oil pressure FORD MUSTANG 2003 Workshop Manual

z
Change engine oil and install a new oil filter, lube front lower control arm and steering linkage
ball joints with zerk fittings (if equipped) every 4,800 km (3,000 miles) or 3 months.
z Inspect brake system and check battery electrolyte level (Patrol cars) every 8,000 km (5,000
miles).
z Install a new fuel filter every 24,000 km (15,000 miles).
z Change automatic transmission fluid, lubricate 4x2 wheel bearings, install new grease seals and
adjust bearings every 48,000 km (30,000 miles).
z Install new spark plugs and change transfer case fluid every 96,000 km (60,000 miles).
z Install a new cabin air filter as required.
When operating in dusty conditions such as unpaved or dusty roads:
zChange engine oil and install a new oil filter every 4,800 km (3,000 miles) or 3 months.
z Install a new fuel filter every 24,000 km (15,000 miles).
z Change automatic transmission fluid every 48,000 km (30,000 miles).
z Change transfer case fluid every 96,000 km (60,000 miles).
z Install a new engine air filter as required.
z Install a new cabin air filter as required.
When operating in off- road conditions:
z Change automatic transmission fluid every 48,000 km (30,000 miles).
z Change transfer case fluid every 96,000 km (60,000 miles).
z Install a new cabin air filter as required.
z Inspect and lubricate U- joints.
z Inspect and lubricate steering linkage ball joints with zerk fittings.
Checks and Services
Certain basic maintenance checks and inspections should be carried out at specified intervals. Any
recognized adverse condition should be corrected as soon as possible.
Maximum Oil Change Interval (Normal Schedule) z8,000 km (5,000 miles) or 6 months, whichever occurs first.
Maximum Oil Change Interval (Special Operating Conditions)
z4,800 km (3,000 miles) or 3 months.
Monthly Checks
Check each of the following items every month:
zAll interior and exterior lights.
z Tires for wear and correct air pressure. Klj . 2 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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z
Generator electrical
field or bearings. z
CARRY OUT generator
load test. REPAIR or
INSTALL a new generator
as necessary. REFER to
Section 414 - 02 .
z Drone type noise zExhaust system. zCARRY OUT the Exhaust System Neutralizing in this
section. REPAIR as
necessary.
z A/C compressor. zCHECK for noise with
vehicle at constant speeds.
CYCLE the compressor on
and off and listen for a
change in pitch. REPAIR as
necessary. REFER to
Section 412 - 03 .
z Powertrain mounts. zCARRY OUT the
Powertrain/Drivetrain Mount Neutralizing in this
section.
z Sputter type
noise— noise
worse when cold,
lessens or
disappears when
vehicle is at
operating
temperature z
Damaged or worn
exhaust system
components. z
INSPECT the exhaust
system for leaks or
damage. REPAIR as
necessary. REFER to
Section 309 - 00 .
z Rattling noise—
noise from the
upper engine
(valve train).
Worse when
engine is cold z
Low oil level. zCHECK oil level. FILL as
necessary.
z Thin or diluted oil. zINSPECT the oil for
contamination. If oil is
contaminated, CHECK for
the source. REPAIR as
necessary. CHANGE the oil
and filter.
z Low oil pressure. zCARRY OUT an oil
pressure test. If not within
specifications, REPAIR as
necessary. REFER to
Section 303 - 00 .
z Worn rocker
arms/fulcrums or
followers. z
CARRY OUT a valve train
analysis. INSTALL new
valve train components as
necessary. REFER to
Section 303 - 01A for 3.8L
engines or Section 303 - 01B
for 4.6L (2V) engines.
z Worn valve guides. zCARRY OUT a valve train
analysis. INSTALL new
valve guides as necessary.
REFER to Section 303 - 01A
for 3.8L engines or
Section 303 - 01B for 4.6L (2V)
engines. Klj . 26 ba
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Section 308 - 02 .
z Grease or oil on the
clutch disc facing. z
CHECK the input shaft
seal and rear main oil
seal. REPAIR as
necessary. INSTALL a
new clutch disc.
REFER to Section 308 -
03A for T50D
transmissions or
Section 308 - 03B for
TR3650 transmissions.
z Clutch disc surface
glazed or damaged. z
INSPECT the clutch
disc surface for a
glazed, hardened or
damage condition.
CARRY OUT a disc
check. INSTALL a new
clutch disc as
necessary. REFER to
Section 308 - 01 .
z Damaged or worn
clutch pressure
plate. z
INSPECT the clutch
pressure plate for wear
or damage. INSTALL a
new clutch pressure
plate as necessary.
REFER to Section 308 -
01 .
z Flywheel surface
damaged or glazed. z
INSPECT the flywheel
for damage or wear.
CARRY OUT a
flywheel runout check.
INSTALL a new
flywheel as necessary.
REFER to Section 303 -
01A for 3.8L engines or
Section 303 - 01B for
4.6L (2V) engines.
z Clutch chatter noise—
noise when clutch
pedal is released at
initial take- off. Clutch is
hard to engage and
disengage z
Pilot bearing worn,
damaged or not
correctly aligned in
bore. z
INSPECT the clutch
pressure plate release
fingers for uneven
wear, clutch
components burnt or a
seized pilot bearing.
INSTALL a new pilot
bearing as necessary.
REFER to Section 308 -
01 .
z Clutch vibration zLoose flywheel
bolts.
z Damaged or loose
clutch pressure
plate.
z Excessive flywheel
runout. z
Go To Pinpoint Test L .
z Transmission
rattling/clattering
noise— noise at idle or
on light acceleration
from a stop. Gear
selection difficult z
Gearshift lever joint
worn or damaged. z
INSTALL a new
gearshift lever. REFER
to Section 308 - 03A for
T50D transmissions or
Section 308 - 03B for
TR3650 transmissions. Klj . 41 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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DIAGNOSIS AND TESTING
Suspension System
Inspection and Verification
1. Road test. zVerify the customer's concern by performing a road test on a smooth road.
2. Inspect tires. zCheck the tire pressure with all normal loads in the vehicle and the tires cold. For
additional information, refer to the vehicle certification (VC) label.
z Verify that all tires are sized to specification.
z Inspect the tires for incorrect wear and damage.
3. Inspect chassis and underbody. zRemove any excessive accumulation of mud, dirt or road deposits from the chassis and
underbody.
4. Inspect for aftermarket equipment. zCheck for aftermarket changes to the steering, suspension, wheel and tire components
(such as competition, heavy duty, etc.) The specifications shown in this manual do not
apply to vehicles equipped with aftermarket equipment.
5. Inspect shock absorbers. All vehicles are equipped with gas- pressurized hydraulic shock absorbers. These shock
absorbers are not adjustable or refillable and cannot be repaired.
zOil Leak: A light film of oil (weepage) on the upper portion of the shock absorber is
permissible and is a result or correct shock lubrication. Weepage is a condition in which a
film of oil accumulates on the thin tube (body) and is normally noticed due to the
collection of dust in this area. If shock absorbers exhibit this weepage condition, they are
functional units and new shock absorbers should not be installed. Leakage is a condition
in which the entire shock absorber body is covered with oil and the oil will drip from the
shock absorber onto the pavement. If condition exists:
„Make sure fluid observed is not from sources other than the shock absorber.
„ Install a new shock absorber, if necessary.
z Vehicle Sag: Many times new shock absorbers are installed in an effort to solve a vehicle
sag concern. Shock absorbers by design are hydraulic damping units only and, unlike
suspension springs, do not support any suspension loads. Therefore, installing a new
shock absorber will not correct a vehicle sag concern.
z Installment in Pairs: In the past it was recommended that new shock absorbers be
installed in pairs if one unit became unrepairable. New shock absorbers no longer need
to be installed in pairs when only one unit is not repairable.
SECTION 204-
00: Suspension System — General Information 2003 Mustang Workshop Manual Visual Inspection Chart
Mechanical Klj . 1 ba
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6. If an obvious cause for an observed or reported condition is found, correct the cause (if
possible) before proceeding to the next step.
7. If the fault is not visually evident, determine the symptom and GO to Symptom Chart .
Symptom Chart z
Front wheel bearing(s)
z Loose or damaged front or rear suspension components
z Loose, damaged or missing suspension fastener(s)
z Damaged spring(s)
z Damaged or leaking strut and spring assemblies
z Damaged or leaking shock absorber(s)
z Worn or damaged suspension bushing(s)
z Loose, worn or damaged steering system components
z Damaged axle components
Symptom Chart Condition
Possible Sources Action
z Dogtracking zExcessive rear
thrust angle. z
CHECK the wheel alignment.
ADJUST as necessary.
z Front or rear
suspension
components. z
INSPECT the front and rear
suspension system. REPAIR
or INSTALL new suspension
components as necessary.
REFER to Section 204 - 01 or
Section 204 - 02 .
z Drive axle
damaged. z
REPAIR as necessary. Refer
to the appropriate section in
Group 205 for the procedure..
z Drift/pull zUnequal tire
pressure. z
ADJUST tire pressure.
z Excessive side-to-
side difference in
caster or camber. z
CHECK the wheel alignment.
ADJUST as necessary.
z Tire forces. zROTATE tires front to rear.
z Unevenly loaded or
overloaded vehicle. z
NOTIFY the customer of
incorrect vehicle loading.
z Steering
components. z
REFER to Section 211 - 00 .
z Brake drag. zREFER to Section 206 - 00 .
z Front bottoming
or riding low z
Strut(s). zINSTALL new strut(s) as
necessary. REFER to Section 204 - 01 .
z Front coil springs
(5310). z
CHECK ride height. INSTALL
new springs as necessary.
REFER to Section 204 - 01 .
z Incorrect tire
wear z
Incorrect tire
pressure (rapid
center rib or inner
and outer edge
wear). z
ADJUST tire pressure. Klj . 2 ba
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Repair the axle as necessary. Make sure the axle lubricant is at the correct level. Refer to
Specifications in this section.
Axle Vent
NOTE:
If a plugged vent cannot be cleared, install a new one.
A plugged vent will cause excessive seal lip wear due to internal pressure buildup. If a leak occurs,
check the vent. Make sure the vent hose is not kinked. Remove the hose from the vent nipple and
clear the hose of any foreign material. While the hose is removed, pass a length of mechanics wire in
and out of the vent to clean it. Connect the hose when done.
Flange Yoke Seal
Leaks at the axle drive pinion seal originate for the following reasons:
zSeal was not correctly installed.
z Poor quality seal journal surface.
Any damage to the seal bore (dings, dents, gouges, or other imperfections) will distort the seal casing
and allow leakage past the outer edge of the axle drive pinion seal.
The axle drive pinion seal can be torn, cut, or gouged if it is not installed carefully. The spring that
holds the axle drive pinion seal against the pinion flange may be knocked out and allow leakage past
the lip.
The rubber lips can occasionally become hard (like plastic) with cracks at the oil lip contact point. The
contact point on the pinion flange may blacken, indicating excessive heat. Marks, nicks, gouges, or
rough surface texture on the seal journal of the pinion flange will also cause leaks.
When a seal leak occurs, install a new seal and check the vent and the vent hose to make sure they
are clean and free of foreign material.
Axle Shaft Seals
Axle shaft oil seals are susceptible to the same kinds of damage as axle drive pinion seals if incorrectly
installed. The seal bore must be clean and the lip handled carefully to avoid cutting or tearing it. The
axle shaft journal surface must be free of nicks, gouges, and rough surface texture.
Differential Seals
Refer to Section 205 - 02A or
Section 205 - 02B .
Analysis of Vibration WARNING: A vehicle equipped with a Traction- Lok® differential will always have both
wheels driving. If only one wheel is raised off the floor and the rear axle is driven by the engine,
the wheel on the floor could drive the vehicle off the stand or jack. Be sure both rear wheels are
off the floor.
Few vibration conditions are caused by the rear axle. On a vibration concern, follow the diagnosis
procedure in Section 100 - 04 unless there is a good reason to suspect the axle.
Tires Klj . 3 ba
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PINPOINT TEST F: HYDRO-
BOOST ERRATIC OPERATION, STICKS,
BINDS OR GRABS z
Check accessory drive belt tension and
condition. Refer to Section 303 - 05 .
z Is the accessory drive belt OK? Yes
GO to
E3 .
No
INSTALL a new accessory drive belt.
REFER to Section 303 - 05 .
E3 CHECK POWER STEERING HOSES
z
Check power steering pressure hoses, power
steering gear pressure hoses and power
steering return hose for cracks or leaks.
z Do power steering pressure hose, power
steering gear hose and power steering
return hose check OK? Yes
GO to
E4 .
No
INSTALL new hoses as necessary.
REFER to Section 211 - 00 .
E4 CHECK BRAKE PEDAL LINKAGE
z
Check brake pedal linkage for binding or
sticking operation.
z Does pedal linkage check OK? Yes
GO to
E5 .
No
INSTALL new pedal linkage as necessary.
REFER to Section 206 - 06 .
E5 CHECK POWER STEERING PUMP SPEED
z
Check engine idle speed against
specifications.
z Is engine idle speed OK? Yes
GO to
E6 .
No
SET engine idle speed to specification.
REFER to Powertrain Control/Emissions
Diagnosis (PC/ED) manual. E6 CHECK FOR PLUGGED RETURN HOSE
z
NOTE: The return hose from the oil cooler to
the power steering reservoir has an in- line
filter in the hose.
z Disconnect power steering return hose from
power steering fluid cooler and power
steering pump reservoir.
z Pass air through hose from the oil cooler end.
z Is hose plugged? Yes
INSTALL a new power steering return
hose.
No
GO to
E7 .
E7 CHECK POWER STEERING PUMP FLOW
AND RELIEF z
Test power steering pump for correct flow
and relief pressure. Refer to Section 211 - 00 .
z Is power steering pump operating
correctly? Yes
INSTALL a new power brake hydro-
boost
unit. REFER to Section 206 - 07 .
No
INSTALL a new power steering pump.
REFER to Section 211 - 02 .
Test Step Result / Action to
Take F1 CHECK SUPPLY HOSE
z
Check for obstructions in power steering return hose and Yes Klj . 11 ba
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Power Steering Pump —
CII
Power Steering Pump — CIII
Power Steering Gear Identification CAUTION: Always use the ID code when ordering service parts. The steering gear identification code is stamped into the housing. 2 — To left turn port
3 — To right turn port
4 — Return port (out)
5 — Pressure port (in)
6 — Oil flow —
right turn 7 — Air transfer tube (between bellows) Klj . 4 ba
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