clock FORD MUSTANG 2003 Workshop Manual

The radio type codes are:
z2 — Premium electronic AM/FM stereo with compact disc (CD) player and clock
z 9 — CDX6+, AM/FM stereo with 6- disc compact disc (CD) changer and MACH 460 subwoofer
sound system
z Z — AM/FM stereo, dual media (MP3) with compact disc (CD) player
Axle Ratio Codes Klj . 10 ba
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A rhythmic tap, similar to a clock noise.
Tip-
In Moan
A light moaning noise heard during light vehicle acceleration, usually between 40- 100 km/h (25-65
mph).
TIR
The acronym for total indicated runout is TIR.
Tire Deflection
The change in tire diameter in the area where the tire contacts the ground.
Tire Flat Spots
A condition commonly caused by letting the vehicle stand while the tires cool off. This condition can be
corrected by driving the vehicle until the tires are warm. Also, irregular tire wear patterns in the tire
tread resulting from wheel- locked skids.
Tire Force Vibration
A tire vibration caused by variations in the construction of the tire that is noticeable when the tire
rotates against the pavement. This condition can be present on perfectly round tires because of
variations in the inner tire construction. This condition can occur at wheel rotation frequency or twice
rotation frequency.
Transient
A noise or vibration that is momentary, a short duration.
Two- Plane Balance
Radial and lateral balance.
Vibration
Any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up
and down.
Whine
A constant, high- pitched noise. Also described as a screech.
Whistle
High- pitched noise (above 500 Hz) with a very narrow frequency band. Examples of whistle noises are
a turbocharger or airflow around an antenna.
Wind Noise
Any noise caused by air movement in, out or around the vehicle. Klj . 10 ba
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Section 204 - 01 .
z Damaged or
worn wheel
bearings z
CHECK for abnormal wheel
bearing play or roughness.
Refer to Wheel Bearing Check in this section.
ADJUST or INSTALL new
wheel bearings as
necessary.
z Clicking or
snapping— occurs
when accelerating
around a corner z
Damaged or
worn outboard
CV joint. z
INSPECT the outboard CV
joint and boot. REPAIR or
INSTALL a new CV joint as
necessary.
z High pitched
chattering— noise
from the rear axle
when the vehicle is
turning z
Incorrect or
contaminated
lubricant. z
CHECK the vehicle by
driving in tight circles (5
clockwise, 5
counterclockwise). FLUSH
and REFILL with the
specified rear axle lubricant
and friction modifier as
necessary.
z Damaged or
worn differential
(differential side
gears and pinion
gears). z
DISASSEMBLE the
differential assembly.
INSPECT the differential
case, pin and gears for wear
or damage. REPAIR or
INSTALL a new differential
as necessary. REFER to
Section 205 - 02A for Ford
7.5 rear axles or Section 205 - 02B for Ford 8.8
integral axles.
z Buzz—buzzing noise
is the same at cruise
or coast/deceleration z
Damaged or
worn tires. z
CHECK for abnormal tire
wear or damage. INSTALL a
new tire as necessary.
REFER to Section 204 - 04 .
z Incorrect
driveline angles. z
CHECK for correct driveline
angles. REPAIR as
necessary. REFER to
Section 205 - 00 .
z Rumble or boom—
noise occurs at
coast/deceleration,
usually driveshaft
speed related and
noticeable over a
wide range of speeds z
Driveshaft is
out-of- balance. z
CHECK the driveshaft for
damage, missing balance
weights or undercoating.
CHECK the driveshaft
balance. CARRY OUT a
driveline vibration test.
REFER to Section 205 - 00 .
z U-joints binding
or seized. z
ROTATE the driveshaft and
CHECK for rough operation
or seized U- joints. INSTALL
new U- joints as necessary.
REFER to Section 205 - 01 .
z Excessive
pinion flange
runout. z
CARRY OUT a runout
check. REPAIR as
necessary. REFER to
Section 205 - 00 .
z Grunting— normally
associated with a
shudder experienced
during acceleration z
Driveshaft slip
yoke binding. z
CLEAN and LUBRICATE
the male and female
splines. Klj . 20 ba
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SPECIFICATIONS
SECTION 204-
00: Suspension System — General Information 2003 Mustang Workshop Manual Alignment Specifications
Item LH RH Total/Split
Front
Caster 3.2° ± 0.75° 3.2° ± 0.75° 0° ±
0.75° Camber—
GT and Base -
0.50° ± 0.75° -
0.50° ± 0.75° 0° ±
0.75° Camber—
Cobra -
0.90° ± 0.40° -
0.90° ± 0.40° 0° ±
0.40° Toe (positive value is toe-in, negative value is toe-
out) — — 0.25° ± 0.25°
Rear, Cobra
Caster — — —
Camber -0.8° ± 0.2° -
0.8° ± 0.2° 0° ±
0.50° Toe (positive value is toe-in, negative value is toe-
out) — — 0.20° ± 0.15°
General Specifications Item Specification
Front Ride Height
Front 4 mm ±
7.6 mm (0.2 in. ± 0.3 in.) Rear Ride Height
Rear —
GT and Base 128 mm (5 in.)
Rear — Cobra 18 mm ±
7.6 mm (1.4 in. ± 0.3 in.) Vehicle Lean (Side-
to-Side Differences) Front —
maximum 13 mm
(0.5 in.) Rear —
maximum 13 mm
(0.5 in.) Dogtracking
Maximum 13 mm (0.5 in.)
Clear vision (negative value is counterclockwise) -
2° ± 3° Ball Joint End Play
Lower ball joint —
maximum 0.8 mm
(1/32 in.)
Torque Specifications Klj . 1 ba
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5.
CAUTION: Use care not to damage the tie- rod end dust boot.
Using the special tool, disconnect the tie- rod from the spindle.
6. Disconnect the front stabilizer bar link (5K483) from the front suspension lower arm (3078). 1. Remove the nut and bushing.
2. Disconnect the link.
7. CAUTION: Do not allow the intermediate shaft to rotate while it is disconnected
from the gear or damage to the clockspring can occur. If there is evidence that the
intermediate shaft has rotated, the clockspring must be removed and recentered. For
additional information, refer to Section 501 - 20B .
Remove the bolt and disconnect the intermediate shaft from the gear. zDiscard the bolt. Klj . 2 ba
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53.
NOTE: Tighten the bolts prior to releasing the carrier spreader.
Install the differential bearing caps in their original locations and positions and tighten the bolts.
54. Remove the special tool.
55. Install the special tool at the 12 o'clock position.
56. Using the special tools, measure the differential ring gear backlash at four equally spaced points. Klj . 31 ba
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DISASSEMBLY AND ASSEMBLY
Caliper
Disassembly
1. Remove the rear disc brake caliper (2552). For additional information, refer to Caliper in the Removal and Installation portion of this section.
2. Drain the brake fluid from the rear disc brake caliper.
3. Secure the rear disc brake caliper in a vise.
4. Turn the rear disc brake piston and adjuster (2B588) counterclockwise with Rear Caliper Piston Adjuster.
SECTION 206-
04: Rear Disc Brake 2003 Mustang Workshop Manual Special Tool(s)
Rear Caliper Piston Adjuster
206-
026 (T87P-2588- A) Rear Caliper Spring
Compressor Set
206-
S027 (T87P-2588- B) Klj . 1 ba
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4 N805572-
S36 Air bag module retaining screws (2 req'd)
5 3L518 Steering wheel spoke cover
(2 req'd)
6 — Lock tabs
7 14A664 Clockspring
8 13318 Turn indicator cancel cam
9 3C610 Snap ring
10 3520 Bearing spring
11 3518 Upper bearing sleeve
12 3517 Upper bearing (small)
13 3517 Lower bearing (large)
14 3524 Shaft assembly
15 390345-
S36 Screw
16 13K359 Multi-
function switch 17 3E695 Lock cam
18 3F609 Tilt wheel handle
19 N806157 Lock cam pivot pin
20 3530 Lower shroud
21 55929 Shroud retaining screws
22 3D544 Release lever
23 3B661 Lock actuator lever (RH)
24 N805856 Lock actuator lever pin
25 3D653 Lock actuator lever (LH)
26 3B664 Lock lever spring (2 req'd)
27 14A099 Wiring shield
28 3D655 Lock lever spring return
29 3E715 Lock lever upper actuator
30 3E696 Lock spring (shaft)
31 11572 Ignition switch
32 N806423-
S56 Steering column mounting lower nuts
33 N806584 Screw
34 3E660 Mounting bracket
35 3D681 Bearing retaining
36 3518 Bearing sleeve
37 3517 Lower bearing
38 3L539 Lower bearing tolerance ring
39 3C131 Sensor ring
40 3520 Bearing spring
41 N808349 Bolt —
flange yoke 42 3N725 Coupling
43 3C611 Tube boot
44 3B676 Intermediate shaft Klj . 2 ba
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Disconnect the battery ground cable and wait at least one minute. For additional information,
refer to
Section 414 - 01 .
2. Remove the steering column opening lower finish panel. 1. Remove the screws.
2. Pull out to release the retaining clips and remove the steering column opening lower finish panel.
3. Remove the steering column opening lower reinforcement. 1. Remove the bolts.
2. Remove the steering column opening lower reinforcement.
4. Pushing in on the release tab, disconnect the clockspring electrical connector at the base of the steering column.
5. Attach the restraint system diagnostic tool to the vehicle harness side of the clockspring electrical connector. Klj . 2 ba
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4. Install the right hand A/C register duct.
zConnect the A/C duct at the air plenum.
z Install the duct at the A/C register and install the two screws.
5. Close the glove compartment.
6. Remove the restraint system diagnostic tool from the clockspring electrical connector.
7. Connect the clockspring electrical connector at the base of the steering column.
8. Install the steering column opening lower reinforcement. 1. Position the steering column opening lower reinforcement.
2. Install the bolts.
9. Install the steering column opening lower finish panel. 1. Align the steering column opening lower finish panel and push in, seating the retaining
clips.
2. Install the screws. Klj . 5 ba
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