brake fluid FORD MUSTANG 2003 Repair Manual

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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z
On some vehicles, the power steering pump high pressure port is inaccessible and the
special tool should then be installed either at the steering gear or at a point in the high
pressure line between the power steering pump and the steering gear.
2. Place a dial thermometer in the power steering pump reservoir.
3. Check the power steering fluid level. If necessary, add power steering fluid. zUse Motorcraft MERCON® Multi-Purpose ATF XT -2-QDX or MERCON® equivalent.
4. Install a digital tachometer.
5. 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.
Start the engine. Place the transmission in neutral. Set the parking brake. Raise the power
steering fluid temperature to 74- 80°C (165-175°F) by rotating the steering wheel fully to the left
and right several times.
6. Set the engine speed to 1500 rpm. Record the flow rate and pressure readings. zIf the flow rate is below the flow rate specification, a new power steering pump may need
to be installed. Continue with the test procedure.
z If the pressure reading is above the maximum pressure specification, then check power
steering hoses for kinks and restrictions.
7. Partially close the gate valve to obtain 750 psi. Set the engine speed at idle. Record the flow rate.
zIf the flow is less than the specified flow rate, then install a new power steering pump. For
additional information, refer to Section 211 - 02 .
8. CAUTION: Do not allow the gate valve to remain closed for more than 5 seconds.
Completely close and partially open the gate valve 3 times. Record the pressure relief valve
actuation pressure reading. zIf the pressure does not meet the relief pressure specification, install a new power
steering pump. For additional information, refer to Section 211 - 02 .
9. Set engine speed to 1500 rpm. Record the flow rate. zIf the flow rate varies more than 3.785 liters/minute (1 gallon/minute) from the initial flow
rate reading, install a new power steering pump. For additional information, refer to
Section 211 - 02 .
10. 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.
Set the engine speed at idle. Turn (or have an assistant turn) the steering wheel to the left and
right stops. Record flow rate and pressure readings at the stops.
zThe pressure reading at both stops should be nearly the same as the maximum pump
relief pressure.
z The flow rate should drop below 1.9 liters/minute (0.5 gallons/minute).
z If the pressure does not reach the maximum pump relief pressure or the flow rate does
not drop below the specified value, excessive internal leakage is occurring. Install a new
steering gear as necessary. For additional information, refer to Section 211 - 02 . Klj . 9 ba
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Symptom Chart
Pinpoint Tests
PINPOINT TEST A: NO COMMUNICATION WITH THE GENERIC
ELECTRONIC MODULE Circuit Failure
B2488 RF Side Repeater Lamp Output
Circuit Failure GEM REFER to
Section 417 - 01 .
C1189 Brake Fluid Level Sensor Input
Short Circuit to Ground GEM REFER to
Section 413 - 01 .
C1223 Lamp Brake Warning Output
Circuit Failure GEM REFER to
Section 413 - 01 .
C1225 Lamp Brake Warning Output
Circuit Short to Battery GEM REFER to
Section 413 - 01 .
Symptom Chart Condition
Possible Sources Action
z No communication with
the generic electronic
module z
CJB Fuse 39
(5A).
z Circuitry.
z GEM. z
Go To Pinpoint Test A .
z The ignition switch is
inoperative z
BJB Fuse IGN
SW (40A).
z Ignition switch.
z Circuitry. z
Go To Pinpoint Test B .
z No power in ACC zIgnition switch.
z Circuitry. z
Go To Pinpoint Test C .
z No power in RUN zIgnition switch.
z Circuitry. z
Go To Pinpoint Test D .
z No power in START zIgnition switch.
z Circuitry. z
Go To Pinpoint Test E .
z The multifunction
switch/hazard switch
does not operate
correctly z
Multifunction
switch. z
Carry out the multifunction
switch component test.
REFER to Wiring Diagrams,
Cell 149, Component
Testing. Test Step Result / Action to Take
CAUTION: Use the correct probe adapter(s) when making measurements. Filaure to
use the correct probe adapter(s) may damage the connector. A1 CHECK THE GENERIC ELECTRONIC MODULE (GEM)
POWER SUPPLY z
Key in OFF position.
z Disconnect: Generic Electronic Module (GEM) C201a. Yes
GO to
A2 . Klj . 4 ba
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The TCC solenoid is used to control the apply and release of the TCC.
Shift Solenoid —
SSA, SSB
Two on/off shift solenoids provide gear selection of first through fourth gears by controlling the
pressure to the three shift valves. One unit containing the two shift solenoids is located in the main
control valve body. The shift solenoids are two- way, normally open style.
a When a manual pull- in occurs above a calibrated speed, the transmission will not downshift from the
higher gear until the vehicle speed drops below this calibrated speed.
EC = Electronically Controlled
HD = Hydraulically Disabled
Transmission Fluid Temperature (TFT) Sensor
The transmission fluid temperature (TFT) sensor is located on the lead frame assembly near the shift
solenoids on the main control valve body. It is a temperature- sensitive device called a thermistor. It
sends a voltage signal to the PCM. The voltage signal varies with transmission fluid temperature. The
PCM uses this signal to determine whether a cold start shift schedule is necessary. The shift schedule
is compensated when the transmission fluid temperature is cold. The PCM also inhibits (TCC)
operation at low transmission fluid temperatures and corrects electronic pressure control.
Vehicle Speed (VSS) Sensor
The source of vehicle speed (VSS) is model dependent. Possible sources of vehicle speed input are
anti- lock brake sensor (ABS), a gear- driven vehicle speed sensor (VSS), or an output shaft speed
sensor (OSS). The VSS signal is either an A/C signal whose frequency changes with speed, or an
SCP data message depending on the source. Some applications will have both. The vehicle speed
signal is an input to various vehicle subsystems such as the powertrain control module (PCM),
instrument cluster (speedometer and odometer), speed control system, etc. The vehicle speed source
must be operational to enter output state control (OSC) mode for diagnostics.
Regardless of the type of vehicle speed system, the PCM always uses the OSS for transmission and Solenoid Operation Chart Selector Lever Position PCM Commanded Gear Solenoids
SSA SSB TCC
P/R/N 1 ON OFF HD
(D) 1 ON OFF HD
(D) 2 OFF OFF EC
(D) 3 OFF ON EC
(D) 4 ON ON EC
w/OD OFF
1 1 ON OFF HD
2 2 OFF OFF EC
3 3 OFF ON EC
Manual 2 2 OFF OFF EC
Manual 1 1 ON OFF HD
1
a 2 OFF OFF EC Klj . 3 ba
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CAUTION: The vehicle should not be driven if the fluid level indicator shows the fluid
below the DO NOT DRIVE mark or internal failure could result.
NOTE: If the vehicle has been operated for an extended period, at high highway speeds, in city traffic,
during hot weather, or while pulling a trailer, the fluid needs to cool down to obtain an accurate
reading.
NOTE: The fluid level reading on the indicator will differ from operating and ambient temperatures. The
correct reading should be within the normal operating temperature range.
Under normal circumstances the fluid level should be checked during normal maintenance. If the
transmission starts to slip, shifts slowly, or shows signs of fluid leaking, the fluid level should be
checked.
1. With the transmission in P (PARK), the engine at idle, foot pressed on the brake, move the range selector lever through each gear and allow engagement of each gear. Place the
transmission range selector lever in the P position.
2. Wipe the fluid level indicator cap and remove the indicator.
3. Wipe the indicator with a clean cloth.
4. Install the indicator back in the filler tube until it is fully seated, then remove the indicator. The fluid level should be within the normal operating temperature range.
High Fluid Level
A fluid level that is too high may cause the fluid to become aerated due to the churning action of the
rotating internal parts. This will cause erratic control pressure, foaming, loss of fluid from the vent tube,
and possible transmission failure. If an overfill reading is indicated, drain and refill the transmission.
Low Fluid Level
A low fluid level could result in poor transmission engagement, slipping, or failure. This could also
indicate a leak in one of the transmission seals or gaskets. Adding Fluid Item Description
1 Fluid level at room temperature 10°-
35°C (50°-95°F) 2 Fluid level at operating temperature 66°-
77°C (150°-170°F) 3 Do not drive mark Klj . 2 ba
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DIAGNOSIS AND TESTING
Transmission Drive Cycle Test
NOTE:
Always drive the vehicle in a safe manner according to driving conditions and obey all traffic
laws.
NOTE: The Transmission Drive Cycle Test must be followed exactly. Malfunctions must occur four
times consecutively for shift error DTC code to be set, and five times consecutively for continuous TCC
code to set.
NOTE: When carrying out the Transmission Drive Cycle Test, refer to the Solenoid Application Chart
for correct solenoid operation.
After carrying out the Quick Test, use the Transmission Drive Cycle Test for checking continuous
codes.
1. Record and then erase Quick Test codes.
2. Warm engine to normal operating temperature.
3. Make sure transmission fluid level is correct.
4. With transmission in OVERDRIVE, moderately accelerate from stop to 80 km/h (50 mph). This allows the transmission to shift into fourth gear. Hold speed and throttle open steady for a
minimum of 15 seconds.
5. With transmission in fourth gear and maintaining steady speed and throttle opening, lightly apply and release brake to operate stoplamps. Then hold speed and throttle steady for a
minimum of five seconds.
6. Brake to a stop and remain stopped for a minimum of 20 seconds.
7. Repeat steps 4 through 6 at least five times.
8. Carry out Quick Test and record continuous DTCs. zIf the DTCs are still present, refer to the Diagnostic Trouble Code Chart. Repair all non
transmission DTCs first as they can directly affect the operation of the transmission.
Repeat the Quick Test and the Road Test to verify the correction. Erase the DTCs, carry
out the Drive Cycle Test and repeat the Quick Test after completing repair on the DTC.
z If the continuous test passes and a concern is still present, refer to Diagnosis By Symptom in this section, OASIS messages, and TSBs for concerns.
After On- Board Diagnostic
NOTE: The vehicle wiring harness, PCM and non- transmission sensors may affect transmission
operations. Repair these concerns first.
After the on- board diagnostic procedures are completed, repair all DTCs.
Begin with non- transmission related DTCs, then repair any transmission related DTCs. Use the
diagnostic trouble code chart for information on condition and symptoms. This chart will be helpful in
referring to the correct manual(s) and aids in diagnosing internal transmission concerns and external
non- transmission inputs. The pinpoint tests are used in diagnosing transmission electrical concerns.
Make sure that the vehicle wiring harness and the PCM are diagnosed as well. The Powertrain SECTION 307-
01: Automatic Transaxle/Transmission 2003 Mustang Workshop Manual Klj . 1 ba
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P0713 TFT, wiring,
PCM -40°C (-
40°F)
indicated TFT
sensor circuit
open Voltage drop
across TFT sensor
exceeds scale set
for temperature -
40°C (-
40°F). Firm shift feel. Go To Pinpoint
Test B .
P1710 TFT TFT sensor in
range
malfunction PCM detected
TFT not changing. Firm shift, TCIL
flashing, increase in
EPC. Go To Pinpoint
Test B .
P1711 TFT TFT out of on-
board
diagnostic
range Transmission not
at operating
temperature
during on-
board
diagnostic. Warm vehicle to
normal operating
temperature. Go To Pinpoint
Test B .
P1713 TFT wiring
PCM TFT
continually
reading cold TFT sensor in
range low failure. Firm shift feel.
Substitute ECT for
TFT Go To Pinpoint
Test B .
P1718 TFT, wiring,
PCM TFT
continually
reading hot TFT sensor in
range high failure. Firm shift feel.
Substitute ECT for
TFT Go To Pinpoint
Test B .
P1783 TFT Transmission
over
temperature
condition
indicated Transmission fluid
temperature
exceeded 127°C
(270°F). Increase in EPC
pressure. Go To Pinpoint
Test B .
P0720 OSS Insufficient
input from
output shaft
speed sensor PCM detected a
loss of OSS signal
during operation. Harsh shifts,
abnormal shift
schedule, no torque
converter clutch
activation. Go To Pinpoint
Test E .
P0721 OSS OSS sensor
signal noisy PCM has detected
an erratic OSS
signal. Harsh shifts,
abnormal shift
schedule, no torque
converter clutch
engagement. Go To Pinpoint
Test E .
P0722 OSS wiring Insufficient
input from
OSS PCM has detected
a loss of OSS
signal. Harsh shifts,
abnormal shift
schedule, no torque
converter clutch
engagement. Go To Pinpoint
Test E .
P0741
** TCC,
internal
components TCC slippage
detected The PCM picked
up an excessive
amount of
slippage during
normal vehicle
operation. TCC
slippage/erratic or
no torque converter
clutch operation.
Flashing
Transmission
Control Indicator
Lamp (TCIL). GO to
Diagnosis By Symptom .
P0743
* TCC, wiring,
PCM TCC solenoid
circuit failure
during on-
board
diagnostic TCC solenoid
circuit fails to
provide voltage
drop across
solenoid. Circuit
open or shorted or
PCM driver failure
during on-
board
diagnostic. Short circuit: engine
stalls in second
(OD, 2 range) at
low idle speeds with
brake applied.
Open circuit: torque
converter clutch
never engages. Go To Pinpoint
Test A .
P1746 EPC, wiring, Shorted PCM Voltage through Open circuit causes Go To Pinpoint Klj . 3 ba
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Stall Speed Test
WARNING: Apply the parking brake firmly while carrying out each stall test.
CAUTION: Carry out line pressure test prior to carrying out stall test. If the line pressure is
low at stall, do not carry out stall test or further transmission damage will occur.
The stall speed test checks:
zthe torque converter clutch operation and installation.
z the holding ability of the forward clutch.
z the reverse clutch (the low- reverse bands).
z the planetary one- way clutch.
z the engine driveability.
Conduct this test with the engine coolant and transmission fluid at correct levels and at normal
operating temperature.
Apply the parking brake firmly for each stall speed test. 1. Find the specified stall rpm for the vehicle; see the stall speed diagnosis chart. Use a grease pencil to mark the rpm on the dial of a tachometer.
2. Connect a tachometer to the engine.
3. NOTE: If the rpm recorded by the tachometer exceeds the maximum limits, release the
accelerator pedal immediately because clutch or band slippage is indicated.
In each of the following ranges (D), 2, 1, R, press the accelerator pedal to the floor and hold it ·
Reverse Clutch Low In Neutral Only ·
Valve Body Low In Overdrive Only ·
Forward Clutch ·
Valve Body Low In 1st Position Only ·
Forward Clutch ·
Valve Body ·
Low/Reverse Servo Low In 2nd Only ·
Intermediate Clutch ·
Valve Bodies ·
Forward Clutch Stall Speed
Application Min. Max.
3.8L engine 2,240 2,619
4.6L 2V engine 2,339 2,738
4.6L 4V MACH 1 engine 2,375 2,767 Klj . 4 ba
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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. Park Mechanism
·
Output shaft ring, parking brake pawl,
parking pawl return spring, park rod
guide cup, parking pawl shaft,
parking pawl actuating rod, manual
lever detent spring damaged or
assembled incorrectly ·
Inspect for damage or incorrect assembly and repair as
required.
Other Concerns: Overheating Possible Component Reference/Action
257 —
ELECTRICAL ROUTINE Refer to Routine 240/340, Torque Converter Operation Concern: No Apply
357 —
HYDRAULIC/MECHANICAL ROUTINE Fluid
·
Incorrect level ·
Adjust fluid to correct level. ·
Condition ·
Inspect condition of fluid. Other
·
Damaged, blocked or reversed cooler lines or
restriction in the transmission oil cooler ·
Inspect for damage and correct
installation. Repair as required. Vehicle Concerns Causing Engine Overheating
·
Refer to the appropriate engine
cooling section. Main Controls
·
Drain back valve, torque clutch control valve, converter
limit valve stuck, damaged or assembled incorrectly ·
Inspect for damage and repair as
required. Torque Converter Clutch
·
No apply ·
Refer to Routine 240/340. Klj . 30 ba
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SPECIFICATIONS
SECTION 308-
02: Clutch Controls 2003 Mustang Workshop Manual General Specifications
Item Specification
Clutch System
System adjustment Self adjusting
Fluid and Lubricant
Super Premium SAE 10W-30
XO- 10W-30- BSP WSS-
M2C153- G
Torque Specifications Description Nm lb-
ft lb-
in Brake booster nuts 25 18 —
Brake pedal support bracket to cowl bolt 25 18 —
Clutch pedal retaining nut 40 30 —
Clutch release lever cable bracket screw (3.8L) 10 — 89
Clutch release lever cable to bulkhead screws 4 — 35
Clutch release lever cable to crossmember retaining screw 8 — 71
Clutch release lever cable to master cylinder retaining screw (4.6L) 8 — 71
Instrument panel reinforcement screws 9 — 80
Instrument panel steering column cover screws 9 — 80 Klj . 1 ba
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