seat adjustment FORD MUSTANG 2003 Workshop Manual

GENERAL PROCEDURES
Toe Adjustment —
Front
1. Start the engine and center the steering wheel.
2. Turn the engine off, and hold the steering wheel in the straight forward position by attaching a rigid link from the steering wheel to the seat.
3. Check the toe settings. Follow the manufacturer's instructions.
4. Remove the clamps.
5. Loosen the nuts. zClean and lubricate the nut(s) and front wheel spindle tie- rod threads.
6. NOTE: Do not allow the steering gear bellows to twist when the front wheel spindle tie- rod
(3280) is rotated.
Rotate the front wheel spindle tie- rods.
SECTION 204-
00: Suspension System — General Information 2003 Mustang Workshop Manual Klj . 1 ba
32003 Mustang Workshop Manual
17. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_4464/S3B~us~en~ ...

2. Install the bearing caps.
3. Install the four bolts.
11. NOTE: Use only flat, clean drive pinion bearing adjustment shims (4663).
NOTE: Selection of too thick a shim results in a deep tooth contact at final assembly. Do not
attempt to force the shim between the special tools. A slight drag indicates correct shim
selection.
Use a drive pinion bearing adjustment shim as a gauge for shim selection.
zAfter determining the correct shim thickness, remove the special tools.
12. Position the correct thickness drive pinion bearing adjustment shim and the differential pinion bearing on the drive pinion gear. Using a suitable press and the special tools, press the
differential pinion bearing until it seats firmly against the drive pinion gear.
13. Place a new collapsible spacer on the pinion shaft against the pinion stem shoulder. Klj . 9 ba
132003 Mustang Workshop Manual
17. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_4464/S3B~us~en~ ...

Tighten the special tool to specification.
9. NOTE: Offset the special tool to obtain an accurate reading.
Rotate the special tool several half- turns to make sure the differential pinion bearings seat
correctly and position the special tool as shown.
10. Install the special tool. 1. Position the special tool.
2. Install the bearing caps.
3. Install the four bolts.
11. NOTE: Use only flat, clean drive pinion bearing adjustment shims (4663).
NOTE: Selection of too thick a shim results in a deep tooth contact at final assembly. Do not
attempt to force the shim between the special tools. A slight drag indicates correct shim
selection.
Use a drive pinion bearing adjustment shim as a gauge for shim selection.
zAfter determining the correct shim thickness, remove the special tools. Klj . 8 ba
132003 Mustang Workshop Manual
17. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_4464/S3B~us~en~ ...

12. Position the correct thickness drive pinion bearing adjustment shim and the differential pinion
bearing on the drive pinion gear. Using a suitable press and the special tools, press the
differential pinion bearing until it seats firmly against the drive pinion gear.
13. Place a new collapsible spacer on the pinion shaft against the pinion stem shoulder.
14. Install the outer differential pinion bearing.
15. Install the rear axle drive pinion shaft oil slinger. Klj . 9 ba
132003 Mustang Workshop Manual
17. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_4464/S3B~us~en~ ...

Rotate the special tool several half turns to seat the pinion bearings. Position the special tool as
shown.
6. Install the special tool. 1. Position the special tool on the differential housing differential bearing seat.
2. Install the differential bearing caps.
3. Install the bolts.
7. Use a drive pinion bearing adjustment shim as a gauge for shim selection. Check the drive pinion bearing adjustment shim thickness between the Gauge Block and the Gauge Tube. A
slight drag indicates correct shim selection.
8. Remove all of the special tools.
9. CAUTION: Use the same pinion bearings and drive pinion bearing adjustment shim
from the drive pinion bearing adjustment shim selection procedure for final assembly.
Position the drive pinion bearing adjustment shim and the pinion bearing on the drive pinion
gear stem.
10. Using the special tools and a suitable press, firmly seat the drive pinion bearing adjustment shim and pinion bearing on the drive pinion gear stem. Klj . 17 ba
352003 Mustang Workshop Manual
17. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_4464/S3B~us~en~ ...

z
incorrectly functioning valve tappet
z air in lubrication system
z excessive valve guide wear
z low oil pressure
Excessive collapsed valve tappet gap can be caused by loose rocker arm seat bolts/nuts, incorrect
initial adjustment or wear of valve tappet face, or worn roller valve tappets, push rod (6565), rocker
arm (6564), rocker arm seat or valve tip. With valve tappet collapsed, check gap between the valve tip
and the rocker arm to determine if any other valve train parts are damaged, worn or out of adjustment.
An incorrectly functioning valve tappet can be sticking, caused by contaminants or varnish inside the
tappet. The tappet can have a check valve that is not functioning correctly, which can be caused by an
obstruction, such as dirt or chips that prevent the check valve from closing, or a broken check valve
spring. A tappet with a leakdown time out of specification can cause tappet noise. If no other cause for
noisy valve tappets can be found, the leakdown rate should be checked and new valve tappets
installed if found to be out of specification.
Assembled valve tappets can be tested with Hydraulic Tappet Leakdown Tester to check the leakdown
rate. The leakdown rate specification is the time in seconds for the plunger to move a specified
distance while under a 22.7 kg (50 lb) load.
Air bubbles in the lubrication system will prevent the valve tappet from supporting the valve spring
load. This can be caused by too high or too low an oil level in the oil pan or by air being drawn into the
system through a hole, crack or leaking gasket on the oil pump screen cover and tube. Klj . 17 ba
172003 Mustang Workshop Manual
17. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_4464/S3B~us~en~ ...

C1 VERIFY DIAGNOSTIC TROUBLE CODES
z
Select PARK.
z Key in OFF position.
z NOTE: DTC codes P0705 and P0708 cannot be set by
an incorrectly adjusted digital TR sensor.
z Carry out on board diagnostic test.
z Are only DTC codes P0705, P0708 present? Yes
GO to
C4 .
No
GO to C2 .
C2 VERIFY DIGITAL TRANSMISSION RANGE SENSOR
ALIGNMENT z
Check to make sure the digital TR sensor harness
connector is fully seated, pins are fully engaged in
connector and in good condition before proceeding.
z Apply the parking brake.
z Select NEUTRAL.
z Disconnect the shift cable/linkage from the manual lever.
z Verify that the digital TR Sensor Alignment Tool fits in
the appropriate slots.
z Is the digital TR sensor adjustment OK? Yes
GO to
C3 .
No
ADJUST the digital TR sensor.
PLACE transmission range
selector lever in P and CLEAR
DTCs. REPEAT OBD Tests.GO
to C3 .
C3 VERIFY SHIFT CABLE/LINKAGE ADJUSTMENT
z
Place the manual lever in the overdrive position.
z Select DRIVE.
z Reconnect the shift cable/linkage.
z Verify that the shift cable/linkage is adjusted OK. Refer
to Section 307 - 05 .
z Is the shift cable/linkage adjusted OK? Yes
GO to
C4 .
No
ADJUST the shift cable/linkage.
REFER to Section 307 - 05 .
C4 CHECK ELECTRICAL SIGNAL OPERATION
z
Select PARK.
z Disconnect: Digital TR Sensor.
z CAUTION: Do not pry on connector. This will
damage the connector and result in a transmission
concern.
z Press the button and pull out on the digital TR harness
connector.
z Inspect both ends of the connector for damage or
pushed- out pins, corrosion, loose wires and missing or
damaged seals.
z Are the connector, pins and harness damaged? Yes
REPAIR as required. CLEAR
DTCs and REPEAT OBD
Tests.
No
If diagnosing a DTC, GO to
C5
.
If diagnosing a starting concern
or a reversing lamp concern,
GO to C10 .
C5 CHECK ELECTRICAL SYSTEM OPERATION (DIGITAL
TR AND PCM) z
Key in OFF position.
z Connect the diagnostic tool.
z Connect: Digital TR Sensor.
z Key in ON position.
z Enter the following diagnostic mode on the diagnostic
tool: TR PIDS TR, TR_D, TR_V.
z Move transmission range selector lever into each gear
and stop.
z Observe any of the following PIDs, TR and TR_D, TR_V
(vehicle dependent) while wiggling harness, tapping on
sensor, or driving the vehicle. Use PIDs TR, and TR_D
for DTCs P0705, P1704, and P1705. Use PIDs TR, and
TR_V for DTC P0708.
z Compare the PIDs to the Digital Transmission Range
(TR) Sensor Diagnosis Chart.
z Do the PIDs TR, TR_D and TR_V match the Digital
Transmission Range (TR) Sensor Diagnosis chart,
and does the TR_D PID remain steady when the Yes
The problem is not in the digital
TR sensor system. REFER to
Diagnosis By Symptom
in this
section for further diagnosis.
No
If TR_D changes when wiggling
harness, tapping on the sensor,
or driving the vehicle, the
problem may be intermittent.
GO to C6 . Klj . 10 ba
222003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2748/S3B~us~en~ ...

Condition.
Shift Linkage
·
Damaged or incorrectly
adjusted ·
Inspect and repair as required. Verify transmission shift cable
adjustment; refer to Section 307 - 05 . Adjust transmission shift cable
as necessary. After repairing transmission shift cable, verify the digital
transmission range (TR) sensor is correctly adjusted. Adjust the
digital TR sensor as necessary. Incorrect Pressures
·
Low forward clutch
pressure, low line
pressure ·
Check pressure at line and forward clutch tap. Refer to Line Pressure
Chart for specification. If pressures are low, check the following
components: oil filter and seal assembly, main controls, pump
assembly, forward clutch assembly. Fluid Filter and Seal
Assembly
·
Plugged, damaged ·
Install a new filter and seal assembly. ·
Filter seal damaged Main Controls
·
3- 4 shift valve, main
regulator valve, manual
valve — stuck,
damaged ·
Inspect for damage. Repair as required. ·
Bolts not tightened to
specifications ·
Tighten bolts to specifications. ·
Gaskets damaged ·
Inspect gaskets for damage and install a new gasket. ·
2- 3 accumulator and
seals damaged ·
Inspect piston, seals and bore for damage. Repair as required. ·
Pressure regulator
valve ·
Inspect the diameter for wear. Pump Assembly
·
Bolts not tightened to
specifications ·
Tighten bolts to specifications. ·
Porosity/cross
leaks/ball missing or
leaking, plugged hole ·
Inspect for porosity and leaks. Repair as required. ·
No. 3 and No. 4 seal
rings damaged ·
Inspect seals for damage. Repair as required. ·
Gaskets damaged ·
Inspect for damage and install a new gasket. Forward Clutch
Assembly
·
Seals, piston damaged ·
Inspect seals for damage. Repair as required. ·
Check balls damaged,
missing, mislocated,
not seating correctly ·
Inspect for mislocation, poor seating, damage. Install a new cylinder
as required. ·
Friction elements
damaged or worn ·
Check for abnormal wear, damage. Repair as required. One-
Way Clutch
Assembly (Planetary) ·
Worn, damaged or
assembled incorrectly ·
Inspect for damage. Repair as required. Output Shaft Klj . 4 ba
312003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2748/S3B~us~en~ ...

the engine mounts
Incorrect Pressures
·
High forward clutch
pressure, high line
pressure, high EPC
pressure ·
Check pressure at line, EPC and forward pressure taps. Refer to
Line Pressure Chart for specifications. If pressures are high, check
the following possible components: main controls, pump assembly. Main Controls
·
Main regulator valve
stuck, damaged ·
Inspect and repair as required. ·
Bolts not tightened to
specifications ·
Tighten bolts to specifications. ·
Gaskets damaged ·
Inspect for damage and install a new gasket. ·
EPC solenoid stuck or
damaged ·
Inspect for damage or contamination. Carry out EPC test in Routine
204. Repair as required. Case
·
2- 3 accumulator
seal/retainer stuck,
damaged ·
Inspect for damage. Repair as required. Pump Assembly
·
Bolts not tightened to
specifications ·
Tighten bolts to specifications. ·
Porosity/cross leaks ·
Inspect for porosity/leaks. Install a new pump as required. ·
Gaskets damaged ·
Inspect for damage and install a new gasket. Forward Clutch Assembly
·
Check balls missing or
damaged ·
Inspect for mislocation, poor seating, damage. Install a new forward
clutch cylinder. ·
Friction element
damaged or worn ·
Inspect for damage. Repair as required. ·
Forward clutch wave
spring damaged ·
Inspect for damage. Repair as required. ·
Forward clutch return
spring damaged ·
Inspect for damage. Repair as required.
Engagement Concern: Delayed/Soft Reverse Possible Component Reference/Action
205 —
ELECTRICAL
ROUTINE ·
No Electrical Concerns 305 —
HYDRAULIC/MECHANICAL ROUTINE Fluid
·
Incorrect level ·
Adjust fluid to correct level. ·
Condition ·
Inspect condition of fluid. Shift Linkage
·
Damaged or incorrectly
adjusted ·
Inspect and repair as required. Verify transmission shift cable
adjustment; refer to Section 307 - 05 . Adjust transmission shift cable
as necessary. After repairing transmission shift cable, verify that the
digital TR sensor is correctly adjusted. Adjust the digital TR sensor Klj . 8 ba
312003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2748/S3B~us~en~ ...

Possible Component Reference/Action
206 —
ELECTRICAL
ROUTINE ·
No Electrical Concerns 306 —
HYDRAULIC/MECHANICAL ROUTINE Fluid
·
Incorrect level ·
Adjust fluid to correct level. ·
Condition ·
Inspect condition of fluid. Shift Linkage
·
Damaged or incorrectly
adjusted ·
Inspect and repair as required. Verify transmission shift cable
adjustment; refer to Section 307 - 05 . Adjust transmission shift cable
as necessary. After repairing transmission shift cable, verify that the
digital TR sensor is correctly adjusted. Adjust the digital TR sensor as
necessary. Incorrect Pressures
·
Low forward clutch
pressure, low line
pressure, low EPC
pressure ·
Check pressure at line, forward clutch and EPC taps; refer to Line
Pressure Chart for specifications. If pressures are low, check the
following components: oil filter and seal assembly, main controls and
pump assembly. Fluid Filter and Seal
Assembly
·
Plugged, damaged ·
Install a new filter and seal assembly. ·
Filter seal damaged Main Controls
·
3- 4 shift valve, main
regulator valve stuck or
damaged ·
Inspect and repair as required. ·
Bolts not tightened to
specifications ·
Tighten bolts to specifications. ·
Gaskets damaged ·
Inspect for damage and repair as required. Case
·
2- 3 or 1- 2 accumulator,
bore damaged or stuck ·
Inspect for damage. Repair as required. Pump Assembly
·
Bolts not tightened to
specification ·
Tighten bolts to specifications. ·
Porosity/cross leaks ·
Inspect pump assembly. Repair as required. ·
Gaskets damaged ·
Inspect for damage. Repair as required. ·
No. 3 and No. 4 seal
rings damaged ·
Inspect for damage. Repair as required. Forward Clutch
Assembly
·
Seals, piston damaged ·
Inspect for damage. Repair as required. ·
Check balls missing,
damaged ·
Inspect for mislocation, poor seating, damage. Install a new cylinder
as required. ·
Friction elements
damaged, worn ·
Check for damage. Repair as required. Klj . 10 ba
312003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2748/S3B~us~en~ ...