weight FORD MUSTANG 2003 Workshop Manual

The last six VIN positions are the production sequence number. This number is also used as the
vehicle serial and warranty number.
z100001- 599999
Vehicle Certification (VC) Label
Vehicle Certification (VC) Label Locator
The upper portion of the vehicle certification (VC) label contains the manufacturer name, the month
and year of manufacture, the certification statement and the VIN. It also includes gross vehicle weight
ratings (GVWR). The VC label is located on the left- hand door jamb. Klj . 5 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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starting point.
Decibel
A unit of measurement, referring to sound pressure level, abbreviated dB.
Drive Engine Run-
Up (DERU) Test
The operation of the engine through the normal rpm range with the vehicle standing still, the brakes
applied and the transmission engaged. This test is used for noise and vibration checks.
Driveline Angles
The differences of alignment between the transmission output shaft, the driveshaft, and the rear axle
pinion centerline.
Driveshaft
The shaft that transmits power to the rear axle input shaft (pinion shaft). In a two- piece driveshaft, it is
the rearmost shaft.
Drivetrain
All power transmitting components from the engine to the wheels; includes the clutch or torque
converter, the transmission, the transfer case, the driveshaft, and the front or rear drive axle.
Drivetrain Damper
A weight attached to the engine, the transmission, the transfer case, or the axle. It is tuned by weight
and placement to absorb vibration.
Drone
A low frequency (100- 200 Hz) steady sound, like a freezer compressor. Also described as a moan.
Drumming
A cycling, low-frequency (20- 100 Hz), rhythmic noise often accompanied by a sensation of pressure on
the ear drums. Also described as a low rumble, boom, or rolling thunder. Dynamic Balance Klj . 5 ba
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The equal distribution of weight on each side of the centerline, so that when the wheel and tire
assembly spins, there is no tendency for the assembly to move from side-
to-side (wobble).
Dynamically unbalanced wheel and tire assemblies can cause wheel shimmy.
Engine Imbalance
A condition in which an engine's center mass is not concentric to the rotation center, causing
excessive motion.
Engine Misfire
When combustion in one or more cylinders does not occur or occurs at the wrong time.
Engine Shake
An exaggerated engine movement or vibration that directly increases in frequency as the engine speed
increases. It is caused by non- equal distribution of mass in the rotating or reciprocating components.
Flexible Coupling
A flexible joint.
Float
A drive mode on the dividing line between cruise and coast where the throttle setting matches the
engine speed with the road speed.
Flutter
Mid to high (100- 2000 Hz) intermittent sound due to air flow. Similar to a flag flapping in the wind.
Frequency
The rate at which a cycle occurs within a given time.
Gravelly Feel
A grinding or growl in a component, similar to the feel experienced when driving on gravel.
Grind
An abrasive sound, similar to using a grinding wheel, or rubbing sand paper against wood.
Hiss
Steady high frequency (200- 800 Hz) noise. Vacuum leak sound.
Hoot
A steady low frequency tone (50- 500 Hz), sounds like blowing over a long neck bottle. Howl Klj . 6 ba
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Lateral runout means measuring the movement or "wobble" of a wheel or tire at the sidewall. Radial
runout means measuring the out-of-
round at the tread surface.
Rustling
Intermittent sound of varying frequency (100- 2000 Hz), sounds similar to shuffling through leaves.
Shake
A low- frequency vibration (5-20 Hz), usually with visible component movement. Usually relates to tires,
wheels, brake drums or brake discs if it is vehicle speed sensitive, or engine if it is engine speed
sensitive. Also referred to as a shimmy or wobble.
Shimmy
An abnormal vibration or wobbling, felt as a side- to-side motion of the steering wheel in the driveshaft
rotation. Also described as waddle.
Shudder
A low- frequency vibration that is felt through the steering wheel or seat during light brake application.
Slap
A resonance from flat surfaces, such as safety belt webbing or door trim panels.
Slip Yoke/Slip Spline
The driveshaft coupling that allows length changes to occur while the suspension articulates and while
the driveshaft rotates.
Squeak
A high- pitched transient sound, similar to rubbing fingers against a clean window.
Squeal
A long- duration, high- pitched noise.
Static Balance
The equal distribution of weight around the wheel. Statically unbalanced wheel and tire assemblies can
cause a bouncing action called wheel tramp. This condition will eventually cause uneven tire wear.
Tap
A light, rhythmic, or intermittent hammering sound, similar to tapping a pencil on a table edge.
Thump
A dull beat caused by two items striking together. Tick Klj . 9 ba
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Section 204 - 01 .
z Damaged or
worn wheel
bearings z
CHECK for abnormal wheel
bearing play or roughness.
Refer to Wheel Bearing Check in this section.
ADJUST or INSTALL new
wheel bearings as
necessary.
z Clicking or
snapping— occurs
when accelerating
around a corner z
Damaged or
worn outboard
CV joint. z
INSPECT the outboard CV
joint and boot. REPAIR or
INSTALL a new CV joint as
necessary.
z High pitched
chattering— noise
from the rear axle
when the vehicle is
turning z
Incorrect or
contaminated
lubricant. z
CHECK the vehicle by
driving in tight circles (5
clockwise, 5
counterclockwise). FLUSH
and REFILL with the
specified rear axle lubricant
and friction modifier as
necessary.
z Damaged or
worn differential
(differential side
gears and pinion
gears). z
DISASSEMBLE the
differential assembly.
INSPECT the differential
case, pin and gears for wear
or damage. REPAIR or
INSTALL a new differential
as necessary. REFER to
Section 205 - 02A for Ford
7.5 rear axles or Section 205 - 02B for Ford 8.8
integral axles.
z Buzz—buzzing noise
is the same at cruise
or coast/deceleration z
Damaged or
worn tires. z
CHECK for abnormal tire
wear or damage. INSTALL a
new tire as necessary.
REFER to Section 204 - 04 .
z Incorrect
driveline angles. z
CHECK for correct driveline
angles. REPAIR as
necessary. REFER to
Section 205 - 00 .
z Rumble or boom—
noise occurs at
coast/deceleration,
usually driveshaft
speed related and
noticeable over a
wide range of speeds z
Driveshaft is
out-of- balance. z
CHECK the driveshaft for
damage, missing balance
weights or undercoating.
CHECK the driveshaft
balance. CARRY OUT a
driveline vibration test.
REFER to Section 205 - 00 .
z U-joints binding
or seized. z
ROTATE the driveshaft and
CHECK for rough operation
or seized U- joints. INSTALL
new U- joints as necessary.
REFER to Section 205 - 01 .
z Excessive
pinion flange
runout. z
CARRY OUT a runout
check. REPAIR as
necessary. REFER to
Section 205 - 00 .
z Grunting— normally
associated with a
shudder experienced
during acceleration z
Driveshaft slip
yoke binding. z
CLEAN and LUBRICATE
the male and female
splines. Klj . 20 ba
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z
Loose rear
spring U- bolts. z
INSPECT the U- bolts.
TIGHTEN the U- bolt nuts to
specification. REFER to
Section 204 - 02 .
z Incorrect or high
CV joint
operating angle. z
CHECK vehicle ride height
is within limits. REPAIR as
necessary. REFER to
Section 206 - 00 .
z Damaged or
worn front
suspension
components. z
CHECK for a loose stabilizer
bar, damaged or loose
strut/strut bushings or loose
or worn ball joints. INSPECT
the steering linkage for wear
or damage. REPAIR or
INSTALL new components
as necessary.
z Driveline angles
out of
specification. z
CHECK for correct driveline
angles. REPAIR as
necessary. REFER to
Section 205 - 00 .
z U-joints binding
or seized. z
ROTATE the driveshaft and
CHECK for rough operation
or seized U- joints. INSTALL
new U- joints as necessary.
REFER to Section 205 - 01 .
z Binding,
damaged or
galled splines
on the driveshaft
slip- yoke z
CLEAN and INSPECT the
splines of the slip- yoke,
driveshaft and coupling
shaft for a worn, damaged
or galled condition.
INSTALL a new slip- yoke or
driveshaft assembly as
necessary. REPAIR as
necessary. REFER to
Section 205 - 01 .
z Driveline vibration—
occurs at cruising
speeds z
U-joints are
worn. z
CHECK for wear or incorrect
seating. INSTALL new U-
joints as necessary. REFER
to Section 205 - 01 .
z Worn or
damaged
driveshaft center
bearing support. z
CHECK the insulator for
damage or wear. ROTATE
the driveshaft and CHECK
for rough operation.
INSTALL a new center
bearing support as
necessary. REFER to
Section 205 - 01 .
z Loose axle
pinion flange
bolts. z
INSPECT the axle pinion
flange. TIGHTEN the pinion
flange bolts to specification.
REFER to Section 205 - 01 .
z Excessive axle
pinion flange
runout. z
CARRY OUT a Runout
Check. REPAIR as
necessary. REFER to
Section 205 - 01 .
z Driveshaft is
out-of- balance. z
CHECK the driveshaft for
damage, missing balance
weights or undercoating.
CHECK driveshaft balance. Klj . 22 ba
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z
Mismatched gear
sets. z
INSPECT the gear sets
for an uneven wear
pattern on the face of
the gear teeth. REPAIR
as necessary. REFER
to Section 308 - 03A for
T50D transmissions or
Section 308 - 03B for
TR3650 transmissions.
z Damaged or worn
transmission
bearing. z
INSPECT the
transmission bearings.
INSTALL new bearings
as necessary. REFER
to Section 308 - 03A for
T50D transmissions or
Section 308 - 03B for
TR3650 transmissions.
z Transmission
growling/humming—
noise occurs in the
forward gears. The
noise is more
prominent when the
gear is loaded. The
problem gear can be
located as the noise
occurs in a specific
gear position z
Gear is cracked,
chipped or rough. z
INSPECT the
transmission gears for
damage or wear.
INSTALL new gears as
necessary. REFER to
Section 308 - 03A for
T50D transmissions or
Section 308 - 03B for
TR3650 transmissions.
z Transmission
hissing— noise in
neutral or in forward
gears. As bearings
wear or break up, the
noise changes to a
thumping noise z
Damaged or worn
bearings. z
INSPECT the
transmission bearings.
INSTALL new bearings
as necessary. REFER
to Section 308 - 03A for
T50D transmissions or
Section 308 - 03B for
TR3650 transmissions.
z Transmission
knocking/thudding—
noise at low speeds in
forward gears z
Bearings with
damaged balls or
rollers or with pitted
and spalled races. z
INSPECT the
transmission bearings.
INSTALL new bearings
as necessary. REFER
to Section 308 - 03A for
T50D transmissions or
Section 308 - 03B for
TR3650 transmissions.
z Transmission
rumble/growl— noise at
higher speeds in
forward gears, more
pronounced in a
coast/deceleration
condition z
Incorrect driveline
angle. z
CHECK the driveline
angle. REPAIR as
necessary. REFER to
Section 205 - 00 .
z Driveshaft out of
balance or
damaged. z
CHECK the driveshaft
for damage, missing
balance weights or
undercoating. Using the
vibration analyzer (VA),
CHECK the driveshaft
balance. CARRY OUT
a driveline vibration
test. For additional Klj . 43 ba
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PINPOINT TEST F: DRUMMING NOISE z
Carry out the Vehicle Cold Soak Procedure
in this section.
z Key in START position.
z Assess the airflow.
z Raise the engine speed to 1500 rpm while
listening for the moan to increase in
proportion to the airflow.
z Key in OFF position.
z Does the moan increase in proportion to
the airflow? Yes
TEST the fan for normal operation. If the
fan tests normal, GO to
E2 . Otherwise,
REPAIR as necessary.
No
Normal system operation. E2 CHECK THE ENGINE DRIVEN COOLING
FAN AT NORMAL OPERATING TEMPERATURE z
Key in START position.
z Run the engine to normal operating
temperature while listening for the moan to
stop.
z Key in OFF position.
z Does the moan stop? Yes
Normal clutch operation.
No
INSTALL a new fan clutch. TEST the
system for normal operation.
Test Step Result / Action to Take
F1 CHECK THE EXHAUST SYSTEM
z
Key in START position.
z Increase the engine rpm until the noise is the loudest. Note
the engine rpm.
z Key in OFF position.
z Add approximately 9 kg (20 lb) of weight to the exhaust
system. First place the weight at the tail pipe and test, then
at the front pipe.
z Key in START position.
z Increase the engine rpm and listen for the drumming noise.
Note the engine rpm if the noise occurs.
z Key in OFF position.
z Using a vibration analyzer (VA), determine the amount of
vibration that occurs with the drumming noise.
z Is the noise/vibration reduced or eliminated, or does the
noise/vibration occur at a different rpm? Yes
CARRY OUT
Exhaust System Neutralizing in this
section. TEST the system
for normal operation.
No
GO to F2 .
F2 POWERTRAIN/DRIVETRAIN MOUNT NEUTRALIZING
z
Carry out Powertrain/Drivetrain Mount Neutralizing in this
section. Test the system for normal operation.
z Is the noise reduced or eliminated? Yes
Vehicle OK. TEST the
system for normal
operation.
No Klj . 52 ba
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