ABS FORD MUSTANG 2003 Workshop Manual

The brake type codes are:
z2 — Four- wheel disc with anti- lock brake system (ABS)
z 3 — Traction control
z 5 — Four- wheel disc with anti- lock brake system (ABS) and traction control
Interior Trim Codes Klj . 8 ba
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The axle ratio is:
zX5 — 3.8L, non- ABS, 3.27 ratio
z Z5 — 3.8L, ABS, 3.27 ratio
z ME — 4.6L, Mach One, 3.55 ratio
z LE — 4.6L, VX, 3.27 ratio
z TE — 3.55 locker (with independent rear suspension) — Cobra
Transmission Codes
The transmission code is:
z5— Five- speed manual (T5OD/TR3150) — base
z B—Six- speed manual (T56), Cobra
z K—Five-speed manual (TR3650), GT
z U— Four- speed automatic (AODE/4R70W) Spring Codes Klj . 11 ba
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z
Engine oil fluid level.
z Windshield washer solvent fluid level.
z Check and drain fuel/water separator.
Six Month Checks
Check each of the following items at least every six months:
zLap/shoulder belts and seat latches for wear and function.
z Spare tire air pressure.
z Power steering fluid level.
z Parking brake for correct operation.
z Safety warning lamps (brake, ABS, air bag, safety belt) for correct operation.
z Coolant system fluid level and correct strength.
z Battery connections. Clean if necessary.
z Clutch fluid level, if equipped.
z Windshield washer spray, wiper operation, clean all wiper blades.
z Lubricate all hinges, latches and outside locks. Inspect for correct operation.
z Lubricate door rubber weatherstrips. Inspect for excessive wear.
z Clean body and door drain holes. Inspect for clogs and obstructions.
Special Checks (Mustang Only)
Carry out the following check every 8,000 km (5,000 miles):
zAdjust clutch by lifting pedal (manual transmission Mustang only, as described in owner guide).
Normal Schedule
The following checks or procedures should be carried out for all cars, minivans, light trucks, sport
utilities, vans, 4x4s, natural gas and propane vehicles.
8,000 Km (5,000 Miles) zChange engine oil and install a new oil filter.
z Rotate tires and inspect for wear.
16,000 Km (10,000 Miles)
zChange engine oil and install a new oil filter.
z Inspect tires for wear. Rotation recommended for optimal tire life.
24,000 Km (15,000 Miles)
zChange engine oil and install a new oil filter. Klj . 3 ba
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Acceleration-
Light
An increase in speed at less than half throttle.
Acceleration- Medium
An increase in speed at half to nearly full throttle, such as 0- 97 km/h (0-60 mph) in approximately 30
seconds.
Acceleration- Heavy
An increase in speed at one- half to full throttle, such as 0- 97 km/h (0-60 mph) in approximately 20
seconds.
Ambient Temperature
The surrounding or prevailing temperature.
Amplitude
The quantity or amount of energy produced by a vibrating component (G force). An extreme vibration
has a high amplitude. A mild vibration has a low amplitude.
Backlash
Gear teeth clearance.
Boom
Low frequency or low pitched noise often accompanied by a vibration. Also refer to Drumming.
Bound Up
An overstressed isolation (rubber) mount that transmits vibration/noise instead of absorbing it.
Brakes Applied
When the service brakes are applied with enough force to hold the vehicle against movement with the
transmission in gear.
Buffet/Buffeting
Strong noise fluctuations (less than 1000 Hz) caused by gusting winds. An example would be wind
gusts against the side glass.
Buzz
A low- pitched sound like (200- 5000 Hz) that from a bee. Often a metallic or hard plastic humming
sound. Also describes a high frequency (200- 800 Hz) vibration. Vibration feels similar to an electric
razor. Camber Klj . 2 ba
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Clonk
A hydraulic knocking sound. Sound occurs with air pockets in a hydraulic system. Also described as
hammering.
Clunk/Driveline Clunk
A heavy or dull, short-
duration, low-frequency sound. Occurs mostly on a vehicle that is accelerating or
decelerating abruptly. Also described as a thunk.
Coast/Deceleration
Releasing the accelerator pedal at cruise, allowing the engine to reduce vehicle speed without
applying the brakes.
Coast/Neutral Coast
Placing the transmission range selector in NEUTRAL (N) or depressing the clutch pedal while at
cruise.
Constant Velocity (CV) Joint
A joint used to absorb vibrations caused by driving power being transmitted at an angle.
Controlled Rear Suspension Height
The height at which a designated vehicle element must be when driveline angle measurements are
made.
Coupling Shaft
The shaft between the transfer case and the front drive axle or, in a two- piece rear driveshaft, the front
section.
CPS
Cycles per second. Same as hertz (Hz).
Cracks
A mid- frequency sound, related to squeak. Sound varies with temperature conditions.
Creak
A metallic squeak.
Cruise
Constant speed on level ground; neither accelerating nor decelerating.
Cycle
The process of a vibrating component going through a complete range of motion and returning to the Klj . 4 ba
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starting point.
Decibel
A unit of measurement, referring to sound pressure level, abbreviated dB.
Drive Engine Run-
Up (DERU) Test
The operation of the engine through the normal rpm range with the vehicle standing still, the brakes
applied and the transmission engaged. This test is used for noise and vibration checks.
Driveline Angles
The differences of alignment between the transmission output shaft, the driveshaft, and the rear axle
pinion centerline.
Driveshaft
The shaft that transmits power to the rear axle input shaft (pinion shaft). In a two- piece driveshaft, it is
the rearmost shaft.
Drivetrain
All power transmitting components from the engine to the wheels; includes the clutch or torque
converter, the transmission, the transfer case, the driveshaft, and the front or rear drive axle.
Drivetrain Damper
A weight attached to the engine, the transmission, the transfer case, or the axle. It is tuned by weight
and placement to absorb vibration.
Drone
A low frequency (100- 200 Hz) steady sound, like a freezer compressor. Also described as a moan.
Drumming
A cycling, low-frequency (20- 100 Hz), rhythmic noise often accompanied by a sensation of pressure on
the ear drums. Also described as a low rumble, boom, or rolling thunder. Dynamic Balance Klj . 5 ba
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NOTE:
A serpentine drive belt decreases the usefulness of this test. In these cases, use a
vibration analyzer, such as the VA, to pinpoint accessory vibrations. An electronic listening
device, such as an EngineEAR, will also help to identify noises from specific accessories.
Remove the accessory drive belts.
z Increase the engine rpm to where the concern occurs.
z If the vibration/noise is duplicated when carrying out this test, the belts and accessories are not
sources.
z If the vibration/noise was not duplicated when carrying out this test, install each accessory belt,
one at a time, to locate the source.
Vehicle Cold Soak Procedure
To carry out this procedure, proceed as follows:
zTest preparations include matching customer conditions (if known). If not known, document the
test conditions: gear selection and engine rpm. Monitor the vibration/noise duration with a watch
for up to three minutes.
z Park the vehicle where testing will occur. The vehicle must remain at or below the concern
temperature (if known) for 6- 8 hours.
z Before starting the engine, conduct a visual inspection under the hood.
z Turn the key on, but do not start the engine. Listen for the fuel pump, anti- lock brake system
(ABS) and air suspension system noises.
z Start the engine.
z CAUTION: Never probe moving parts.
Isolate the vibration/noise by carefully listening. Move around the vehicle while listening to find
the general location of the vibration/noise. Then, search for a more precise location by using a
stethoscope or EngineEAR.
z GO to Symptom Chart — Idle Noise/Vibration to assist with the diagnosis.
6: Check OASIS/TSBs/Repair History
After verifying the customer concern, check for OASIS reports, TSBs and the vehicle repair history for
related concerns. If information relating to a diagnosis/repair is found, carry out the procedure(s)
specified in that information.
If no information is available from these sources, carry out the vehicle preliminary inspection to
eliminate any obvious faults.
7: Diagnostic Procedure
Qualifying the concern by the particular sensation present can help narrow down the concern. Always
use the "symptom" to "system" to "component" to "cause" diagnosis technique. This diagnostic method
divides the problem into related areas to correct the customer concern.
zVerify the "symptom".
z Determine which "system(s)" can cause the "symptom".
„If a vibration concern is vehicle speed related, the tire and wheel rpm/frequency or
driveshaft frequency should be calculated.
„ If a vibration concern is engine speed related, the engine, engine accessory or engine
firing frequencies should be calculated. Klj . 9 ba
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„
Loudness proportional to vehicle speed. Low- frequency noise at high
speeds, noise and loudness increase with speed. GO to Symptom Chart —
Driveline Noise/Vibration .
„ A low- pitched noise (drumming). GO to Symptom Chart — Engine
Noise/Vibration .
„ Vibration occurs at a particular speed (mph) regardless of acceleration or
deceleration. GO to Symptom Chart — Tire Noise/Vibration .
„ Noise varies with wind/vehicle speed and direction. GO to Symptom Chart — Air Leak and Wind Noise .
„ Related to engine speed.
„Noise varies with engine rpm. GO to Symptom Chart — Engine
Noise/Vibration .
„ Vibration occurs at a particular speed (mph) regardless of engine speed
(rpm).
2. Acceleration
„Wide open throttle (WOT)
„Engine induced contact between components. Inspect and repair as
necessary.
„ Noise is continuous throughout WOT. Exhaust system or engine ground
out. GO to Symptom Chart — Engine Noise/Vibration .
„ Light/moderate acceleration
„Tip- in moan. Engine/exhaust noise. GO to Symptom Chart — Engine
Noise/Vibration .
„ Knock-type noise. GO to Symptom Chart — Engine Noise/Vibration .
„ Driveline shudder. GO to Symptom Chart — Driveline Noise/Vibration .
„ Engine vibration. GO to Symptom Chart — Engine Noise/Vibration .
3. Turning noise. GO to Symptom Chart — Steering Noise/Vibration .
4. Braking
„Clicking sound is signaling ABS is active. Acceptable ABS sound.
„ A continuous grinding/squeal. GO to Symptom Chart — Brake Noise/Vibration .
„ Brake vibration/shudder. GO to Symptom Chart — Brake Noise/Vibration .
5. Clutching
„A noise occurring during clutch operation. GO to Symptom Chart — Transmission
(Manual) and Transfer Case Noise/Vibration .
„ Vibration. GO to Symptom Chart — Transmission (Manual) and Transfer Case
Noise/Vibration .
6. Shifting
„Noise or vibration condition related to the transmission (automatic). GO to
Symptom Chart — Transmission (Automatic) Noise/Vibration .
„ Noise or vibration related to the transmission (manual). GO to Symptom Chart —
Transmission (Manual) and Transfer Case Noise/Vibration .
7. Engaged in four- wheel drive. GO to Symptom Chart — Transmission (Manual) and
Transfer Case Noise/Vibration .
8. Cruising speeds
„Accelerator pedal vibration. GO to Symptom Chart — Engine Noise/Vibration .
„ Driveline vibration. GO to Symptom Chart — Driveline Noise/Vibration .
„ A shimmy or shake. GO to Symptom Chart — Tire Noise/Vibration .
9. Driving at low/medium speeds Klj . 11 ba
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with header.
z Convertible top
flapping with the
top up z
Vinyl top contacting
interior headliner. z
Working from front to
back, INSTALL a 6.35 mm
(0.25 in) foam sheet
between the headliner
and the vinyl top at the
suspected area. Allow a
clearance of 50 mm (2 in)
-75 mm (3 in) away from
the roof bows and the side
rails.
z Noise from roof
rack z
Roof rack rails or
crossbars loose. z
TIGHTEN the fasteners.
z Roof rack fasteners
missing. z
INSTALL the approved
fasteners.
z Roof rack crossbars
installed backward. z
REINSTALL the
crossbars.
z Roof rack rub strips
partially lifting from
roof. z
REAPPLY adhesive or
fasteners or INSTALL new
rub strips as necessary.
z Roof rack gaskets
loose or misaligned. z
REINSTALL the gasket.
z Wind noise from
bug
shield/exterior
windshield sun
visor z
Turbulence created by
location and shape. z
REMOVE per customer
direction if it is a dealer
installed option. Symptom Chart—
Brake Noise/Vibration Condition
Possible Sources Action
z Rattling noise zCaliper
mounting bolts
loose. z
CHECK the caliper bolts.
TIGHTEN to specifications.
REFER to Section 206 - 03
for front disc brakes or
Section 206
- 04 for rear
disc brakes.
z Damaged or
worn caliper
pins or
retainers. z
CHECK the caliper pins
and retainers for lubrication
and correct fit. LUBRICATE
or INSTALL new
components as necessary.
z Missing or
damaged anti-
rattle clips or
springs. z
CHECK the brake pads for
missing clips or broken
springs. INSTALL new
components as necessary.
REFER to Section 206 - 03
for front disc brakes or
Section 206
- 04 for rear
disc brakes.
z Loose brake
disc shield. z
TIGHTEN the brake disc
shield bolts to specification.
REFER to Section 206 - 03 .
z Clicking noise— with
brakes applied with
ABS brakes z
ABS hydraulic
control unit. z
Acceptable condition.
z Squealing noise— zDisc brake zAcceptable condition. Klj . 16 ba
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closing/opening
the window
z Squeak— heard
outside of vehicle
when
closing/opening
the door z
Exhaust shield
rubbing against
the chassis or
exhaust pipe. z
CHECK the exhaust system.
REPAIR as necessary. REFER
to Section 309 - 00 .
z Squeak— occurs
with initial brake
pedal application z
Disc brake pads. zUnder certain conditions,
asbestos free pads can
generate a squeak noise. This
noise is normal and does not
indicate a concern.
z Squeak— a
constant noise
that occurs with
brake pedal
applications z
Damaged or
worn disc brake
pads. z
INSPECT the pads for oil,
grease or brake fluid
contamination. CHECK for
glazed linings. A brake disc with
hard spots will also cause a
squeak type noise. REPAIR or
INSTALL new pads as
necessary. REFER to Section 206 - 03 for front disc brakes and
Section 206 - 04 for rear disc
brakes.
z Squeak— noise
occurs over
bumps or when
turning z
Worn control
arm bushings. z
INSPECT the control arm
bushings. Spray with lubricant
and CARRY OUT a "bounce
test" to determine which
bushing. REPAIR as necessary.
REFER to Section 204 - 01 .
z Worn or
damaged shock
absorber/strut. z
INSPECT the shock absorber
for damage. CARRY OUT a
"bounce test" to isolate the
noise. INSTALL a new shock
absorber/strut as necessary.
REFER to Section 204 - 01 for
the front shock absorber/strut or
Section 204 - 02 for the rear
shock absorber/strut.
z Rattle— heard
when
closing/opening
the door or
window z
Loose internal
door
mechanism,
bracket or
attachment. z
REPEAT the motion or CARRY
OUT a "tap test" to duplicate the
noise. INSPECT the door for
loose components. TIGHTEN
loose components or USE the
Rotunda Squeak and Rattle Kit
to isolate any rattling
components.
z Rattle — GT
models only,
noise occurs from
the rear of the
vehicle z
A loose or under
torqued shock
damper
attaching nut. z
VERIFY the torque on the
shock damper- to-axle nuts is 63
Nm (46 lb- ft). VERIFY the
torque for the shock damper- to-
rail bracket nuts is 90 Nm (66
lb- ft). Do not over torque.
TIGHTEN as necessary.
z Squeak or rattle—
heard inside the
vehicle over rough
roads/bumps z
Misaligned glove
compartment
door/hinge. z
ALIGN the glove compartment
door.
z Instrument panel
trim loose or z
INSPECT the instrument panel
trim for missing or loose clips or Klj . 32 ba
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