ECU FORD MUSTANG 2003 Repair Manual

DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES
Torque Converter End Play Check
1. Install the special tool into the torque converter pump drive. zTighten the inner post until the tool is securely locked.
2. Install the special tool on the converter pump drive hub and zero the dial indicator.
3. Lift up on the special tool and note the dial indicator reading. zIf the reading exceeds end play limits, install a new or remanufactured torque converter.
SECTION 307-
01: Automatic Transaxle/Transmission 2003 Mustang Workshop Manual Special Tool(s)
Dial Indicator Gauge with
Holding Fixture
100-
002 (TOOL- 4201-C) or
equivalent End Play Gauge, Torque
Converter
307-
071 (T80L-7902- A) or
equivalent Torque Converter End Play Klj . 1 ba
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52. Install the 2-
3 accumulator assembly.
1. Install the accumulator piston.
2. Install the accumulator piston spring.
3. Install the accumulator spring retainer.
53. Using the special tools apply regulated air pressure to the test ports. Verify that the components are applied and released.
54. NOTE: The tab on the electrical connector is secured by main control valve body.
Install the electrical connector into the case.
55. NOTE: The alignment bolts are valve body assembly bolts and are in the valve body.
Align the main control valve body alignment bolts and position the main control valve body. Klj . 18 ba
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INSTALLATION
Transmission
1. CAUTION: During this move, to avoid damage, do not allow the transmission to get
into a nose- down position as this will cause the torque converter to move forward and
disengage from the pump gear. The converter housing is piloted into position by dowels
in the rear of the engine block. The torque converter must rest squarely against the
flexplate. This indicates that the converter pilot is not binding in the engine crankshaft.
Position and secure the transmission on the high- lift transmission jack.
2. CAUTION: Make sure the torque converter is fully seated in the transmission before
positioning the transmission to the engine.
Using the special tool, install the transmission to the engine.
zAlign the orange balancing marks on the converter stud and the flexplate bolt hole. 3. Reconnect the harness. SECTION 307-
01: Automatic Transaxle/Transmission 2003 Mustang Workshop Manual Special Tool(s)
Retainer, Torque Converter
307-
346 (T97T-7902- A)
Material Item Specification
Multi-
Purpose Grease
D0AZ- 19584- AA ESB-
M1C93-
B MERCON® V Automatic
Transmission Fluid
XT
-5-QM, XT -5-DM MERCON® V Klj . 1 ba
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REMOVAL AND INSTALLATION
Transmission Fluid Cooler Tubes
Removal
1. Disconnect the battery cables.
2. Raise and support the vehicle. For additional information, refer to Section 100 - 02 .
3. Remove the nuts.
4. Remove the fluid cooler tube bracket at the engine.
5. NOTE: Use a backup wrench to hold the case fitting secure.
Remove the fluid cooler tubes at the transmission. Installation SECTION 307-
02: Transaxle/Transmission Cooling 2003 Mustang Workshop Manual Klj . 1 ba
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1.
NOTE: Use a backup wrench to hold the case fitting secure.
Install the fluid cooler tubes at the transmission.
2. Install the fluid cooler tube bracket at the engine.
3. Install the nuts.
4. Lower the vehicle.
5. Connect the battery cables.
6. Fill the transmission with fluid and verify proper operation. zUse Motorcraft MERCON® V Automatic Transmission Fluid XT -5-QM or equivalent
meeting MERCON® V specification. Klj . 2 ba
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REMOVAL
Transmission
1. Disconnect the battery ground cable. For additional information, refer to Section 414 - 01 .
2. Lift up on the clutch pedal and secure it in place.
3. Remove the gearshift lever knob (7213).
4. Remove the console panel gearshift plate. Lift the gearshift lever boot over the gearshift lever (7210).
5. Remove the bolts and the shift lever.
6. Raise and support the vehicle. For additional information, refer to Section 100 - 02 .
7. Disconnect the heated oxygen sensor electrical connectors. SECTION 308-
03A: Manual Transaxle/Transmission — T5OD 2003 Mustang Workshop Manual Klj . 1 ba
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8. Remove the nuts. Position and secure the muffler and tailpipe out of the way.
9. Remove the LH nuts.
10. Remove the RH nuts.
11. Remove the dual converter Y- pipe.
12. CAUTION: Index- mark the driveshaft flange and pinion flange, and the driveshaft
slip yoke and transmission output shaft.
Remove the driveshaft. For additional information, refer to Section 205 - 01 . Klj . 2 ba
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1.
CAUTION: Use a vise with brass jaws or wood blocks.
Secure the input shaft in a vise. Using the special tools and a slide hammer, remove the input
shaft bearing cup. zInspect the cup for wear or damage. Install a new bearing cup and bearing as necessary.
2. Using the special tool and a press, remove the input shaft front bearing. Item Part Number Description
1 7025 Input shaft bearing
2 7017 Input shaft
3 — Input shaft bearing cup Klj . 2 ba
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GENERAL PROCEDURES
Fittings —
Vapor Tube
Disconnect
1. WARNING: The evaporative emission system contains fuel vapor and condensed
fuel vapor. Although not present in large quantities, it still presents the danger of
explosion or fire. Disconnect the battery ground cable from the battery to minimize the
possibility of an electrical spark occurring, possibly causing a fire or explosion if fuel
vapor or fuel liquid is present in the area.
Disconnect the battery ground cable.
2. Disconnect the vapor tube from the fitting. 1. Squeeze the fitting.
2. Disconnect the vapor tube from the fitting.
Connect 1. Clean and inspect the fitting and the tube for damage.
2. Push the tube into the fitting until it snaps in place.
3. Pull on the connection to make sure the fitting is secure.
SECTION 310-
00: Fuel System — General Information 2003 Mustang Workshop Manual Klj . 1 ba
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2. Inspect to determine if one of the following mechanical or electrical concerns apply:
a A leak in the vacuum control circuit may occur during acceleration (slow leak), at all times
(large leak), or only when specific functions are selected (indicating a leak in that portion of the
circuit). The vacuum hoses used in the passenger compartment control circuit are constructed
from PVC plastic material. The vacuum hoses used in the engine compartment are constructed
of Hytrel® . Because of the materials used, never pinch the vacuum hoses off during diagnosis
to locate a leak. A wood golf tee can be used as a plug when it is necessary to plug one end of
a vacuum hose for leak test purposes.
3. If the inspection reveals obvious concerns that can be readily identified, repair as required.
4. If the concern remains after the inspection, connect the scan tool to the data link connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the scan
tool menu. If the vehicle selection cannot be entered:
zcheck that the program card is correctly installed.
z check the connections to the vehicle.
z check the ignition switch position.
If the scan tool still does not allow the vehicle selection to be entered, refer to the scan tool manual. 5. Carry out the DATA LINK DIAGNOSTIC TEST using the scan tool. If the scan tool responds with:
zCKT 914, CKT 915 or CKT 70 = ALL MODULE NO RESPONSE/NOT EQUIPPED, go to
Communication System Diagnostics in Section 418 - 00 to diagnose network concern.
z If the powertrain control module (PCM) is not listed for a communication concern, turn
the A/C function selector switch to OFF and execute self- test diagnostics for the PCM.
6. If any PCM DTCs are retrieved, and are related to the concern, go to the Powertrain Control Module Diagnostic Trouble Code (DTC) Index to continue diagnostics.
7. If no DTCs related to the concern are retrieved, go to the Symptom Chart to continue diagnostics.
Symptom Chart Visual Inspection Chart Mechanical Electrical
z
Loose, missing or damaged A/C compressor
drive belt.
z Loose or disconnected A/C clutch.
z Loose, misrouted or damaged vacuum lines. a
z Broken or leaking refrigerant lines.
z Broken or leaking vacuum control motor. z
Open fuses.
z Blower motor inoperative.
z A/C compressor inoperative.
z Circuitry open/shorted.
z Disconnected electrical
connectors.
Powertrain Control Module Diagnostic Trouble Code (DTC) Index DTC Description Action
P1460 WOT A/C cutout circuit
malfunction Refer to the Powertrain Control/Emissions Diagnosis
(PC/ED) manual.
P1464 A/C demand out of self-
test
range GO to DTC P1464. Klj . 5 ba
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