ESP FORD MUSTANG 2003 Workshop Manual

Protocol 3
Protocol 3
The following offers a more detailed explanation of the coding strategy used for protocol 3.
Model Year
z Y — 2000
z 1 — 2001
z 2 — 2002
z 3 — 2003
Vehicle Line
z ZE — Mustang
Transmission
z 1 — Automatic transmission
z 2 — Manual transmission
Unique Calibration
The Emissions/CAFE/CO2 Compliance Department is responsible for assigning these calibration
numbers. Unique calibration identifications are assigned to cover similar vehicles to differentiate tires,
drive configurations, final drive ratios and other calibration- significant factors. 5 Design level (design level assigned to the engine)
Item Description
1 Model year (model year in which calibration strategy was first introduced)
2 Vehicle code
3 Transmission code
4 Unique calibration (designates different hardware to similar vehicles). Example: tires, drive
ratios, etc.
5 Fleet code (describes fleet to which the vehicle belongs). Example: 6 -
evaporative emissions 6 Certification region (lead region where multiple regions are included in one calibration).
Example: A - U.S. federal
7 Revision level (will advance as revisions occur). Not printed on label Klj . 14 ba
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DESCRIPTION AND OPERATION
Noise, Vibration and Harshness (NVH)
Noise is any undesirable sound, usually unpleasant in nature. Vibration is any motion, shaking or
trembling, that can be felt or seen when an object moves back and forth or up and down. Harshness is
a ride quality issue where the vehicle's response to the road transmits sharply to the customer.
Harshness normally describes a firmer than usual response from the suspension system. Noise,
vibration and harshness (NVH) is a term used to describe these conditions, which result in varying
degrees of dissatisfaction. Although, a certain level of NVH caused by road and environmental
conditions is normal. This section is designed to aid in the diagnosis, testing and repair of NVH
concerns.
Acceptable Noise, Vibration and Harshness
All internal combustion engines and drivelines produce some noise and vibration; operating in a real
world environment adds noise that is not subject to control. Vibration isolators, mufflers and dampers
reduce these to acceptable levels. A driver who is unfamiliar with a vehicle can think that some sounds
are abnormal when actually the sounds are normal for the vehicle type. For example, Traction-
Lok®
differentials produce a slight noise on slow turns after extended highway driving. This is acceptable
and has no detrimental effect on the locking axle function. As a technician, it is very important to be
familiar with vehicle features and know how they relate to NVH concerns and their diagnosis. For
example, if the vehicle has automatic overdrive, it is important to test drive the vehicle both in and out
of overdrive mode.
Diagnostic Theory
The shortest route to an accurate diagnosis results from:
zsystem knowledge, including comparison with a known good system.
z system history, including repair history and usage patterns.
z condition history, especially any relationship to repairs or sudden change.
z knowledge of possible sources.
z using a systematic diagnostic method that divides the system into related areas.
The diagnosis and correction of noise, vibration and harshness concerns requires:
za road or system test to determine the exact nature of the concern.
z an analysis of the possible causes.
z testing to verify the cause.
z repairing any concerns found.
z a road test or system test to make sure the concern has been corrected or brought back to
within an acceptable range.
Glossary of Terms SECTION 100-
04: Noise, Vibration and Harshness 2003 Mustang Workshop Manual Klj . 1 ba
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WOT
The acronym for wide open throttle is WOT.
Tools and Techniques
Electronic Vibration Analyzer (EVA)
The EVA is a hand-
held electronic diagnostic tool which will assist in locating the source of
unacceptable vibrations. The vibration sensor can be remotely mounted anywhere in the vehicle for
testing purposes. The unit displays the three most common vibration frequencies and their
corresponding amplitudes simultaneously. A bar graph provides a visual reference of the relative
signal strength (amplitude) of each vibration being displayed and its relative G force. The keypad is
arranged to make the EVA simple to program and use. Some of the functions include the ability to
average readings as well as record, play back and freeze readings. The EVA has a strobe balancing
function that can be used to detect imbalance on rotating components such as a driveshaft or engine
accessories.
The EVA allows for a systematic collection of information that is necessary to accurately diagnose and
repair NVH problems. For the best results, carry out the test as follows:
a. Test drive the vehicle with the vibration sensor inside the vehicle.
b. Place the sensor in the vehicle according to feel. „If the condition is felt through the steering wheel, the source is most likely in the front of
the vehicle.
„ A vibration that is felt in the seat or floor only will most likely be found in the driveline,
drive axle or rear wheels and tires.
c. Record the readings. Also note when the condition begins, when it reaches maximum intensity, and if it tends to diminish above/below a certain speed.
„Frequencies should be read in the "average" mode. Item Description
1 EVA screen
2 Frequency mode displayed in rpm or Hz
3 Active sensor input (A or B)
4 Current active mode
5 G force indicators or the strongest frequencies in descending strength of each vibration
6 Strength of each vibration
7 Frequency in rpm/Hz of each vibration Klj . 11 ba
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NOTE:
It may be necessary to have the customer ride along or drive the vehicle to point out the
concern. During the road test, take into consideration the customer's driving habits and the driving
conditions. The customer's concern just may be an acceptable operating condition for that vehicle.
The following is a brief overview of each test in the order in which it appears. A review of this
information helps to quickly identify the most appropriate process necessary to make a successful
diagnosis. After reviewing this information, select and carry out the appropriate test(s), proceeding to
the next step of this process.
zThe Slow Acceleration Test is normally the first test to carry out when identifying an NVH
concern, especially when a road test with the customer is not possible.
z The Heavy Acceleration Test helps to determine if the concern is torque- related.
z The Neutral Coast Down Speed Test helps to determine if the concern is vehicle speed- related.
z The Downshift Speed Test helps to determine if the concern is engine speed- related.
z The Steering Input Test helps to determine how the wheel bearings and other suspension
components contribute to a vehicle speed- related concern.
z The Brake Test helps to identify vibrations or noise that are brake related.
z The Road Test Over Bumps helps isolate a noise that occurs when driving over a rough or
bumpy surface.
z The Engine Run- Up Tests consist of the Neutral Run- Up Test and the Engine Load Test. These
tests help to determine if the concern is engine speed- related.
z The Neutral Run- Up Test is used as a follow- up test to the Downshift Speed Test when the
concern occurs at idle.
z The Engine Load Test helps to identify vibration/noise sensitive to engine load or torque. It also
helps to reproduce engine speed- related concerns that cannot be duplicated when carrying out
the Neutral Run- Up Test or the Neutral Coast Down Test.
z The Engine Accessory Test helps to locate faulty belts and accessories that cause engine
speed- related concerns.
z The Vehicle Cold Soak Procedure helps to identify concerns occurring during initial start- up and
when an extended time lapse occurs between vehicle usage.
Slow Acceleration Test
To carry out this test, proceed as follows:
zSlowly accelerate to the speed where the reported concern occurs. Note the vehicle speed, the
engine rpm and, if possible, determine the vibration frequency.
z Attempt to identify from what part of the vehicle the concern is coming.
z Attempt to identify the source of the concern.
z Proceed as necessary.
Heavy Acceleration Test
To carry out this test, proceed as follows:
zAccelerate hard from 0- 64 km/h (0-40 mph).
z Decelerate in a lower gear.
z The concern is torque related if duplicated while carrying out this test.
z Proceed as necessary. Klj . 6 ba
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For a vibration concern, use the vehicle speed to determine tire/wheel frequency and rpm. Calculate
tire and wheel rpm and frequency by carrying out and following:
zMeasure the diameter of the tire.
z Record the speed at which the vibration occurs.
z Obtain the corresponding tire and wheel rpm and frequency from the Tire Speed and Frequency
Chart.
„If the vehicle speed is not listed, divide the vehicle speed at which the vibration occurs by
16 km/h (10 mph). Multiply that number by 16 km/h (10 mph) tire rpm listed for that tire
diameter in the chart. Then divide that number by 60. For example: a 40 mph vibration
with 835 mm (33 in) tires. 40 ÷ 10 = 4. Multiply 4 by 105 = 420 rpm. Divide 420 rpm by 60
seconds = 7 Hz at 40 mph.
Tire Speed and Frequency Chart Tire
Diameter Tire RPM/Hz Tire RPM/Hz Tire RPM/Hz Tire RPM/Hz
mm (inch) @ 16 km/h (10
mph) @ 80 km/h (50
mph) @ 97 km/h (60
mph) @ 113 km/h (70
mph) 483 (19) 182 910/15 1092/18 1274/21
508 (20) 173 865/14 1038/17 1211/20
533 (21) 165 825/14 990/16 1155/19
560 (22) 158 790/13 948/16 1106/18
585 (23) 151 755/13 906/15 1057/18
610 (24) 145 725/12 870/14 1015/17
635 (25) 139 695/12 834/14 973/16
660 (26) 134 670/11 804/13 938/16
685 (27) 129 645/11 774/13 903/15
710 (28) 124 620/10 744/12 868/14
735 (29) 119 595/10 714/12 833/14
760 (30) 115 575/10 690/11 805/13
785 (31) 111 555/9 666/11 777/13
810 (32) 108 540/9 648/11 756/13
835 (33) 105 525/9 630/10 735/12
864 (34) 102 510/8 612/10 714/12 Klj . 69 ba
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Component Tests
Driveline Vibration
An analysis of driveline vibration can also be conducted using the Vibration Analyzer; follow the
manufacturer's directions.
Driveline vibration exhibits a higher frequency and lower amplitude than does high-
speed shake.
Driveline vibration is directly related to the speed of the vehicle and is usually noticed at various speed
ranges. Driveline vibration can be perceived as a tremor in the floorpan or is heard as a rumble, hum,
or boom. Driveline vibration can exist in all drive modes, but may exhibit different symptoms depending
upon whether the vehicle is accelerating, decelerating, floating, or coasting. Check the driveline angles
if the vibration is particularly noticeable during acceleration or deceleration, especially at lower speeds.
Driveline vibration can be duplicated by supporting the axle upon a hoist or upon jack stands, though
the brakes may need to be applied lightly in order to simulate road resistance.
1. Raise the vehicle promptly after road testing. Use a twin- post hoist or jack stands to prevent tire
flat- spotting. Engage the drivetrain and accelerate to the observed road test speed to verify the lubricant type.
205 - 02B . CLEAN and
REFILL the axle to
specification.
z Axle overheating zLubricant level too
low. z
CHECK the lubricant level.
FILL the axle to specification.
z Incorrect or
contaminated
lubricant type. z
INSPECT the axle for
damage. REPAIR as
necessary. CLEAN and
REFILL the axle to
specification.
z Bearing preload
adjusted too tight. z
CHECK the ring and pinion for
damage. INSPECT the ring
and pinion wear pattern.
ADJUST the preload as
necessary.
z Excessive gear
wear. z
INSPECT all the axle gears
for wear or damage. INSTALL
new components as
necessary.
z Incorrect ring gear
backlash. z
INSPECT the ring gear for
scoring. INSPECT the ring
and pinion wear pattern.
ADJUST the ring gear
backlash as necessary.
z Broken gear teeth
on the ring gear
or pinion z
Overloading the
vehicle. z
INSTALL a new ring and
pinion. REFER to Section 205 - 02A or
Section 205 - 02B .
z Axle shaft broken zOverloading the
vehicle. z
INSTALL a new axle shaft.
REFER to Section 205 - 02A or
Section 205 - 02B .
z Misaligned axle
shaft tube. z
INSPECT the axle for
damage. CHECK axle shaft
tube alignment. INSTALL a
new axle shaft. REFER to
Section 205 - 02A or
Section 205 - 02B . Klj . 11 ba
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If the marks are on opposite sides of the driveshaft, the yoke or pinion flange is responsible for the
vibration.
When installing a new pinion flange, the driveshaft runout must not exceed 0.89 mm (0.035 inch).
When runout is within limits, recheck for vibration at road speed. If vibration persists, balance the
driveshaft.
7. To balance the driveshaft, install one or two hose clamps on the driveshaft, near the rear. Position of the hose clamp head(s) can be determined by trial- and-error.
8. Mark the rear of the driveshaft into four approximately equal sectors and number the marks 1 through 4. Install a hose clamp on the driveshaft with its head at position No. 1.
Check for vibration at road speed. Recheck with the clamp at each of the other positions to find the
position that shows minimum vibration. If two adjacent positions show equal improvement, position the
clamp head between them. 9. If the vibration persists, add a second clamp at the same position and recheck for vibration. Klj . 13 ba
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sides of the cup to prevent the cup from cocking in the casting.
Installation
Using special tool 205- 054
NOTE: This is the preferred method for installing the pinion bearing cups. If necessary, proceed to
Using special tools 205- 153, 205-054, and 205-D055 in this procedure for an alternate method.
1. Position the special tools and the inner and outer pinion bearing cups in their respective bores. 1. After placing the inner and outer bearing cups in their bores, place the special tool on the inner bearing cup.
2. Place the special tool on the outer bearing cup.
3. Install the special tool.
2. Tighten the special tool to seat the pinion bearing cups in their bores.
3. CAUTION: Always install new differential pinion bearings when installing new
pinion bearing cups.
NOTE: If the feeler gauge can fit between a cup and the bottom of its bore at any point around
the cup, remove and reseat the cup. Klj . 5 ba
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10. Using the special tools, remove the inner rear axle pinion bearing cup (4628).
Installation
Using special tool 205- 024
NOTE: This is the preferred method for installing the pinion bearing cups. If necessary, proceed to
Using special tools 205- 153, 205-024, 205-231, and 205- D055 in this procedure for an alternate
method.
1. Position the special tools and the inner and outer pinion bearing cups in their respective bores. 1. After placing the inner and outer bearing cups in their bores, place the special tool on the
inner bearing cup.
2. Place the special tool on the outer bearing cup.
3. Install the special tool.
2. Tighten the special tool to seat the pinion bearing cups in their bores.
3. CAUTION: Always install new differential pinion bearings when installing new
pinion bearing cups. NOTE: If the feeler gauge can fit between a cup and the bottom of its bore at any point around Klj . 5 ba
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9.
CAUTION: Do not use acids or solvents when cleaning the differential clutch pack.
Wipe components only with a clean, lint- free cloth.
Clean and inspect the differential clutch packs for wear and damage and install new parts as
necessary.
Assembly
1. CAUTION: 118 ml (4 oz) of the specified Ford Friction Modifier must be used in the
axle.
Lubricate each steel clutch plate and soak all friction plates for no less than 15 minutes.
zUse Additive Friction Modifier C8AZ- 19B546-A or equivalent meeting Ford specification
EST- M2C118- A
2. CAUTION: Do not mix the differential clutch packs or shims from one side with the
other.
Assemble the differential clutch packs (without the shims) on their respective differential side
gears. Klj . 4 ba
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