
z Interlock cable. z
Circuitry.
z Central junction box (CJB) fuse:
„17 (15A)
„ 28 (15A)
„ 35 (15A)
z Brake pedal position (BPP) switch.
z Wiring harness.
z Loose or corroded connections.
z Bulb.
SYMPTOM CHART Condition
Possible Sources Action
z The shift interlock
system does not
release/lock correctly z
Circuitry.
z CJB Fuse 17 (15A)
or Fuse 35 (15A).
z Shift lock actuator.
z Brake pedal position
(BPP) switch. z
Go To Pinpoint Test A . Klj . 1 ba
62003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2748/S3B~us~en~ ...