jacking 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-
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DESCRIPTION AND OPERATION
Lifting
CAUTION: Do not allow the lift adapters to contact the steering linkage, suspension arms,
stabilizer arms, or to compress the lower suspension arm stabilizer bar insulator (5493).
Damage to the suspension, exhaust and steering linkage components may occur if care is not
exercised when positioning the hoist adapters prior to lifting the vehicle.
CAUTION: Never use the differential housing as a lift point. Damage to the differential
housing and cover may occur.
CAUTION: Do not lift vehicle on rocker panel pinch flange or convertible cross brace.
Body damage may occur.
Lift the vehicle using the Lifting Points procedure in this section.
Lifting Points—Drive On Lift
CAUTION: To prevent possible damage to the underbody, do not drive the vehicle onto
the drive on lift without first checking for possible interference.
Check for interference between the upright flanges of the hoist rails and the underbody.
If an interference exists, modify the hoist flanges or build up the approach ramps as necessary to
provide clearance. Lifting Points — Frame Contact Lift, Single Post Lift, Two Post Lift SECTION 100-
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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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PINPOINT TEST M: TRANSFER CASE VIBRATION the system for normal operation.
No
GO to
L6 .
L6 CHECK THE FLYWHEEL BOLTS
z
Check for loose flywheel bolts.
z Are the bolts loose? Yes
TIGHTEN the bolts to
specifications. REFER to
Section 308 - 01 . TEST the system for
normal operation.
No
GO to L7 .
L7 CHECK THE FLYWHEEL SURFACE
z
Inspect the flywheel surface for wear or damage.
Check the flywheel runout.
z Is there any damage or excessive wear? Yes
INSTALL a new flywheel. TEST
the system for normal operation.
No
Clutch system normal. CONDUCT
a diagnosis on other suspect
systems.
Test Step Result / Action to Take
M1 INSPECT THE TRANSFER CASE
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 Inspect the transfer case for loose or missing mounting bolts.
Check for fluid seepage between the transfer case and the
transmission.
z Are the mounting bolts missing or loose? Yes
TIGHTEN to
specifications or
INSTALL new bolts as
necessary. TEST the
system for normal
operation.
No
GO to
M2 .
M2 INSPECT THE REAR DRIVESHAFT
z
NOTE: Verify that the driveshaft and pinion flange index marks
are aligned.
z Inspect the driveshaft for missing weights, damage or
undercoating.
z Inspect the U- joints for freedom of movement.
z Check driveshaft runout and, if necessary, check the pinion
flange runout.
z Is the driveshaft or U- joints worn or damaged or
misaligned? Yes
REPAIR or INSTALL a
new driveshaft as
necessary. TEST the
system for normal
operation.
No
GO to
M3 .
M3 CHECK THE DRIVELINE ANGLES
z
Measure the rear driveshaft and pinion angles. Refer to Section 205 - 00 .
z Measure the front driveshaft and pinion angles. Refer to Section 205 - 00 .
z Are the driveline angles incorrect? Yes
REPAIR as necessary.
TEST the system for
normal operation.
No Klj . 62 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-
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GENERAL PROCEDURES
Powertrain/Drivetrain Mount Neutralizing
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.
1. Raise and support the vehicle.
2. Loosen, but do not remove, the powertrain/drivetrain mount fasteners.
3. Lower the vehicle.
4. CAUTION: Do not twist or strain the powertrain/drivetrain mounts.
Move the vehicle in forward and reverse 0.6- 1.2 meters (2-4 ft).
5. Raise and support the vehicle.
6. Tighten the powertrain/drivetrain mount fasteners.
7. Lower the vehicle.
8. Test the system for normal operation.
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GENERAL PROCEDURES
Exhaust System Neutralizing
WARNING: Exhaust gases contain carbon monoxide, which is harmful to health and
potentially lethal. Repair exhaust system leaks immediately. Never operate the engine in an
enclosed area.
WARNING: Exhaust system components are hot.
NOTE: Neutralize the exhaust system to relieve strain on mounts which can be sufficiently bound up to
transmit vibration as if grounded.
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.
CAUTION: Make sure the system is warmed up to normal operating temperature, as
thermal expansion can be the cause of a strain problem.
Raise and support the vehicle.
2. Loosen all exhaust hanger attachments and reposition the hangers until they hang free and straight.
3. Loosen all exhaust flange joints.
4. Place a stand to support the muffler parallel to the vehicle frame with the muffler pipe bracket free of stress.
5. Tighten the muffler connection.
6. Tighten all the exhaust hanger clamps and flanges (tighten the exhaust manifold flange joint last).
zVerify there is adequate clearance to prevent grounding at any point in the system. Make
sure that the catalytic converter and heat shield do not contact the frame rails.
z After neutralization, the rubber in the exhaust hangers should show some flexibility when
movement is applied to the exhaust system.
z With the exhaust system installed securely and cooled, the rear hanger should be angled
forward.
7. Lower the vehicle.
8. Test the exhaust system for normal operation.
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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.
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