past FORD MUSTANG 2003 Workshop Manual

Neutral Coast Down Speed Test
To carry out this test, proceed as follows:
zDrive at a higher rate of speed than where the concern occurred when carrying out the Slow
Acceleration Test.
z Place the transmission in NEUTRAL and coast down past the speed where the concern occurs.
z The concern is vehicle speed- related if duplicated while carrying out this test. This eliminates
the engine and the torque converter as sources.
z If the concern was not duplicated while carrying out this test, carry out the Downshift Speed
Test to verify if the concern is engine speed related.
z Proceed as necessary.
Downshift Speed Test
To carry out this test, proceed as follows:
zShift into a lower gear than the gear used when carrying out the Slow Acceleration Test.
z Drive at the engine rpm where the concern occurs.
z The concern is engine speed related if duplicated while carrying out this test. This eliminates the
tires, wheels, brakes and the suspension components as sources.
z If necessary, repeat this test using other gears and NEUTRAL to verify the results.
z Proceed as necessary.
Steering Input Test
To carry out this test, proceed as follows:
zDrive at the speed where the concern occurs, while making sweeping turns in both directions.
z If the concern goes away or gets worse, the wheel bearings, hubs, U- joints (contained in the
axles of 4WD applications), and tire tread wear are all possible sources.
z Proceed as necessary.
Brake Test
To carry out this test, proceed as follows:
zWarm the brakes by slowing the vehicle a few times from 80–32 km/h (50–20 mph) using light
braking applications. At highway speeds of 89–97 km/h (50– 60 mph), apply the brake using a
light pedal force.
z Accelerate to 89–97 km/h (55–60 mph).
z Lightly apply the brakes and slow the vehicle to 30 km/h (20 mph).
z A brake vibration noise can be felt in the steering wheel, seat or brake pedal. A brake noise can
be heard upon brake application and diminish when the brake is released.
Road Test Over Bumps
To carry out this test, proceed as follows: Klj . 7 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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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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8.
CAUTION: Differential seal damage will occur if installing the halfshaft without the
special tool.
Install the special tool.
9. Position the halfshaft for installation.
10. Seat the CV joint stub shaft in the differential side gear. 1. Slide the stub shaft into the differential housing until the shaft splines are past the differential seal.
2. Remove the special tool.
3. Align the stub shaft splines and the side gear splines, and slide the stub shaft into the gear until it seats.
„When seated, the axle circlip will lock the stub shaft in the differential side gear.
Check the circlip engagement by attempting to pull the inboard CV joint out of the
differential side gear. If the circlip has not seated, push the CV joint inward until
the circlip is fully engaged in the differential side gear. Klj . 9 ba
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4. Position the halfshaft for installation.
5. Seat the CV joint stub shaft in the differential side gear.
1. Slide the stub shaft into the axle housing until the shaft splines are past the differential seal.
2. Remove the special tool.
3. Align the stub shaft splines and the side gear splines, and slide the stub shaft into the gear until it seats.
„When seated, the axle circlip will lock the stub shaft in the differential side gear.
Check the circlip engagement by attempting to pull the inboard CV joint out of the
differential side gear. If the circlip has not seated, push the CV joint inward until
the circlip is fully engaged in the differential side gear.
6. Connect the axle shaft to the hub. 1. Making sure the serrations on the shaft line up with the serrations in the hub, install the axle shaft into the hub.
2. Install a new retainer. Do not tighten the retainer at this time. Klj . 6 ba
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REMOVAL AND INSTALLATION
Pads
Removal
1. Remove brake master cylinder filler cap (2162). Check brake fluid level in brake master cylinder reservoir (2K478). Remove fluid until brake master cylinder reservoir is half full.
2. Raise and support the vehicle. For additional information, refer to Section 100 - 02 .
3. Remove the wheel and tire assembly. For additional information, refer to Section 204 - 04 .
4. CAUTION: Install new pads if worn to or past the specified thickness above the
metal backing plate or rivets. Install pads in complete axle sets.
Inspect the pads for wear and contamination.
5. Remove the caliper bolts. 1. Hold the guide pins stationary.
2. Remove and discard the caliper bolts.
SECTION 206-
03: Front Disc Brake 2003 Mustang Workshop Manual Klj . 1 ba
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REMOVAL AND INSTALLATION
Brake Pads —
Cobra
Removal 1. Remove brake fluid in the master cylinder reservoir until the reservoir is half full.
2. Raise and support the vehicle. For additional information, refer to Section 100 - 02 .
3. Remove the tire and wheel assembly. For additional information, refer to Section 204 - 04 .
4. CAUTION: Install new pads if worn to or past the specified thickness above the
metal backing plate or rivets. Install new pads in complete axle sets.
Inspect the pads for wear and contamination.
5. Remove the caliper locating pin E- clip.
6. Remove the caliper locating pin.
SECTION 206-
03: Front Disc Brake 2003 Mustang Workshop Manual Klj . 1 ba
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REMOVAL AND INSTALLATION
Pads
Removal
1. Use a suitable suction device to lower the brake fluid level in the master cylinder reservoir.
2. Raise and support the vehicle. For additional information, refer to Section 100 - 02 .
3. Remove the wheel and tire assembly. For additional information, refer to Section 204 - 04 .
4. Inspect the pads for wear or contamination, install new if worn to or past specification.
5. CAUTION: Do not allow the rear disc brake caliper (2552) to hang from the rear
wheel brake hose (2A442).
Remove the rear disc brake caliper bolts and position the caliper aside.
6. Remove the brake pads.
SECTION 206-
04: Rear Disc Brake 2003 Mustang Workshop Manual Special Tool(s)
Rear Caliper Piston Adjuster
206-
026 (T87P-2588- A) Klj . 1 ba
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1. If compression improves considerably, piston rings are faulty.
2. If compression does not improve, valves are sticking or seating incorrectly.
3. If two adjacent cylinders indicate low compression pressures and squirting oil on each piston
does not increase compression, the head gasket may be leaking between cylinders. Engine oil
or coolant in cylinders could result from this condition.
Use the Compression Pressure Limit Chart when checking cylinder compression so that the
lowest reading is within 75 percent of the highest reading.
Cylinder Leakage Detection
When a cylinder produces a low reading, use of the Engine Cylinder Leak Detection/Air Pressurization
Kit will be helpful in pinpointing the exact cause.
The leakage detector is inserted in the spark plug hole, the piston is brought up to dead center on the
compression stroke, and compressed air is admitted.
Once the combustion chamber is pressurized, a special gauge included in the kit will read the
percentage of leakage. Leakage exceeding 20 percent is excessive.
While the air pressure is retained in the cylinder, listen for the hiss of escaping air. A leak at the intake
valve (6507) will be heard in the throttle body (9E926). A leak at the exhaust valve (6505) can be
heard at the tail pipe. Leakage past the piston rings will be audible at the positive crankcase ventilation
(PCV) connection. If air is passing through a blown head gasket to an adjacent cylinder, the noise will
be evident at the spark plug hole of the cylinder into which the air is leaking. Cracks in the cylinder
block or gasket leakage into the cooling system may be detected by a stream of bubbles in the radiator
(8005).
Oil Consumption Test
The following diagnostic procedure is used to determine the source of excessive internal oil
consumption. 1. NOTE: Oil use is normally greater during the first 16,100 km (10,000 miles) of service. As
mileage increases, oil use generally decreases. Vehicles in normal service should get at least
1,450 km per liter (900 miles per quart) after 16,000 km (10,000 miles) of service. High speed
driving, towing, high ambient temperature and other factors may result in greater oil use.
Define excessive oil consumption, such as the number of miles driven per liter (quart) of oil
used. Also determine customer's driving habits, such as sustained high speed operation,
towing, extended idle and other considerations.
2. Verify that the engine has no external oil leak as described under Engine Oil Leaks in the Diagnosis and Testing portion of this section.
3. Verify that the engine has the correct oil level dipstick (6750).
4. Verify that the engine is not being run in an overfilled condition. Check the oil level at least five minutes after a hot shutdown with the vehicle parked on a level surface. In no case should the
level be above MAX or the letter F in FULL. If significantly overfilled, carry out Steps 6a through
6d.
5. Verify the spark plugs are not oil saturated. If the spark plugs are oil saturated and compression is good it can be assumed the valve seals or valve guides are at fault. Klj . 9 ba
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Engines need oil to lubricate the following internal components:
zcylinder block cylinder walls
z pistons and piston, pin and rings (6102)
z intake and exhaust valve stems
z intake and exhaust valve guides
z all internal engine components
When the pistons move downward, a thin film of oil is left on the cylinder walls. As the vehicle is
operated, some oil is also drawn into the combustion chambers past the intake and exhaust valve
stem seals and burned.
The following is a partial list of conditions that can affect oil consumption rates:
zengine duty cycle
z operator driving habits
z ambient temperature
z quality and viscosity of the oil
Operation under varying conditions can frequently be misleading. A vehicle that has been run for
several thousand miles on short trips or in below- freezing ambient temperatures may have consumed
a "normal" amount of oil. However, when checking the engine oil level, it may measure up to the FULL
or MAX on the oil level dipstick due to dilution (condensation and fuel) in the engine crankcase. The
vehicle might then be driven at high speeds on the highway where the condensation and fuel boil off.
The next time the engine oil is checked, it may appear that a liter (quart) of oil was used in about 160
km (100 miles). This perceived 160 km (100 miles) per liter (quart) oil consumption rate causes
customer concern even though the actual overall oil consumption rate is about 2,400 km (1,500 miles)
per liter (quart).
Make sure the selected engine oil meets the current recommended API performance category with
SAE viscosity grade as shown in the vehicle Owner's Guide. It is also important that the engine oil is
changed at the intervals specified. Refer to the vehicle Owner's Guide.
Oil Pressure Test
1. Disconnect and remove the oil pressure sensor (9278) from the engine.
2. Connect the Oil Pressure Gauge to the oil pressure sender oil galley port.
3. Run the engine until normal operating temperature is reached.
4. Run the engine at the specified rpm and record the gauge reading.
5. The oil pressure should be within specifications; refer to the specification chart in the appropriate engine section.
6. If the pressure is not within specification, check the following possible sources: zinsufficient oil
z oil leakage
z worn or damaged oil pump
z oil pump screen cover and tube (6622)
z excessive main bearing clearance Klj . 13 ba
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