steering FORD MUSTANG 2003 Repair Manual

to
Section 204 - 00 .
z Incorrect tire rotation
intervals. z
ADVISE customer of
condition. ROTATE
tires.
z Tires show
excess wear in
center of tread z
Tires overinflated. zADJUST air pressure.
z Other excessive
tire wear
problems z
Incorrect tire rotation
intervals. z
ADVISE customer of
condition. ROTATE
tires.
z Incorrect tire pressure. zADJUST pressure.
z Loose or leaking shock
absorbers. z
TIGHTEN or INSTALL
new shock absorbers
as necessary.
z Incorrect wheel alignment. zSET alignment to
specification. REFER
to Section 204 - 00 .
z Loose, worn or damaged
suspension components. z
REFER to Section 204 - 00 .
z Wheel and tire assembly
out of balance. z
BALANCE wheel and
tire assembly.
z Excessive lateral or radial
runout of wheel. z
REFER to Section 100 - 04 .
z Wobble or
shimmy z
Damaged wheel bearings. zREFER to Section 204 - 00 .
z Loose or damaged
suspension components. z
REFER to Section 204 - 00 .
z Bent wheel. zINSTALL a new wheel
as necessary.
z Damaged tire. zINSTALL a new tire as
necessary.
z Loose wheel nuts. zTIGHTEN to
specification.
z High- speed
shake z
Wheel hub face/pilot/bolt
circle runout.
z Tires/wheels.
z Wheel bearings.
z Suspension/steering
linkage.
z Engine.
z Transmission.
z Brake discs/imbalance. z
REFER to Section 100 - 04 .
z Vehicle vibration zDriveline — engine.
z Tires. z
REFER to Section 100 - 04 . Klj . 3 ba
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REMOVAL AND INSTALLATION
Axle Housing
Removal
1. CAUTION: The vehicle must be on level ground and at curb height.
Mark the rear shock absorbers relative to their protective sleeve. zDuring installation, raise the suspension to this reference mark before tightening the
suspension component fasteners.
SECTION 205-
02C: Rear Drive Axle/Differential — Ford 8.8-Inch IRS 2003 Mustang Workshop Manual Special Tool(s)
Plug Set, Differential
205-
294 (T89P-4850- B) Protector, Differential Seal
(Pair)
205-
461 Remover, Halfshaft
205-
475 Remover, Steering Arm
211-
003 (T64P-3590- F) Klj . 1 ba
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REMOVAL AND INSTALLATION
Halfshaft
Removal
NOTE:
This procedure applies to both the LH and RH halfshafts.
1. CAUTION: The vehicle must be on level ground and at curb height.
Mark the rear shock absorber relative to the protective sleeve. zDuring installation, raise the suspension to this reference mark before tightening the
suspension component fasteners.
SECTION 205-
05: Rear Drive Halfshafts 2003 Mustang Workshop Manual Special Tool(s)
Differential Plug
205-
294 (T89P-4850- B) Differential Seal Protector
205-
461 Front Hub Remover
205-
D070 (D93P-1175- B) or
Equivalent Halfshaft Removal Tool
205-
475 Steering Arm Remover
211-
003 (T64P-3590- F) Klj . 1 ba
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For low or spongy brake pedal concerns:
zcheck and, if necessary, refill the brake master cylinder reservoir.
z bleed the brake system and retest the brake pedal feel.
z if the brake pedal is still low or feels spongy, check the brake pedal mounting for looseness and
correct installation. Check the power brake booster and the brake master cylinder for loose
mounting. Correct as necessary and retest the system for normal operation.
For a slow or incomplete brake pedal return concern:
zinspect for binding, damage, correct installation or interference at the brake pedal.
z check the power brake booster for binding, damage and correct installation.
Vibration When Brakes are Applied
For vibration concerns when brakes are applied, perform the following procedure.
Visually inspect: ztire condition and pressure.
z suspension bushings and ball joints.
Correct as necessary. 1. Verify and isolate the concern. Brake roughness can be felt in: zthe steering wheel.
z the seat.
z the brake pedal.
2. After verifying the concern, check for related concerns in the: zOn- Line Automotive Service Information System (OASIS).
z Technical Service Bulletins.
3. Check wheel bearing end- play and correct as necessary.
4. NOTE: Begin at the front of the vehicle unless the vibration has been isolated to the rear.
Remove the tire and wheel.
5. Remove the brake caliper.
6. 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. Do z
Power brake booster
z Brake pedal linkage
z Vacuum booster hose
z Tires
z Foreign material Klj . 3 ba
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Pinpoint Tests
PINPOINT TEST A: THE BRAKES PULL OR DRIFT booster hose as
necessary.
z Red Brake Warning
Indicator Inoperative z
Circuit.
z Bulb. z
REFER to Section 413 -
01 .
z Brake Noise zDisc brake
component. z
MACHINE or INSTALL a
new brake component as
necessary. REFER to
Section 206 - 03 or
Section 206 - 04 .
z Hydro-Boost, No
Power Assist z
Power steering
pump.
z Linkage.
z Power steering
fluid flow.
z Hydro-boost unit. z
Go To Pinpoint Test E .
z Hydro-Boost Erratic
Operation, Sticks,
Binds or Grabs z
Supply hose.
z Hydro-boost unit. z
Go To Pinpoint Test F .
z Hydro-Boost Brake
System Operation
Suspect z
Leakage.
z Hydro-boost unit. z
Go To Pinpoint Test G .
Test Step Result / Action to Take
A1 CHECK THE TIRES
NOTE:
Check tire pressure with the brakes off.
z Check tires for uneven and excessive wear and for correct
pressure.
z Are the tires OK? Yes
GO to
A2 .
No
CORRECT as necessary.
RETEST for normal
operation. A2 CHECK THE ALIGNMENT
z
Check the caster, camber and toe. Refer to Section 204 -
00 . Yes
GO to
A3 .
No
CORRECT alignment as
necessary. REFER to Section 204 - 00 . RETEST for correct
operation. Klj . 6 ba
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PINPOINT TEST D: EXCESSIVE/ERRATIC BRAKE PEDAL TRAVEL
PINPOINT TEST E: HYDRO-
BOOST, NO POWER ASSIST 4481 kPa (510-
650 psi)? INSTALL a new proportioning valve.
RETEST for normal operation.
Test Step Result / Action to Take
D1 CHECK FOR SPONGY PEDAL
z
Key in ON position.
z Operate the brake pedal and note pedal feel.
z Does the pedal feel spongy? Yes
BLEED the brake system. REFER to
Bleeding —
System in this section.
RETEST for normal operation.
No
GO to D2 .
D2 CHECK THE BRAKE PEDAL
z
Inspect the brake pedal and bracket for
binding, obstruction or damage.
z Is the brake pedal OK? Yes
GO to
D3 .
No
REPAIR or INSTALL a new brake pedal as
necessary. RETEST for normal operation. D3 CHECK THE BRAKE COMPONENTS
z
Inspect the calipers bolts, anchor plate bolts
and anti- rattle springs for binding, damage,
contamination and correct installation.
z Are the bolts and springs OK? Yes
GO to
D4 .
No
REPAIR or INSTALL new components as
necessary. RETEST for normal operation. D4 CHECK THE BOOSTER AND MASTER
CYLINDER z
Check the power brake booster and brake
master cylinder for correct installation and
correct push rod adjustment. Refer to
Section 206 - 06 and to Section 206 - 07 .
z Are the power brake booster and the
brake master cylinder OK? Yes
INSPECT the front wheel bearings for
wear, damage and correct installation and
the rear axle end play. CORRECT as
necessary. RETEST for normal operation.
No
CORRECT as necessary. RETEST for
normal operation.
Test Step Result / Action to Take
E1 CHECK FLUID LEVEL IN POWER STEERING
PUMP z
Check fluid level in power steering pump.
z Is level within specification? Yes
GO to
E2 .
No
CHECK for leakage of power steering
fluid. ADD fluid as necessary. E2 CHECK ACCESSORY DRIVE BELT Klj . 10 ba
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PINPOINT TEST F: HYDRO-
BOOST ERRATIC OPERATION, STICKS,
BINDS OR GRABS z
Check accessory drive belt tension and
condition. Refer to Section 303 - 05 .
z Is the accessory drive belt OK? Yes
GO to
E3 .
No
INSTALL a new accessory drive belt.
REFER to Section 303 - 05 .
E3 CHECK POWER STEERING HOSES
z
Check power steering pressure hoses, power
steering gear pressure hoses and power
steering return hose for cracks or leaks.
z Do power steering pressure hose, power
steering gear hose and power steering
return hose check OK? Yes
GO to
E4 .
No
INSTALL new hoses as necessary.
REFER to Section 211 - 00 .
E4 CHECK BRAKE PEDAL LINKAGE
z
Check brake pedal linkage for binding or
sticking operation.
z Does pedal linkage check OK? Yes
GO to
E5 .
No
INSTALL new pedal linkage as necessary.
REFER to Section 206 - 06 .
E5 CHECK POWER STEERING PUMP SPEED
z
Check engine idle speed against
specifications.
z Is engine idle speed OK? Yes
GO to
E6 .
No
SET engine idle speed to specification.
REFER to Powertrain Control/Emissions
Diagnosis (PC/ED) manual. E6 CHECK FOR PLUGGED RETURN HOSE
z
NOTE: The return hose from the oil cooler to
the power steering reservoir has an in- line
filter in the hose.
z Disconnect power steering return hose from
power steering fluid cooler and power
steering pump reservoir.
z Pass air through hose from the oil cooler end.
z Is hose plugged? Yes
INSTALL a new power steering return
hose.
No
GO to
E7 .
E7 CHECK POWER STEERING PUMP FLOW
AND RELIEF z
Test power steering pump for correct flow
and relief pressure. Refer to Section 211 - 00 .
z Is power steering pump operating
correctly? Yes
INSTALL a new power brake hydro-
boost
unit. REFER to Section 206 - 07 .
No
INSTALL a new power steering pump.
REFER to Section 211 - 02 .
Test Step Result / Action to
Take F1 CHECK SUPPLY HOSE
z
Check for obstructions in power steering return hose and Yes Klj . 11 ba
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PINPOINT TEST G: HYDRO-
BOOST BRAKE SYSTEM OPERATION
SUSPECT connections between the power steering pump reservoir and
between the power steering pump reservoir and the hydro-
boost
power brake booster.
z Are there any obstructions? REMOVE
obstructions or
INSTALL a new
hose.
No
GO to
F2 .
F2 CHECK BOOSTER OPERATION
z
Have an assistant check the fluid in the power steering pump
reservoir while rapidly applying the brake pedal approximately one
inch.
z Does the fluid show any movement or spouting? Yes
System OK.
No
INSTALL a new
hydro-boost
assembly. Test Step Result / Action to Take
G1 CHECK BASIC OPERATION
z
Key in OFF position.
z Press and release brake pedal several times to deplete all
hydraulic pressure from the hydro- boost power brake
booster.
z Press and hold brake pedal with light pressure.
z Key in START position.
z Does the brake pedal fall slightly and hold, and is less
pressure now required to hold brake pedal at the new
position? Yes
Hydro-
boost is OK.
No
GO to G2 .
G2 CHECK FOR HYDRAULIC BRAKE LEAK
z
With engine running, press and release brake pedal several
times.
z Hold brake pedal down with medium pressure, 34- 47 Nm
(25- 35 lb- ft).
z Does brake pedal move toward floor? Yes
GO to
G3 .
No
GO to G4 .
G3 CHECK FOR LEAKS —
BRAKE FLUID LINES z
Check for leaks at brake lines, including brake master
cylinder and brake hose.
z Do components check OK? Yes
COMPLETE master cylinder
By-
Pass Condition Test in
this section.
No
INSTALL new hoses and
lines as necessary. G4 CHECK HYDRO-
BOOST CONNECTIONS z
Clean the hydro- boost power brake booster, power steering
pressure hose, power steering gear pressure hose and
power steering return hose and connection.
z Start engine and run at idle.
z Check hose connections for leakage.
z Do hose connections check OK? Yes
GO to
G5 .
No
REPAIR or INSTALL new
hose and connections as
necessary. G5 CHECK FOR HYDRO-
BOOST LEAK Klj . 12 ba
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Component Tests
Brake Booster
1. Check the hydraulic brake system for leaks or insufficient fluid.
2. With the transmission (7003) in NEUTRAL, stop the engine (6007) and apply the parking brake control (2780). Apply the brake pedal several times to exhaust all vacuum in the system.
3. Apply the brake pedal and hold it in the applied position. Start the engine. If the vacuum system is operating, the brake pedal will tend to move downward under constant foot pressure. If no
motion is felt, the power brake booster system is not functioning. Continue with the following
steps.
4. Remove the vacuum booster hose from the check valve connection. Manifold vacuum must be available at the check valve end of the vacuum booster hose with the engine at idle speed and
the transmission in NEUTRAL. If the manifold vacuum is available to the power brake booster,
connect the vacuum booster hose to the power brake booster check valve and repeat Steps 2
and 3.
5. If no downward movement of the brake pedal is felt, install a new power brake booster.
6. Operate the engine a minimum of 10 seconds at fast idle. Stop the engine, and let the vehicle stand for 10 minutes. Then apply the brake pedal with approximately 89 N (20 lb) of force. The
brake pedal feel should be the same as that noted with the engine operating. If the brake pedal
feels hard (no power assist), install a new power brake booster check valve and retest. If the
brake pedal feels spongy, bleed the hydraulic system to remove air. For additional information,
refer to Bleeding — System in this section. Check Valve z
Engine running at idle speed.
z CAUTION: Do not hold the brake pedal at 444 Nm
(100 lb) force for more than 5 seconds at a time.
z Apply brake pedal with approximately 444 Nm (100 lb)
force and hold.
z Check hydro-boost unit input seal, housing seal,
accumulator seal, piston seal and spool plug seal for
leakage.
z Is hydro- boost unit free of leaks? Yes
GO to
G6 .
No
INSTALL a new hydro- boost
unit. G6 CHECK RESERVE RETENTION
z
Engine running at idle speed.
z CAUTION: Do not hold the brake pedal at 444 Nm
(100 lb) force for more than 5 seconds at a time.
z Charge system to pressure by holding the steering wheel at
stop or by pressing the brake pedal with approximately 444
Nm (100 lb) force.
z Key in OFF position.
z Wait five seconds.
z Press brake pedal and observe if there is any power brake
reserve.
z Is there any power brake reserve? Yes
Hydro-
boost unit is OK.
No
INSTALL a new hydro- boost
unit. Klj . 13 ba
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7. Bleed each brake tube at the brake master cylinder as follows:
1. Have an assistant pump the brake pedal, and then hold firm pressure on the brake pedal.
2. Loosen the rear most brake tube fittings until a stream of brake fluid comes out. While the assistant maintains pressure on the brake pedal, tighten the brake tube fitting.
3. Repeat this operation until clear, bubble- free fluid comes out.
4. Refill the brake master cylinder reservoir as necessary. Repeat the bleeding operation at the front brake tube.
Master Cylinder Priming — 4.6L
1. CAUTION: Use only bleed screws on the engine side of the brake master cylinder
(2140). The hydro- boost bleed screw, located near the dash on the hydro- booster
casting, is for the booster cavity filled with power steering fluid, not brake fluid.
Connect a clear waste line to the bleed screw closet to the booster first and the other end in a
container partially filled with recommended brake fluid.
2. Open the bleeder screw, have an assistant push the brake pedal down slowly through full travel, close the bleeder screw, then return brake pedal slowly to full released position. Wait five
seconds, then repeat operation until air bubbles cease to appear.
3. Repeat Step 2 for bleeder screw farthest from hydro- booster. Klj . 3 ba
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