washer fluid FORD MUSTANG 2003 Workshop Manual

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
112003 Mustang Workshop Manual
17. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_4464/S3B~us~en~ ...

misaligned.
screws. REPAIR as necessary.
z Loose interior
component or
trim. z
CARRY OUT a "touch test".
ELIMINATE the noise by
pressing or pulling on interior
trim and components. USE the
Rotunda Squeak and Rattle Kit
to isolate any rattling/squeaking
components.
z Squeak or rattle—
noise with a
vibration concern z
Damaged or
worn body
mounts. z
INSPECT the upper and lower
absorbers and washers for
damage or wear. CHECK the
body mount brackets for
damage. CHECK the nuts and
bolts are tightened to
specifications. TIGHTEN as
necessary.
z Damaged or
worn sub- frame
mounts. z
INSPECT the upper and lower
absorbers for damage or wear.
CHECK the sub- frame for
damage. CHECK the nuts and
bolts are tightened to
specifications. TIGHTEN as
necessary. Symptom Chart—
Steering Noise/Vibration Condition
Possible Sources Action
z Steering grunt or
shudder — occurs
when turning into
or out of a turn at
low speeds
(temperature
sensitive) z
Steering gear or power
steering hoses. z
GO to Steering Gear
Grunt/Shudder Test
component test in this
section.
z Steering System
clonk— hydraulic
knocking sound z
Air in the steering
hydraulic system. z
CHECK for leaks in the
system. PURGE the air
from the system.
REFER to Section 211 -
00 .
z Power steering
pump moan —
loud humming
noise occurs when
the steering wheel
is rotated to the
stop position.
Produces a 120-
600 Hz frequency
that changes with
rpm z
Power steering hose
grounded out to
chassis. z
INSPECT the power
steering hoses. REPAIR
as necessary.
z Aerated fluid. zCHECK for leaks in the
system. PURGE the air
from the system.
REFER to Section 211 -
00 .
z Steering gear isolators. zINSPECT the isolators
for wear or damage.
REPAIR as necessary.
z Low fluid. zCHECK the fluid level. Klj . 33 ba
702003 Mustang Workshop Manual
17. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_4464/S3B~us~en~ ...

REMOVAL AND INSTALLATION
Caliper
Removal
1. Raise and support the vehicle. For additional information, refer to Section 100 - 02 .
2. Remove the wheel and tire assembly. For additional information, refer to Section 204 - 04 .
3. WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact
with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes
with running water for 15 minutes, get medical attention if irritation persists. If taken
internally, drink water and induce vomiting. Get medical attention immediately.
CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is
spilled onto a painted or plastic surface, wash it with water immediately.
Disconnect the front brake hose (2078). 1. Remove the front brake flow bolt.
2. Disconnect the front brake hose.
3. Remove and discard the copper washers. Plug the front brake hose.
4. Remove the caliper bolts. 1. Hold the guide pins stationary.
2. Remove the caliper bolts.
SECTION 206-
03: Front Disc Brake 2003 Mustang Workshop Manual Klj . 1 ba
42003 Mustang Workshop Manual
17. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_4464/S3B~us~en~ ...

S427
110 7B498 Seal assembly —
manual control lever 111 373907-S2 Nut —
1/4 spring (retains identification tag to
7000) 112 7B148 Tag —
identification (part of 7005) 113 7D273 Connector assembly —
fluid tube (2 req'd) 114 7N171 Plug —
converter housing access 115 7B210 Pin —
manual lever shaft retainer 116 391131 Seal —
0.426 x 0.070 O- ring 117 N805862-
S Seal —
14.0 x 1.78 O- ring 118 7G383 Solenoid valve —
transmission pressure control 119 7A441 Pawl —
parking pawl 120 7D071 Shaft —
parking pawl 121 7D419 Cup —
park rod guide (part of 7A039) 122 7D070 Spring —
parking pawl return 123 7A232 Rod assembly —
park pawl actuating 124 7A115 Lever assembly —
manual valve detent lever 125 N800287-
S536 Nut —
M14 x 1.5 hex intermediate detent lever
(attaches 7A115 to 7A256) 126 7H188 Piston assembly —
overdrive servo 127 7F201 Spring —
overdrive servo piston 128 7F203 Rod —
overdrive servo actuating (part of 7H188) 129 7H179 Washer —
backup overdrive servo (part of
7H188) 130 7G277 Spring —
overdrive cushion spring (part of
7H188) 131 7F200 Piston assembly —
overdrive servo (part of
7H188) 132 97411-
S Ring —
retaining (part of 7H188) 133 7384 Ring —
2.85 retaining type TVP "H" internal
(retains 7H188 to 7005) 134 7D031 Spring —
reverse band servo piston 135 7D189 Piston assembly —
reverse band servo 136 7D036 Cover assembly —
reverse band servo piston 137 388215-
S100 Retaining ring internal
— 3-13/16 138 7H292 Piston — 2-
3 accumulator (bonded seals) 139 7F285 Spring
— 2-3 shift accumulator piston (model
dependent) 140 7B264 Retainer — 2-
3 shift accumulator spring 141 7F284 Spring
— 1-2 shift accumulator (model
dependent) 142 7F251 Piston — 1-
2 shift accumulator (bonded seals) 143 7F284 Spring
— 1-2 shift accumulator Klj . 6 ba
82003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2748/S3B~us~en~ ...

Assembly
1. CAUTION: Before beginning assembly, carry out and inspect the following:
When building up subassemblies and assembling the transmission, ALWAYS use new
gaskets and seals.
All fasteners must be tightened to the torque specification indicated. In addition to
appearing in the section, the necessary torques can be found in the General
Specifications Chart.
When building up subassemblies, each component part should be lubricated with clean
transmission fluid. It is also good practice to lubricate the subassemblies as they are
installed in the case.
Needle bearings, thrust washers and seals should be lightly coated with petroleum jelly
during subassembly buildup or transmission assembly.
Many components and surfaces in the transmission are precision machined. Careful
handling during disassembly, cleaning, inspection and assembly can prevent
unnecessary damage to machined surfaces.
Install the valve body cover plate. 1. Position the valve body cover plate gasket and cover plate.
2. Install the two guide pin bolts.
3. Install the bolts.
2. Tighten the bolts in the sequence shown. Klj . 5 ba
82003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2748/S3B~us~en~ ...

DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES
Pump and Intermediate Clutch Piston
Pump and Intermediate Clutch Piston —
Disassembled View
SECTION 307-
01: Automatic Transaxle/Transmission 2003 Mustang Workshop Manual Special Tool(s)
Installer, Front Pump Fluid
Seal
307-
014 (T63L-77837- A) Protector, Piston Seal
307-
339 (T95L-77005- A) Item Part Number Description
1 7902 Torque converter
2 7A248 Front pump O-
ring 3 N605789-S101 Bolt
4 — Pump body assembly
5 N605787-S1000 Front pump support bolt
6 7D014 No. 1 pump support thrust washer
7 7D020 Reverse clutch cylinder seal
8 7D019 Forward clutch cylinder seal
9 7E005 Intermediate clutch piston
10 7F224 Intermediate clutch piston outer seal Klj . 1 ba
72003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2748/S3B~us~en~ ...

CAUTION: Before beginning assembly, carry out and inspect the following:
When building up subassemblies and assembling the transmission, ALWAYS use new gaskets
and seals.
All fasteners must be tightened to the torque specification indicated. In addition to appearing in
the section, the necessary torques can be found in the General Specifications Chart.
When building up subassemblies, each component part should be lubricated with clean
transmission fluid. It is also good practice to lubricate the subassemblies as they are installed
in the case.
Needle bearings, thrust washers and seals should be lightly coated with petroleum jelly during
subassembly buildup or transmission assembly.
Many components and surfaces in the transmission are precision machined. Careful handling
during disassembly, cleaning, inspection and assembly can prevent unnecessary damage to
machined surfaces.
1. Use the special tools to install the rear case bushing if removed. 1. Position the rear case bushing and the special tool inside the case.
2. Assemble the special tools through the back of the case.
2. Place the transmission in the vertical position.
3. Coat the No. 9 case rear bearing with petroleum jelly and install on the case boss.
4. CAUTION: Be sure the No. 7 needle bearing and direct clutch hub are installed as
shown in the Subassembly section. Internal damage and shift problems may occur. D0AZ-
19584- AA B
MERCON® V Automatic
Transmission Fluid
XT
-5-QM, XT -5-DM MERCON® V Klj . 3 ba
252003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2748/S3B~us~en~ ...

Assembly
1. Soak the blocking rings in transmission fluid for ten minutes. zUse MERCON® Multi- Purpose ATF Transmission Fluid XT -2-QDX or equivalent.
2. Assemble the first and second synchronizer. 1. Install the synchronizer hub insert springs and the synchronizer inserts into the synchronizer hub.
2. Install the sliding sleeve onto the hub.
3. NOTE: If not done so previously, soak the blocking ring in MERCON® Multi- Purpose ATF
Transmission Fluid XT -2-QDX or equivalent for ten minutes.
NOTE: Align the slots in the synchronizer blocking ring with the tabs in the first and second
speed synchronizer.
Install the second speed synchronizer blocking ring and the inner and outer cones as an
assembly.
4. Install the second speed synchronizer thrust washer.
5. Using the special tool, install the output shaft bearing snap ring. Klj . 5 ba
102003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2308/S3B~us~en~ ...

6. Install the second speed gear bearing spacer and the second speed bearing.
7.
NOTE: Align the slots in the second gear with the tabs on the synchronizer blocking ring.
Install the second gear onto the output shaft.
8. Install the thrust washer and the snap ring.
9. NOTE: If not done so previously, soak the blocking ring in MERCON® Multi- Purpose ATF
Transmission Fluid XT -2-QDX or equivalent for ten minutes. Klj . 6 ba
102003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2308/S3B~us~en~ ...

21.
NOTE: If not done so previously, soak the blocking ring in transmission fluid for ten minutes.
Install the fifth speed cluster gear, the synchronizer blocking ring, the synchronizer assembly,
and the fifth gear shifter fork as an assembly.
22. CAUTION: To prevent component damage when installing the extension housing
(7A039), the alignment tab on the reverse brake ring (7M000) must engage the alignment
slot in the extension housing.
NOTE: If not done so previously, soak the blocking ring in transmission fluid for ten minutes.
Install the synchronizer blocking ring, the reverse brake ring, the thrust washer, and the fifth
speed synchronizer retaining snap ring.
23. Apply pipe sealant to the reversing lamp switch threads and install the switch.
24. Install the reverse gearshift lever retaining clip. Klj . 8 ba
142003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2308/S3B~us~en~ ...