roof FORD MUSTANG 2003 Workshop Manual

glass
zAir traveling up
windshield molding
along A- pillar. z
INSTALL foam rope the
full length of the A- pillar.
z Windshield/backlite
misaligned or not
installed correctly. z
REINSTALL the
windshield/backlite.
z Rear hood seal at base
of windshield
misaligned/damaged. z
REALIGN or INSTALL a
new seal as necessary.
z Air leak at cowl zCowl gasket
misaligned/damaged. z
REALIGN or INSTALL a
new seal as necessary.
z Air leak around
liftgate perimeter z
Loose fit seal. zPINCH the seal carrier to
improve retention on the
seal flange or INSERT
foam in the carrier.
z Seal misaligned. zREINSTALL the seal.
z Liftgate misaligned. zREALIGN the liftgate.
CHECK the liftgate fit in
the body opening and
ADJUST as necessary.
z Scuff plate misaligned. zREINSTALL the scuff
plate.
z Seal or seal push pins
damaged. z
INSTALL a new seal.
z Air leak around
the liftgate flip
window
perimeter z
Loose fit seal. zPINCH the seal carrier to
improve the retention to
the seal flange.
z Seal misaligned. zREINSTALL the seal.
z Glass misaligned. zREALIGN the glass.
z Seal damaged. zINSTALL a new seal.
z Wind noise from
antenna z
Shape of antenna. zINSTALL an antenna boot
or a spiral antenna.
z Air leak around
antenna cable access
hole. z
INSPECT the antenna
access hole grommet.
REPAIR as necessary.
z Air leak from
closed roof
opening panel z
Seal installed
incorrectly. z
REINSTALL the seal.
z Roof opening panel
glass/door misaligned. z
REALIGN the roof
opening panel glass/door.
z Roof opening panel
damaged. z
INSTALL a new roof
opening panel.
z Buffeting from an
open roof
opening panel z
Wind deflector
inoperative/damaged. z
REPAIR or INSTALL a
new wind deflector as
necessary.
z Wind deflector height
incorrect. z
ADJUST the wind
deflector higher.
z Wind noise
created by
airflow over or
behind body
panels z
Fender splash shield
misaligned. z
REALIGN the fender
splash shield. Klj . 14 ba
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with header.
z Convertible top
flapping with the
top up z
Vinyl top contacting
interior headliner. z
Working from front to
back, INSTALL a 6.35 mm
(0.25 in) foam sheet
between the headliner
and the vinyl top at the
suspected area. Allow a
clearance of 50 mm (2 in)
-75 mm (3 in) away from
the roof bows and the side
rails.
z Noise from roof
rack z
Roof rack rails or
crossbars loose. z
TIGHTEN the fasteners.
z Roof rack fasteners
missing. z
INSTALL the approved
fasteners.
z Roof rack crossbars
installed backward. z
REINSTALL the
crossbars.
z Roof rack rub strips
partially lifting from
roof. z
REAPPLY adhesive or
fasteners or INSTALL new
rub strips as necessary.
z Roof rack gaskets
loose or misaligned. z
REINSTALL the gasket.
z Wind noise from
bug
shield/exterior
windshield sun
visor z
Turbulence created by
location and shape. z
REMOVE per customer
direction if it is a dealer
installed option. Symptom Chart—
Brake Noise/Vibration Condition
Possible Sources Action
z Rattling noise zCaliper
mounting bolts
loose. z
CHECK the caliper bolts.
TIGHTEN to specifications.
REFER to Section 206 - 03
for front disc brakes or
Section 206
- 04 for rear
disc brakes.
z Damaged or
worn caliper
pins or
retainers. z
CHECK the caliper pins
and retainers for lubrication
and correct fit. LUBRICATE
or INSTALL new
components as necessary.
z Missing or
damaged anti-
rattle clips or
springs. z
CHECK the brake pads for
missing clips or broken
springs. INSTALL new
components as necessary.
REFER to Section 206 - 03
for front disc brakes or
Section 206
- 04 for rear
disc brakes.
z Loose brake
disc shield. z
TIGHTEN the brake disc
shield bolts to specification.
REFER to Section 206 - 03 .
z Clicking noise— with
brakes applied with
ABS brakes z
ABS hydraulic
control unit. z
Acceptable condition.
z Squealing noise— zDisc brake zAcceptable condition. Klj . 16 ba
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NOTE:
If the axle shaft assembly is removed, check runout of the shaft itself. The forged (unmachined)
part of the shaft is allowed to have as much as 3.0 mm (0.120 inch) runout. This alone will not cause a
vibration condition.
1. Position the special tool on the wheel hub or axle flange face, as close to the outer edge as possible. Zero the indicator to allow the pointer to deflect either way.
2. Rotate the hub or flange one full turn and note the maximum and minimum readings. The difference between the maximum and minimum readings will be the total face runout. The
runout must not exceed 0.127 mm (0.005 inch).
Drive Pinion Stem and Pinion Flange
Check the pinion flange runout when all other checks have failed to show the cause of vibration.
One cause of excessive pinion flange runout is incorrect installation of the axle drive pinion seal.
Check to see if the spring on the seal lip has been dislodged before installing the ring gear and pinion.
Axle Noise
NOTE: Before disassembling the axle to diagnose and correct gear noise, eliminate the tires, exhaust,
trim items, roof racks, axle shafts and wheel bearings as possible causes. Follow the diagnostic
procedures in Section 100 - 04 .
The noises described as follows usually have specific causes that can be diagnosed by observation as
the unit is disassembled. The initial clues are the type of noise heard during the road test.
Gear Howl and Whine
Howling or whining of the ring gear and pinion is due to an incorrect gear pattern, gear damage or
incorrect bearing preload.
Bearing Whine
Bearing whine is a high- pitched sound similar to a whistle. It is usually caused by worn/damaged
pinion bearings, which are operating at driveshaft speed. Bearing noise occurs at all driving speeds.
This distinguishes it from gear whine which usually comes and goes as speed changes.
As noted, pinion bearings make a high- pitched, whistling noise, usually at all speeds. If however there
is only one pinion bearing that is worn/damaged, the noise may vary in different driving phases. If
pinion bearings are scored or damaged or there is a specific pinion bearing noise, new pinion bearings
must be installed. A worn/damaged bearing will normally be obvious at disassembly. Examine the
large end of the rollers for wear. If the pinion bearings original blend radius has worn to a sharp edge, a new pinion bearing must be installed. Klj . 6 ba
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z
Do not drop assembled halfshafts. The impact will cut the boots from the inside without
evidence of external damage.
z Inspect all machined surfaces and splines for damage.
Wheel and Tire Balancing, Rear
WARNING: Do not balance the rear wheels and tires while mounted on the vehicle.
Possible tire disintegration, differential or halfshaft failure can result, causing personal injury
or extensive component damage. Use an off- vehicle wheel and tire balancer only.
Hoisting
CAUTION: Use a frame- contact hoist only. Vehicle or component damage can result if
other types of hoists are used.
Never raise the vehicle using the halfshafts as lift points.
Undercoating and Rustproofing
During undercoating and rustproofing procedures, protect the boots from the coating materials.
Foreign materials on the rubber boots will cause extreme advanced wear. Klj . 3 ba
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Brake Pressure Control Valve
The brake pressure control valve proportions the pressure to the rear brakes.
zWhen the brake pedal is applied, brake fluid pressure passes through the proportioning valves
to the rear brake system until the valve split point is reached.
z Above its split point, the proportioning valve begins to reduce the hydraulic pressure to the rear
brakes, creating a balanced braking condition between the front and rear brakes.
Brake Tubes and Hoses CAUTION: Never use copper tubing. It is subject to fatigue, cracking and corrosion which
could result in brake tube failure.
Steel tubing is used throughout the brake hydraulic system. All brake tube fittings must be correctly
double flared to provide strong leakproof connections. When bending the tubing to fit the underbody or
rear axle contours, be careful not to kink or crack the tube.
If a section of brake tube is damaged, the entire section must be removed and a new tube of the same
type, size, shape and length installed.
When replacing hydraulic brake tubing, hoses, or connectors, tighten all connections securely. After
installation, bleed the brake system. For additional information, refer to Section 206 - 00 . Klj . 3 ba
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DESCRIPTION AND OPERATION
Insulation
Insulation is comprised of urethane, PVC, and recycled felt. Insulation is installed:
zUnder the roof panel (50202).
z Above and below the instrument panel (04304).
z On the cowl sides.
z Over the front and rear floor areas.
z On a Coupe, in the B and C- pillar sections.
z Under the hood.
SECTION 501-
00: Body System — General Information 2003 Mustang Workshop Manual Klj . 1 ba
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SPECIFICATIONS
SECTION 501-
08: Exterior Trim and Ornamentation 2003 Mustang Workshop Manual Torque Specifications
Description Nm lb-
in Hood scoop 3 27
Radiator grille screws 6 53
Rear spoiler nuts/screws 9 80
Roof side moulding screws 3 27
Roof side moulding nuts 3 27 Klj . 1 ba
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DESCRIPTION AND OPERATION
Exterior Trim and Ornamentation
The exterior trim and ornamentation consists of the following components:
zbody side scoop
z hood scoop (if equipped)
z front spoiler (Mach 1)
z radiator grille
z rear spoiler (if equipped)
z rocker panel moulding
z roof side moulding
SECTION 501-
08: Exterior Trim and Ornamentation 2003 Mustang Workshop Manual Klj . 1 ba
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REMOVAL AND INSTALLATION
Moulding —
Roof Side
Removal and Installation 1. Remove the weatherstrip.
2. Remove the exterior roof side moulding screws.
3. Remove the interior roof side moulding screws. 4. Remove the roof side moulding screw. SECTION 501-
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5. Release the clips.
1. Lift up to release the two clips.
2.NOTE: Grasp the roof side moulding and lift up to release the money clip.
Remove the money clip.
6. Remove the upper quarter trim panel. For additional information, refer to Section 501 - 05 .
7. Remove the nuts and the roof side moulding. Klj . 2 ba
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