warning FORD MUSTANG 2003 Repair Manual

Inspection and Verification
1. Verify the customer concern by operating the system.
2. Visually inspect for obvious signs of mechanical and electrical damage.
3. 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 scan tool does not communicate with the vehicle: 1. Check that the program card is correctly installed.
2. Check the connections to the vehicle.
3. Check the ignition switch position.
4. If the scan tool still does not communicate with the vehicle, refer to the scan tool manual.
5. Carry out the DATA LINK DIAGNOSTIC TEST. If the scan tool responds with: 1. CKT914, CKT915 or CKT70 = ALL ECUS NO RESP/NOT EQUIP, refer to Section 418-00.
2. NO RESP/NOT EQUIP for the anti- lock brake control module, Go To Pinpoint Test A .
3. SYSTEM PASSED, retrieve and record the continuous diagnostic trouble codes (DTCs),
erase the continuous DTCs and carry out self- test diagnostics for the anti-lock brake
control module.
6. If the DTCs retrieved are related to the concern, go to the Anti- Lock Brake Control Module
Diagnostic Trouble Code (DTC) Index to continue diagnostics.
7. If no DTCs related to the concern are retrieved, GO to Symptom Chart to continue diagnostics.
Anti-Lock Brake Control Module Diagnostic Trouble Code (DTC) Index
NOTE: If a wheel speed signal fault or a pump motor fault is detected, the yellow ABS warning
indicator cannot be reset with the key OFF and key ON method. The vehicle must be driven over 12
km/h (8 mph) for the anti- lock brake control module to do a re- check of the system before the yellow
ABS warning indicator is turned OFF. Visual Inspection Chart Mechanical Electrical
z
Low brake fluid
z Anti- lock brake sensor
z Anti- lock brake sensor indicator
z Base brake system
z Wheel bearings z
Central junction box (CJB) Fuse:
„5 (15A)
„ 15 (10A)
„ 29 (15A)
„ 33 (15A)
„ 35 (15A)
z Battery junction box (BJB) Fuse:
„ABS 1 (50A)
„ ABS 2 (20A)
z Circuitry
z Damaged or corroded connectors
z ABS warning indicator
z Loose grounds Klj . 2 ba
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Pinpoint Tests
PINPOINT TEST A: NO COMMUNICATION WITH THE ANTI-
LOCK
BRAKE CONTROL MODULE test. Condition
Possible Sources Action
z No communication with the anti-
lock brake control module z
CJB Fuse 29
(15A).
z Circuitry.
z Anti- lock brake
control module. z
Go To Pinpoint Test A .
z Unable to enter self- test zAnti- lock brake
control module. z
Go To Pinpoint Test B .
z The yellow ABS warning indicator
does not self- check z
Circuitry.
z Anti- lock brake
control module.
z Instrument
cluster. z
Go To Pinpoint Test I .
z Spongy brake pedal with no
warning indicator z
Air in the brake
system.
z Base brake
system.
z Hydraulic control
unit (HCU). z
Go To Pinpoint Test J .
z REFER to
Section 206 -
00 .
z Poor vehicle tracking during anti-
lock function z
Air in the brake
system.
z Hydraulic control
unit (HCU).
z Base brake
system. z
Go To Pinpoint Test K .
z REFER to
Section 206 -
00 .
z The traction control is
inoperative— does not operate
correctly z
CJB 5 (15A).
z Circuitry.
z Traction control
switch.
z Instrument
cluster.
z Anti- lock brake
control module. z
Go To Pinpoint Test L .
z The traction control indicator is
inoperative— traction control
switch z
Circuitry.
z Traction control
switch.
z Instrument
cluster. z
Go To Pinpoint Test M .
Test Step Result / Action to
Take A1 CHECK CIRCUIT 601 (LB/PK) FOR AN OPEN
z
Key in OFF position.
z Disconnect: Anti- Lock Brake Control Module C141.
z Key in ON position.
z Measure the voltage between anti- lock brake control module C141
Pin 8, Circuit 601 (LB/PK), harness side and ground. Yes
GO to
A2 .
No
REPAIR the circuit. Klj . 6 ba
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PINPOINT TEST H: DTC C1233 (LF), C1234 (RF), C1235 (RR), C1236
(LR), ANTI-
LOCK BRAKE SENSOR INPUT SIGNAL MISSING
PINPOINT TEST I: THE YELLOW ABS WARNING INDICATOR DOES
NOT SELF- CHECK mode on the diagnostic tool:
CLEAR the DTCs.
z Key in OFF position.
z Key in ON position.
z Test drive the vehicle over 24
km/h (15 mph).
z Enter the following diagnostic
mode on the diagnostic tool:
Retrieve DTCs.
z Is DTC C1222 retrieved? INSTALL a new anti-
lock brake control module;
REFER to Module . REPEAT the self-
test.
No
If another DTC is retrieved, GO to the Anti- Lock Brake
Control Module Diagnostic Trouble Code (DTC) index.
If no DTCs are retrieved, system is OK. Test Step Result / Action to Take
H1 CHECK THE SUSPECT ANTI-
LOCK BRAKE
SENSOR z
Check the suspect anti- lock brake sensor
mounting.
z Check the suspect anti- lock brake sensor for
excessive dirt build up, obstructions, and
damage.
z Is the suspect anti- lock brake sensor and
mounting OK? Yes
GO to
H2 .
No
REPAIR as necessary. CLEAR the
DTCs. REPEAT the self- test. H2 CHECK THE SUSPECT ANTI-
LOCK BRAKE
SENSOR INDICATOR z
Check the suspect anti- lock brake sensor
indicator for corrosion, nicks, bridged teeth,
damaged teeth, correct mounting, and
alignment with the anti- lock brake sensor.
z Check the air gap and bearing end play.
z Is the suspect anti- lock brake sensor
indicator OK? Yes
GO to
H3 .
No
INSTALL a new anti- lock brake sensor
indicator; REFER to Sensor Indicator —
Front or
Sensor Indicator — Rear .
CLEAR the DTCs. REPEAT the self- test. H3 CHECK THE ANTI-
LOCK BRAKE SENSOR
OUTPUT z
Key in ON position.
z Enter the following diagnostic mode on the
diagnostic tool: CLEAR the DTCs.
z Key in OFF position.
z Key in ON position.
z Have an assistant monitor the anti- lock brake
control module PIDs LF_WSPD, RF_WSPD,
LR_WSPD, and RR_WSPD while driving at
various speeds.
z NOTE: the vehicle must be driven 16 km (10
miles) during this test step.
z Test drive the vehicle for 16 km (10 miles).
z Are the anti- lock brake control module PIDs
approximately the same at all times? Yes
INSTALL a new anti-
lock brake control
module; REFER to Module . REPEAT
the self- test.
No
INSTALL a new anti- lock brake sensor;
REFER to Sensor — Front or
Sensor —
Rear . CLEAR the DTCs. REPEAT the
self- test. Klj . 14 ba
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PINPOINT TEST J: SPONGY BRAKE PEDAL WITH NO WARNING
INDICATOR
PINPOINT TEST K: POOR VEHICLE TRACKING DURING ANTI-
LOCK
FUNCTION Test Step Result / Action to Take
I1 CHECK THE ABS WARNING INDICATOR CIRCUITRY
z
Key in OFF position.
z Disconnect: Anti- Lock Brake Control Module C141.
z Key in ON position.
z Depress and release the shorting bar connector
internal to the anti- lock brake control module C141,
harness side, while checking the yellow ABS warning
indicator in the instrument cluster.
z Does the yellow ABS indicator illuminate with the
shorting bar released and OFF with the shorting
bar depressed? Yes
INSTALL a new anti-
lock brake
control module; REFER to
Module . TEST the system for
normal operation.
No
REFER to Section 413 - 01 .
Test Step Result / Action to Take
J1 CHECK THE VEHICLE COMPONENTS
z
Check the brake pedal and power
booster/brake master cylinder for correct
attachment.
z Are the components OK? Yes
GO to
J2 .
No
REPAIR as necessary. TEST the system for
normal operation. J2 BLEED THE BRAKE SYSTEM
z
Bleed the brake system; REFER to Section 206 - 00 .
z Check for spongy brake pedal.
z Is the brake pedal spongy? Yes
INSTALL a new HCU; REFER to
Hydraulic Control Unit . TEST the system for normal
operation.
No
The brake system is OK. TEST the system
for normal operation. Test Step Result / Action to Take
K1 BLEED THE BRAKE SYSTEM
z
Bleed the brake system; REFER to Section 206 - 00 .
z Check for vehicle tracking poorly.
z Does the vehicle track poorly? Yes
GO to
K2 .
No
The brake system is OK. TEST the
system for normal operation. K2 CHECK THE LF ABS VALVE OPERATION
z
Lift the vehicle and rotate all the wheels to
make sure they rotate freely (the vehicle must
be in neutral).
z NOTE: Trigger must be depressed twice.
Each depress runs the pump motor for two
seconds. Yes
INSTALL a new HCU; REFER to
Hydraulic Control Unit
. TEST the system
for normal operation.
No Klj . 15 ba
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Component Tests
Steering Linkage
1. NOTE: Excessive vertical motion of the studs relative to the sockets may indicate excessive
wear.
With the parking brake applied, perform the following:
zHave an assistant rotate the steering wheel back and forth 360 degrees and watch for
relative motion of the studs in the tie- rod end ball sockets.
z Watch for loose steering gear mounting.
2. Another method is to raise the front wheels (1007) off the ground, grasp the wheel at the front and rear and watch for excessive play or binding in the joints while trying to steer the wheels.
3. Install new steering components as necessary. For additional information, refer to the appropriate Group 2 steering section.
Turning Effort Test
NOTE: Make sure that the front wheels are properly aligned and the tire pressure is correct before
checking the effort.
1. Park the vehicle on dry concrete and set the parking brake.
2. Insert a thermometer into the power steering pump reservoir.
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.
Idle the engine for two to three minutes. Turn the steering wheel from stop- to-stop several times
to warm the fluid to 50- 60°C (122-140°F).
4. With the engine running, attach special tool 211- 034 (T74P-3504-Y) to the rim of the steering
wheel.
5. Measure the pull required to turn the steering wheel one complete revolution in each direction. Refer to Steering Wheel Turning Effort under General Specifications in this section.
Pump Flow and Pressure Test WARNING: Do not touch the flowmeter during the test procedure, or severe burns and
serious injury may occur.
1. CAUTION: Make sure that the connection point will not interfere with any of the
engine accessory drive components or drive belts.
Install special tool 211- F001 (014-00207) at the high pressure port of the power steering pump.
Make sure the power steering analyzer gate valve is fully open. Klj . 8 ba
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GENERAL PROCEDURES
System Flushing —
CII Power Steering Pump
WARNING: Do not mix oil types. Any mixture or any unapproved oil can lead to seal
deterioration and leaks. A leak can ultimately cause loss of fluid, which can result in a loss of
power steering assist.
1. Remove the fuel pump fuse from the battery junction box.
2. Disconnect the power steering return hose. Plug the reservoir.
3. Attach an extension hose between the power steering return hose and an empty container.
4. Raise the front wheels off the floor. For additional information, refer to Section 100 - 02 .
5. Check the fluid level. If necessary, fill the reservoir to the correct level. zUse Motorcraft MERCON® Multi-Purpose ATF XT -2-QDX or MERCON® equivalent.
6. CAUTION: Do not crank the engine for more than 15 seconds at a time. Allow the
starter to cool for 1 minute before cranking again. Premature starter failure can occur.
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.
Turn the steering wheel from stop- to-stop while cranking the engine until the fluid exiting the
power steering return hose is clear of all contamination and foreign material.
zAdd Motorcraft MERCON® Multi-Purpose ATF XT -2-QDX or MERCON® equivalent as
needed.
7. Lower the vehicle.
8. Disconnect the extension hose from the power steering return hose. Remove the plug. Attach the power steering return hose to the reservoir.
SECTION 211-
00: Steering System — General Information 2003 Mustang Workshop Manual Klj . 1 ba
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GENERAL PROCEDURES
System Flushing —
CIII Power Steering Pump
WARNING: Do not mix oil types. Any mixture or any unapproved oil can lead to seal
deterioration and leaks. A leak can ultimately cause loss of fluid, which can result in a loss of
power steering assist.
1. Remove the fuel pump fuse from the battery junction box.
2. Disconnect the power steering return hose. Plug the reservoir.
3. Attach an extension hose between the power steering return hose and an empty container.
4. Raise the front wheels off the floor. For additional information, refer to Section 100 - 02 .
5. Check the fluid level. If necessary, fill the reservoir to the correct level. zUse Motorcraft MERCON® Multi-Purpose ATF XT -2-QDX or MERCON® equivalent.
6. CAUTION: Do not crank the engine for more than 15 seconds at a time. Allow the
starter to cool for 1 minute before cranking again. Premature starter failure can occur.
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 could occur.
Turn the steering wheel from stop- to-stop while cranking the engine until the fluid exiting the
power steering return hose is clear of all contamination and foreign material.
zAdd Motorcraft MERCON® Multi-Purpose ATF XT -2-QDX or MERCON® equivalent as
needed.
7. Lower the vehicle.
8. Disconnect the extension hose from the power steering return hose. Remove the plug. Attach the power steering return hose to the reservoir.
SECTION 211-
00: Steering System — General Information 2003 Mustang Workshop Manual Klj . 1 ba
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GENERAL PROCEDURES
Fill
1. WARNING: Do not mix oil types, any mixture or any unapproved oil can lead to seal
deterioration and leaks. A leak can ultimately cause loss of fluid, which can result in a
loss of power steering assist.
Check the fluid level. If necessary, fill the reservoir to the correct level.
zUse Motorcraft MERCON® Multi-Purpose ATF XT -2-QDX or MERCON® equivalent.
2. Remove the fuel pump fuse from the battery junction box.
3. Raise the front wheels off the floor. For additional information, refer to Section 100 - 02 .
4. CAUTION: Do not crank the engine for more than 15 seconds at a time. Allow the
starter to cool for 1 minute before cranking again. Premature starter failure can occur.
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.
Turn the steering wheel from stop- to-stop while cranking the engine.
5. Lower the vehicle.
6. CAUTION: Do not overfill the reservoir.
Check the fluid level. If necessary, fill the reservoir to the correct level. zUse Motorcraft MERCON® Multi-Purpose ATF XT -2-QDX or MERCON® equivalent.
7. Install the fuel pump fuse.
SECTION 211-
00: Steering System — General Information 2003 Mustang Workshop Manual Klj . 1 ba
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NOTE:
All fasteners are important because they can affect the performance of vital parts and systems.
Incorrect installation of the fasteners can result in major repair expenses. They must be installed new
with fasteners of the same part number if installation becomes necessary. Do not install a new part of
lesser quality or substitute a design. Torque values must be used as specified during assembly to
make sure these parts function correctly.
The body of the steering column (3C529) is made of magnesium die castings. The steering column is
attached to a support that is an integral part of the instrument panel. The lower attachments of the
steering column are through a bracket that bends during collapse. The upper attachments are through
plastic shear modules that separate from the main casting during collapse. A clip and washer are
attached to the shear modules to reduce steering column shake and to assist in installation of the
steering column. 45 N621906 Nut
46 N803942 Bolt
47 3A525 Intermediate shaft coupling
48 11A128 Ignition key warning switch terminal
49 N806583 Bearing housing retaining screw
50 N804865-
S58 Screw
51 14A06 Wire connector bracket
52 3E715 Lock lever lower actuator
53 3E691 Lock pawl
54 3F723 Actuator housing
55 3E745 Lock actuator cover
56 3F719 Ignition/shifter interlock cable
57 N808124-
58M Screw
58 3D655 Position spring
59 3D656 Tilt flange bumper
60 N806582 Tilt pivot screws
61 11582 Ignition switch lock cylinder
62 3E700 Lock housing bearing
63 3E717 Lock gear
64 3530 Upper shroud
65 3511 Lock cylinder housing
66 N805857 Lock actuator lever pin
67 3D681 Bearing retainer Klj . 3 ba
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GENERAL PROCEDURES
Supplemental Restraint System (SRS) Deactivation and
Reactivation
Deactivation
WARNING: Always wear safety glasses when repairing an air bag supplemental restraint
system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury
in the event of an accidental deployment.
WARNING: After deployment, the air bag surface can contain deposits of sodium
hydroxide, a product of the gas generant combustion that is irritating to the skin. Wash your
hands with soap and water afterwards.
WARNING: Never probe the connectors on the air bag module. Doing so can result in air
bag deployment, which can result in personal injury.
WARNING: Air bag modules with discolored or damaged trim covers must be installed
new, not repainted.
WARNING: The restraint system diagnostic tool is for restraint system service only.
Remove from vehicle prior to road use. Failure to remove could result in injury and possible
violation of vehicle safety standards.
1. WARNING: To avoid accidental deployment and possible personal injury, the
backup power supply must be depleted before repairing or replacing any front or side air
bag supplemental restraint system (SRS) components and before servicing, replacing,
adjusting or striking components near the front or side air bag sensors, such as doors,
instrument panel, console, door latches, strikers, seats and hood latches.
Please refer to the appropriate vehicle shop manual to determine location of the front air
bag sensors.
The side air bag sensors are located at or near the base of the B- pillar.
To deplete the backup power supply energy, disconnect the battery ground cable and
wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). SECTION 211-
04: Steering Column 2003 Mustang Workshop Manual Special Tool(s)
Diagnostic Tool, Restraint
System (2 Req'd)
418-
F088 (105- R0012) Klj . 1 ba
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