service FORD MUSTANG 2003 Workshop Manual

NOTE:
Powertrain calibration information is limited to a maximum of five characters per line on the
Vehicle Certification Label. Because of this, calibration identification consisting of more than five
characters will wrap to the second line on the VC label.
Powertrain calibration information is printed in the lower right corner of the Vehicle Certification Label.
Only the base calibration information is printed. Revision levels will not appear, however, this
information can be found in the On Line Automotive Service Information System (OASIS). For the
current model year, Ford Motor Company is using three different protocols which describe powertrain
base calibration. These protocols are designed to provide worldwide standardization for vehicle
calibration. If the electronic calibration strategy has been used since 1998 and carried into the current
model year, protocol 1 will be used. Refer to Protocol 1 below. If the electronic calibration strategy has
been used since 1999 and is carried into the current model year, protocol 2 will be used. Refer to
Protocol 2 below. For new electronic calibration strategies introduced since the 2000 model year, use
protocol 3. Refer to Protocol 3 below.
Protocol 1
Protocol 2 Item Description
1 Model year (model year in which calibration strategy was first introduced)
2 Engine code
3 Engine revision level
Item Description
1 Model year (model year in which calibration strategy was first introduced)
2 Engine code
3 Transmission code
4 Emission standard (designates the specific country emission standard) Klj . 13 ba
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DESCRIPTION AND OPERATION
Maintenance Schedule —
Vehicles with Gasoline Engines
The maintenance schedule is designed to protect against major repairs resulting from neglect or
inadequate maintenance and to prolong the life of the vehicle.
General Maintenance Information
NOTE: This is a generic maintenance schedule for all Ford, Lincoln and Mercury vehicles. There may
be items listed that do not apply to all vehicles.
The Normal Schedule applies to operation of the vehicle under typical, everyday driving conditions.
The maintenance frequency in this schedule typifies what the vast majority of vehicles will require. The
listed services should be carried out at specified mileage intervals. There are, however, additional
services required that only the noted vehicles require.
If the vehicle is operated in one or more of the following special operating conditions, those additional
services will be required. The special operating conditions are:
ztowing or carrying heavy loads.
z extensive idling and/or driving at low speeds for long distances.
z driving in dusty conditions.
z off- road operation.
There are also exceptions to the Normal Operating Schedule which will require more frequent
maintenance for some components. Those exceptions are:
znatural gas and propane vehicles — fuel tank intervals.
z normal vehicle axle — maintenance and lubrication.
z police and taxi vehicles — maintenance and lubrication.
z engine oil and yellow coolant — time and mileage-based interval.
Special Operating Condition Requirements
When towing a trailer or using a camper or car- top carrier:
z Change engine oil and install a new oil filter every 4,800 km (3,000 miles) or 3 months.
z Change transfer case fluid every 96,000 km (60,000 miles).
z Change manual transmission fluid as required.
z Inspect and lubricate U- joints as required.
During extensive idling and/or low speed driving for long distances, as in heavy commercial use such
as delivery, taxi, patrol car or livery: SECTION 100-
03: Maintenance Schedule 2003 Mustang Workshop Manual Klj . 1 ba
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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
Inspect wheel ends for end play and noise.
z Inspect engine cooling system and hoses.
z Inspect exhaust system and heat shields.
z Inspect steering linkage, suspension and (if equipped) driveshaft and ball joints.
z Rotate tires and inspect for wear.
z Install a new engine air filter.
z Install a new fuel filter.
z If equipped, install a new cabin air filter.
z Change automatic transmission/transaxle fluid on all vehicles equipped with AX4S, 4F50N,
4R100, 4F27E. Inspect automatic transmission fluid level using dipstick on all other vehicles, if
equipped.
z If equipped, install new climate controlled seat filters (Navigator, Lincoln LS and Aviator).
Additional services for natural gas and propane vehicles include inspecting fuel tanks, as well as
draining coalescent fuel filter bowl and installing a new filter.
152,000 Km (95,000 Miles)
zChange engine oil and install a new oil filter.
z Inspect tires for wear. Rotation recommended for optimal tire life.
160,000 Km (100,000 Miles)
zChange engine oil and install a new oil filter.
z Inspect accessory drive belt(s).
z Rotate tires and inspect for wear.
z Install new spark plugs.
z If filled with yellow coolant, change coolant or at 5 years, whichever comes first.
z Install a new PCV on all cars and light trucks under 6,000 pounds Gross Vehicle Weight (GVW).
z Drain coalescent fuel filter and replace filter (NGV).
168,000 Km (105,000 Miles)
zChange engine oil and install a new oil filter.
z Inspect automatic transmission fluid level if equipped with dipstick.
z Inspect brake pads, shoes, rotors, drums, brake lines, hoses and parking brake system.
z Inspect wheel ends for end play and noise.
z Inspect engine coolant system and hoses.
z Inspect steering linkage, suspension and (if equipped) driveshaft and ball joints.
z Rotate tires and inspect for wear.
z If equipped, install a new cabin air filter.
z If filled with green engine coolant, change coolant. 176,000 Km (110,000 Miles) Klj . 7 ba
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z
Change engine oil and install a new oil filter.
z Inspect tires for wear. Rotation recommended for optimal tire life.
184,000 Km (115,000 Miles)
zChange engine oil and install a new oil filter.
z Inspect tires for wear. Rotation recommended for optimal tire life.
192,000 Km (120,000 Miles)
zChange engine oil and install a new oil filter.
z Inspect brake pads, shoes, rotors, drums, brake lines, hoses and parking brake system.
z Inspect wheel ends for end play and noise.
z Inspect engine cooling system and hoses.
z Inspect exhaust system and heat shields.
z Inspect steering linkage, suspension and (if equipped) driveshaft and ball joints.
z Rotate tires and inspect for wear.
z Install a new engine air filter.
z Install a new fuel filter. (See ADDITIONAL INFORMATION below.)
z If equipped, install a new cabin air filter.
z Install new accessory drive belt(s) (Escort).
z Install a new PCV valve on all cars and light trucks over 6,000 Gross Vehicle Weight.
z Change automatic transmission/transaxle fluid on all vehicles equipped with AX4S, 4F50N,
4R100, 4F27E. Inspect automatic transmission fluid level using dipstick on all other vehicles, if
equipped.
z Install a new camshaft belt on all 2.0L, 4- cylinder engines (Escort, Focus, ZX2 and Escape).
z If equipped, install new climate controlled seat filters (Navigator, Lincoln LS and Aviator).
ADDITIONAL INFORMATION: Additional services for natural gas and propane vehicles include
inspecting fuel tanks, as well as draining coalescent fuel filter bowl and installing a new filter.
200,000 Km (125,000 Miles)
zChange engine oil and install a new oil filter.
z Inspect tires for wear. Rotation recommended for optimal tire life.
z Drain coalescent fuel filter and replace filter (NGV).
208,000 Km (130,000 Miles)
zChange engine oil and install a new oil filter.
z Inspect tires for wear. Rotation recommended for optimal tire life.
216,000 Km (135,000 Miles)
zChange engine oil and install a new oil filter. Klj . 8 ba
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Exceptions To Normal Schedule
Yellow Coolant
zChange coolant at 5 years or 160,000 km (100,000 miles) of the vehicle's life, whichever comes
first.
z After the initial change, change coolant every 3 years or 80,000 km (50,000 miles) thereafter.
Natural Gas and Propane Vehicles
zInspect NGV fuel tanks from the date of tank manufacture every 3 years.
z Inspect propane fuel tanks from vehicle build date every 5 years.
z Install new NGV fuel tanks from the date of tank manufacture every 15 years.
Normal Vehicle Axle Maintenance
Rear axles and power take off (PTO) units containing synthetic lubricant and light duty trucks equipped
with Ford- design axles are lubricated for life. These lubricants are not to be checked or changed
unless service is required, or if a leak is suspected, or the axle assembly has been submerged in
water.
The axle and PTO should be changed anytime they have been submerged in water. Non- synthetic
rear axle lubricants should be replaced every 4,800 km (3,000 miles) or three months, whichever
occurs first, during extended trailer tow operation above 21°C (70°F) ambient and wide open throttle
for extended periods above 45 mph.
The 3,000 mile lube change interval may be waived if the axle was filled with 75W140 synthetic gear
lubricant meeting Ford specification WSL- M2C192-A, part number F1TZ-19B546- B or equivalent. Add
four ounces of additive friction modifier C8AZ-19B546- A (EST-M2C118- A) or equivalent for complete
refill of Traction- Lok rear axles.
The axle lubricant should be changed anytime an axle has been submerged in water.
Police and Taxi Vehicle Axle Maintenance
Replace rear axle lubricant every 160,000 km (100,000 miles). Rear axle lubricant change may be
waived if the axle was filled with 75W140 synthetic gear lubricant meeting Ford specification WSL-
M2C192- A, part number FITZ-19580-B or equivalent. Add four ounces of additive friction modifier
C8AZ- 19B546- A (EST-M2C118- A) or equivalent for complete refill of Traction- Lok rear axles.
The axle lubricant should be changed anytime an axle has been submerged in water. Klj . 10 ba
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Acceleration-
Light
An increase in speed at less than half throttle.
Acceleration- Medium
An increase in speed at half to nearly full throttle, such as 0- 97 km/h (0-60 mph) in approximately 30
seconds.
Acceleration- Heavy
An increase in speed at one- half to full throttle, such as 0- 97 km/h (0-60 mph) in approximately 20
seconds.
Ambient Temperature
The surrounding or prevailing temperature.
Amplitude
The quantity or amount of energy produced by a vibrating component (G force). An extreme vibration
has a high amplitude. A mild vibration has a low amplitude.
Backlash
Gear teeth clearance.
Boom
Low frequency or low pitched noise often accompanied by a vibration. Also refer to Drumming.
Bound Up
An overstressed isolation (rubber) mount that transmits vibration/noise instead of absorbing it.
Brakes Applied
When the service brakes are applied with enough force to hold the vehicle against movement with the
transmission in gear.
Buffet/Buffeting
Strong noise fluctuations (less than 1000 Hz) caused by gusting winds. An example would be wind
gusts against the side glass.
Buzz
A low- pitched sound like (200- 5000 Hz) that from a bee. Often a metallic or hard plastic humming
sound. Also describes a high frequency (200- 800 Hz) vibration. Vibration feels similar to an electric
razor. Camber Klj . 2 ba
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DIAGNOSIS AND TESTING
Noise, Vibration and Harshness (NVH)
To assist the service advisor and the technician, a Write-
up Job Aid and an NVH Diagnostic Guide are
included with this material. The Write- up Job Aid serves as a place to record all important symptom
information. The NVH Diagnostic Guide serves as a place to record information reported on the Write-
up Job Aid as well as data from the testing to be carried out.
To begin a successful diagnosis, fill out the NVH Diagnostic Guide, record the reported findings, then
proceed to each of the numbered process steps to complete the diagnosis. SECTION 100-
04: Noise, Vibration and Harshness 2003 Mustang Workshop Manual Special Tool(s)
ChassisEAR
107-
R2102 or equivalent Electronic Vibration Analyzer
100-
F027 (014- 00344) or
equivalent EngineEAR
107-
R2100 or equivalent Ultrasonic Leak Detector
134-
R0135 or equivalent Klj . 1 ba
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Customer Interview
The diagnostic process starts with the customer interview. The service advisor must obtain as much
information as possible about the problem and take a test drive with the customer. There are many
ways a customer will describe NVH concerns and this will help minimize confusion arising from
descriptive language differences. It is important that the concern is correctly interpreted and the
customer descriptions are recorded. During the interview, ask the following questions:
zWhen was it first noticed?
z Did it appear suddenly or gradually? Klj . 4 ba
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z
Drive the vehicle over a bump or rough surface one wheel at a time to determine if the noise is
coming from the front or the back and the left or the right side of the vehicle.
z Proceed as necessary.
Neutral Engine Run- Up (NERU) Test
To carry out this test, proceed as follows:
zInstall a tachometer.
z Increase the engine rpm up from an idle to approximately 4000 rpm while in PARK on front
wheel drive vehicles with automatic transmissions, or NEUTRAL for all other vehicles. Note the
engine rpm and, if possible, determine the vibration frequency.
z Attempt to identify what part of the vehicle the concern is coming from.
z Attempt to identify the source of the concern.
z Proceed as necessary.
Drive Engine Run- Up (DERU) Load Test
To carry out this test, proceed as follows:
z WARNING: Block the front and rear wheels, and apply the parking brake and the
service brake, or injury to personnel can result.
CAUTION: Do not carry out the Engine Load Test for more than five seconds or
damage to the transmission or transaxle can result.
Block the front and rear wheels.
z Apply the parking brake and the service brake.
z Install a tachometer.
z Shift the transmission into DRIVE, and increase and decrease the engine rpm between an idle
to approximately 2000 rpm. Note the engine rpm and, if possible, determine the vibration
frequency.
z Repeat the test in REVERSE.
z If the vibration/noise is duplicated when carrying out this test, inspect the engine and
transmission or transaxle mounts.
z If the concern is definitely engine speed- related, carry out the Engine Accessory Test to narrow
down the source.
z Proceed as necessary.
Engine Accessory Test
To carry out this test, proceed as follows:
z WARNING: Block the front and rear wheels, and apply the parking brake and the
service brake, or injury to personnel can result.
CAUTION: Limit engine running time to one minute or less with belts removed or
serious engine damage will result. Klj . 8 ba
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