flat tire FORD MUSTANG 2003 Workshop Manual

DESCRIPTION AND OPERATION
Jacking
WARNING: Never run the engine with one wheel off the ground, such as when changing a
tire. The wheel still on the ground could cause the vehicle to move.
CAUTION: The jack (17080) provided with the vehicle is intended to be used in an
emergency for changing a deflated tire. To avoid damage to the vehicle, never use the jack to
lift the vehicle for any other purpose. Refer to the Owner Guide when using the jack supplied
with the vehicle.
CAUTION: Under no circumstances should the vehicle ever be lifted by the suspension
arm brackets, rear stabilizer or differential housing or convertible cross brace. Severe damage
to the vehicle could result.
CAUTION: Do not attempt to use jack pressure on either the front bumper (17757) or the
rear bumper (17906) of any vehicle. Damage to the bumper covers will occur.
Lift the vehicle using the Jacking Points procedure in this section.
Jacking Points
To lift the front or either side of the front end, position the floor jack under the front frame lift points. SECTION 100-
02: Jacking and Lifting 2003 Mustang Workshop Manual Klj . 1 ba
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Lateral runout means measuring the movement or "wobble" of a wheel or tire at the sidewall. Radial
runout means measuring the out-of-
round at the tread surface.
Rustling
Intermittent sound of varying frequency (100- 2000 Hz), sounds similar to shuffling through leaves.
Shake
A low- frequency vibration (5-20 Hz), usually with visible component movement. Usually relates to tires,
wheels, brake drums or brake discs if it is vehicle speed sensitive, or engine if it is engine speed
sensitive. Also referred to as a shimmy or wobble.
Shimmy
An abnormal vibration or wobbling, felt as a side- to-side motion of the steering wheel in the driveshaft
rotation. Also described as waddle.
Shudder
A low- frequency vibration that is felt through the steering wheel or seat during light brake application.
Slap
A resonance from flat surfaces, such as safety belt webbing or door trim panels.
Slip Yoke/Slip Spline
The driveshaft coupling that allows length changes to occur while the suspension articulates and while
the driveshaft rotates.
Squeak
A high- pitched transient sound, similar to rubbing fingers against a clean window.
Squeal
A long- duration, high- pitched noise.
Static Balance
The equal distribution of weight around the wheel. Statically unbalanced wheel and tire assemblies can
cause a bouncing action called wheel tramp. This condition will eventually cause uneven tire wear.
Tap
A light, rhythmic, or intermittent hammering sound, similar to tapping a pencil on a table edge.
Thump
A dull beat caused by two items striking together. Tick Klj . 9 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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z
After determining the "system", use the diagnostic tools to identify the worn or damaged
"components".
z After identifying the "components", try to find the "cause" of the failure.
Once the concern is narrowed down to a symptom/condition, proceed to NVH Condition and Symptom
Categories.
NVH Condition and Symptom Categories
A good diagnostic process is a logical sequence of steps that lead to the identification of a causal
system. Use the condition and symptom categories as follows:
zIdentify the operating condition that the vehicle is exhibiting.
z Match the operating condition to the symptom.
z Verify the symptom.
z Identify which category or system could cause the symptom.
z Refer to the diagnostic symptom chart that is referred to.
Operating Condition— Vehicle is Not Moving
1. Static operation zNoise occurs during component/system functioning. GO to Symptom Chart — Squeak
and Rattle .
2. While cranking 1. Grinding or whine, differential ring gear or starter motor pinion noise. GO to Symptom Chart — Engine Noise/Vibration .
2. Rattle. Exhaust hanger, exhaust heat shield or A/C line noise. GO to Symptom Chart —
Squeak and Rattle .
3. Vibration. Acceptable condition.
3. At idle zIdle noise. GO to Symptom Chart — Idle Noise/Vibration .
z Idle vibration or shake. GO to Symptom Chart — Idle Noise/Vibration .
4. During Gear Selection 1. Vehicle parked on a steep incline. Acceptable noise.
2. Vehicle parked on a flat surface. GO to Symptom Chart — Driveline Noise/Vibration .
3. Vehicle with a manual transmission. GO to Symptom Chart — Transmission (Manual)
and Transfer Case Noise/Vibration .
Operating Condition— Vehicle is Moving
1. Depends more on how the vehicle is operated 1. Speed related
„Related to vehicle speed
„Pitch increases with vehicle speed. GO to Symptom Chart — Tire
Noise/Vibration .
„ Noise occurs at specific vehicle speed. A high- pitched noise (whine). GO to
Symptom Chart — Driveline Noise/Vibration . Klj . 10 ba
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information, REFER to
Section 205
- 00 .
REPAIR as necessary.
z Transmission
rumble/growl— noise at
all speeds in forward
gears, more
pronounced in a heavy
acceleration condition z
Damaged or worn
transmission
bearing or gears
(high mileage
vehicles). z
CHECK transmission
fluid for excessive
metal particles.
REPAIR as necessary.
REFER to Section 308 -
03A for T50D
transmissions or
Section 308 - 03B for
TR3650 transmissions.
z Transfer case whine—
noise at all ranges z
Incorrect fluid level
or fluid quality. z
CHECK that the
transfer case is filled to
the correct level and
with the specified fluid.
REFER to Section 308 -
03A for T50D
transmissions or
Section 308 - 03B for
TR3650 transmissions.
z Worn oil pump. zDISASSEMBLE the
transfer case. CHECK
the oil pump for wear or
damage. REPAIR as
necessary.
z Under- inflated or
oversized tires. z
CONFIRM that the tires
and wheels are correct
for the vehicle. CHECK
that the tire inflation
pressures are correct.
z Transfer case
growl/rumble— noise at
all ranges (A small
amount of planetary
noise can be heard
when the transfer case
is operated in low
range.) z
Damaged or worn
bearings or
planetary gear. z
DISASSEMBLE the
transfer case. CHECK
the bearings or
planetary gear for wear
or damage. REPAIR as
necessary.
z Transfer case
scraping/grating—
noise at all ranges z
Excessively
stretched drive
chain hitting the
case. z
DISASSEMBLE the
transfer case. CHECK
the drive chain for wear
or damage. REPAIR as
necessary.
z Transfer case
howl/hum— noise at all
ranges or high range
only z
Worn or damaged
sun (input) gear,
clutch pack
(intermediate) gear
or output shaft gear. z
DISASSEMBLE the
transfer case. CHECK
the gears for wear or
damage. REPAIR as
necessary.
z Transfer case
howl/hum— noise at
low range only z
Worn or damaged
intermediate gear
and sliding gears
(clutch pack). z
DISASSEMBLE the
transfer case. CHECK
the gears for wear or
damage. REPAIR as
necessary.
z Transfer case
vibration— vibration felt
with vehicle in 4WD z
Transfer case
mounting.
z Driveshaft out of
balance.
z Excessive pinion z
Go To Pinpoint Test M . Klj . 44 ba
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PINPOINT TEST I: REAR SUSPENSION NOISE z
WARNING: The electrical power to the air
suspension system must be shut off prior to hoisting,
jacking or towing an air suspension vehicle. This can
be accomplished by turning off the air suspension
switch. Failure to do so can result in unexpected
inflation or deflation of the air springs, which can result
in shifting of the vehicle during these operations.
z Raise and support the vehicle.
z Check the steering system for wear or damage. Carry out a
steering linkage test. Refer Section 211 - 00 .
z Inspect the tire wear pattern. Refer to Tire Wear Patterns
chart in this section.
z Are the steering components worn or damaged? REPAIR the steering
system. INSTALL new
components as necessary.
TEST the system for normal
operation.
No
GO to
H3 .
H3 FRONT SHOCK ABSORBER/STRUT CHECK
z
Check the front shock absorbers/strut mounts for loose
bolts or nuts.
z Check the front shock absorbers/struts for wear or damage.
Carry out a "bounce test".
z Are the front shock absorbers/struts loose or
damaged? Yes
TIGHTEN to specifications if
loose. INSTALL new front
shock absorbers/struts if
damaged. TEST the system
for normal operation.
No
GO to
H4 .
H4 CHECK THE FRONT SPRINGS
z
Check the front spring and front spring mounts/brackets for
wear or damage.
z Are the front springs or spring mounts/brackets worn
or damaged? Yes
REPAIR or INSTALL new
components as necessary.
TEST the system for normal
operation.
No
GO to
H5 .
H5 CHECK THE CONTROL ARMS/RADIUS ARMS
z
Inspect the control arm bushings for wear or damage.
z Inspect for twisted or bent control/radius arm.
z Are the control/radius arms damaged or worn? Yes
REPAIR or INSTALL new
components as necessary.
TEST the system for normal
operation.
No
GO to
H6 .
H6 CHECK THE STABILIZER BAR/TRACK BAR
z
Check the stabilizer bar/track bar bushings and links for
damage or wear.
z Check the stabilizer bar/track bar for damage.
z Check for loose or damaged stabilizer bar isolators or
brackets.
z Are the stabilizer bar/track bar components loose, worn
or damaged? Yes
REPAIR or INSTALL new
components as necessary.
TEST the system for normal
operation.
No
Suspension system OK.
CONDUCT diagnosis on
other suspect systems.
Test Step Result / Action to Take Klj . 54 ba
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PINPOINT TEST J: WHEEL AND TIRE I1 ROAD TEST THE VEHICLE
z
Test drive the vehicle.
z NOTE: An assistant will be needed for this road test.
z During the road test, drive the vehicle over a rough road.
Using ChassisEARs, determine from which
area/component the noise is originating.
z Is there a squeak, creak or rattle noise? Yes
GO to
I2 .
No
The suspension system is
OK. Conduct a diagnosis on
other suspect systems. I2 REAR SHOCK ABSORBER/STRUT CHECK
z
WARNING: The electrical power to the air
suspension system must be shut off prior to hoisting,
jacking or towing an air suspension vehicle. This can
be accomplished by turning off the air suspension
switch. Failure to do so can result in unexpected
inflation or deflation of the air springs, which can result
in shifting of the vehicle during these operations.
z Raise and support the vehicle.
z Check the rear shock absorber/strut mounts for loose bolts
or nuts.
z Check the rear shock absorbers/struts for damage. Carry
out a shock absorber check.
z Are the rear shock absorbers/struts loose or damaged? Yes
TIGHTEN to specifications if
loose. INSTALL new rear
shock absorbers/struts if
damaged. TEST the system
for normal operation.
No
GO to
I3 .
I3 CHECK THE REAR SPRINGS
z
Check the rear springs and rear spring mounts/brackets for
wear or damage.
z Are the rear springs or spring mounts/brackets worn or
damaged? Yes
REPAIR or INSTALL new
components as necessary.
TEST the system for normal
operation.
No
GO to
I4 .
I4 CHECK THE CONTROL ARMS/TRAILING ARMS
z
Inspect the control arm/trailing arm bushings for wear or
damage. Check for loose control arm/trailing arm bolts.
z Inspect for twisted or bent control arm/trailing arms.
z Are the control arm/trailing arms loose, damaged or
worn? Yes
REPAIR or INSTALL new
components as necessary.
TEST the system for normal
operation.
No
GO to
I5 .
I5 CHECK THE STABILIZER BAR/TRACK BAR
z
Check the stabilizer bar/track bar bushings and links for
damage or wear.
z Check the stabilizer bar/track bar for damage.
z Check for loose or damaged stabilizer bar isolators or
brackets.
z Are the stabilizer bar/track bar components loose, worn
or damaged? Yes
REPAIR or INSTALL new
components as necessary.
TEST the system for normal
operation.
No
Suspension system OK.
CONDUCT diagnosis on
other suspect systems.
Test Step
Result / Action to Klj . 55 ba
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operation.
K3 MEASURE THE LATERAL RUNOUT AND THE RADIAL
RUNOUT OF THE FRONT WHEELS ON THE VEHICLE z
Measure the lateral runout and the radial runout of the front
wheels on the vehicle. Refer to Go To Pinpoint Test J .
z Are the measurements within specifications? Yes
GO to
K4 .
No
INSTALL new wheels as
necessary and BALANCE
the assembly. TEST the
system for normal
operation. K4 MEASURE THE LATERAL RUNOUT OF THE FRONT TIRES
ON THE VEHICLE z
Measure the lateral runout of the front tires on the vehicle. Go To Pinpoint Test J .
z Is the runout within specifications? Yes
GO to
K5 .
No
INSTALL new tires as
necessary and BALANCE
the assembly. TEST the
system for normal
operation. K5 MEASURE THE RADIAL RUNOUT OF THE FRONT TIRES
ON THE VEHICLE z
Measure the radial runout of the front tires on the vehicle. Go To Pinpoint Test J .
z Is the runout within specifications? Yes
BALANCE the front wheel
and tire assemblies. If any
tire cannot be balanced,
INSTALL a new tire.
TEST the system for
normal operation.
No
GO to
K6 .
K6 MATCH MOUNT THE TIRE AND WHEEL ASSEMBLY
z
Mark the high runout location on the tire and also on the
wheel. Break the assembly down and rotate the tire 180
degrees (halfway around) on the wheel. Inflate the tire and
measure the radial runout.
z Is the runout within specifications? Yes
BALANCE the assembly.
TEST the system for
normal operation.
No
If the high spot is not
within 101.6 mm (4
inches) of the first high
spot on the tire, GO to
K7
.
K7 MEASURE THE WHEEL FLANGE RUNOUT
z
Dismount the tire and mount the wheel on a wheel balancer.
Measure the runout on both wheel flanges. Go To Pinpoint Test J . Yes
LOCATE and MARK the
low spot on the wheel.
INSTALL the tire,
matching the high spot on
the tire with the low spot
on the wheel. BALANCE
the assembly. TEST the
system for normal
operation. If the condition Klj . 59 ba
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GENERAL PROCEDURES
Brake Disc Machining
WARNING: The electrical power to the air suspension system must be shut off prior to
hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off
the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the
air springs, which can result in shifting of the vehicle during these operations.
CAUTION: Do not install brake discs that are less than the minimum thickness specified.
Do not machine a brake disc below the minimum thickness specification.
1. Check wheel bearing end- play and correct as necessary.
2. NOTE: Begin at the front of the vehicle unless the vibration has been isolated to the rear.
Remove the tire and wheel assembly.
3. Remove the brake caliper and the brake caliper anchor plate. Refer to the appropriate section in Group 206 for the procedure.
4. Inspect the brake linings. Install new brake linings if below specification. For additional information, refer to the appropriate brake section.
5. Measure and record the brake disc thickness. Install a new brake disc if the thickness after machining will be at or below specification. The specification is molded into the brake disc.
zDo not machine a new brake disc.
SECTION 100-
04: Noise, Vibration and Harshness 2003 Mustang Workshop Manual Special Tool(s)
Gauge, Clutch Housing
308-
021 (T75L-4201- A) Dial Indicator Gauge with
Holding Fixture
100-
002 (TOOL- 4201-C) or
equivalent
Material Item Specification
Metal Surface Cleaner
F4AZ-
19A536- RA or equivalent WSE-
M5B392-
A High Temperature Nickel Anti-
Seize Lubricant
F6AZ-
9L494- AA or equivalent ESE-
M12A4-A Klj . 1 ba
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GENERAL PROCEDURES
Wheel Bearing Check
1. WARNING: The electrical power to the air suspension system must be shut off prior
to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by
turning off the air suspension switch. Failure to do so can result in unexpected inflation
or deflation of the air springs, which can result in shifting of the vehicle during these
operations.
Raise the vehicle until the front tires are off the floor.
zMake sure the wheels are in a straight forward position.
2. NOTE: Make sure the wheel rotates freely and that the brake pads are retraced sufficiently to
allow free movement of the tire and wheel assembly.
Spin the tire by hand to check the wheel bearings for roughness.
3. Grip each front tire at the top and bottom and move the wheel inward and outward while lifting the weight of the tire off the front wheel bearing.
4. If the tire and wheel (hub) is loose on the spindle, does not rotate freely, or has a rough feeling when spun, carry out one of the following:
1. On vehicles with inner and outer bearings, inspect the bearings and cups for wear or damage. Adjust or install new bearings and cups as necessary.
2. On vehicles with one sealed bearing, install a new wheel hub.
SECTION 100-
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