wheel bolts FORD MUSTANG 2003 Workshop Manual

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
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REFILL as necessary.
z Power steering pump
brackets loose or
misaligned. z
CHECK bolts, brackets
and bracket alignment.
TIGHTEN bolts to
specification. REPAIR
or INSTALL new
brackets as necessary.
REFER to Section 211 -
02 .
z Steering gear clunk
— occurs only
while cornering
over a bump (can
be temperature
sensitive) z
Steering gear. zINSPECT the steering
gear for loose mounting
bolts. TIGHTEN as
necessary. REFER to
Section 211 - 02 .
z Feedback (rattle,
chuckle or
knocking noise in
the steering gear)
— a condition
where roughness is
felt in the steering
wheel when the
vehicle is driven
over rough
surfaces z
Column
intermediate/flexible
shaft joints damaged or
worn. z
INSTALL a new
intermediate/flexible
shaft. REFER to Section 211 - 04 .
z Loose, damaged or
worn tie- rod ends. z
TIGHTEN the nuts to
specification or
INSTALL new tie- rod
ends as necessary.
REFER to Section 211 -
02 .
z Steering gear
insulators or mounting
bolts loose or
damaged. z
TIGHTEN the bolts or
INSTALL new bolts as
necessary. REFER to
Section 211 - 02 .
z Steering column
intermediate shaft bolts
are loose. z
TIGHTEN the bolts to
specification. REFER to
Section 211 - 04 .
z Steering column
damaged or worn. z
REPAIR or INSTALL a
new steering column as
necessary. REFER to
Section 211 - 04 .
z Loose suspension
bushings, bolts or ball
joints. z
INSPECT the
suspension system.
TIGHTEN or INSTALL
new components as
necessary. REFER to
Section 204 - 01 .
z Feedback (nibble
at the steering
wheel) — a
condition where
slight rotational
movement is felt in
the steering wheel
when the vehicle is
driven over rough
or grooved z
Lateral runout in the
tire or wheel. z
GO to Pinpoint Test H . Klj . 34 ba
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surfaces
zYoke spring in the
steering gear. z
CHECK TSBs for
revised yoke spring for
applicable vehicles.
z Accessory drive
belt squeal/chirp—
when rotating the
steering wheel
from stop to stop z
Loose or worn
accessory drive belt. z
ADJUST or INSTALL a
new accessory belt as
necessary. REFER to
Section 303 - 05 .
z Power steering
gear hiss z
Steering column
intermediate/flexible
shaft- to-steering gear
is binding or
misaligned. z
REPAIR or INSTALL a
new
intermediate/flexible
shaft as necessary.
REFER to Section 211 -
04 .
z Grounded or loose
steering column boot at
the dash panel. z
REPAIR as necessary.
z Damaged or worn
steering gear input
shaft and valve. z
REPAIR or INSTALL a
new steering gear as
necessary. REFER to
Section 211 - 02 .
z Steering column
rattle z
Loose bolts or
attaching brackets. z
TIGHTEN the bolts to
specifications.
z Loose, worn or
insufficiently lubricated
column bearings. z
LUBRICATE or
INSTALL new steering
column bearings as
necessary. REFER to
Section 211 - 04 .
z Steering shaft
insulators damaged or
worn. z
INSTALL new
insulators. REFER to
Section 211 - 04 .
z Intermediate/flexible
shaft compressed or
extended. z
INSPECT the rubber
spider coupling for
damage. INSTALL a
new
intermediate/flexible
shaft. REFER to Section 211 - 04 .
z Steering column
squeak or cracks z
Insufficient lubricated
steering shaft
bushings. z
LUBRICATE the
steering shaft and shaft
tube seals.
z Loose or misaligned
steering column
shrouds. z
TIGHTEN or ALIGN the
steering column
shrouds.
z Steering wheel rubbing
against steering
column shrouds. z
REPOSITION the
steering column
shrouds.
z Insufficient lubricated
speed control slip ring. z
LUBRICATE the speed
control slip ring.
z Upper or lower bearing
sleeve out of position. z
REPOSITION the
bearing sleeves.
z Power steering
pump noisy z
Incorrect assembly of
components.
z Imperfections on the
outside diameter or z
REPAIR or INSTALL a
new power steering
pump as necessary.
REFER to Section 211 -Klj . 35 ba
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Symptom Chart—
Transmission (Manual) and Transfer Case Noise/Vibration Condition
Possible Sources Action
z Clutch rattling noise—
occurs with clutch
engaged, noise
changes/disappears
with clutch pedal
depressed z
Flywheel bolts,
clutch housing bolts
or clutch pressure
plate bolts loose. z
TIGHTEN the bolts to
specifications. CHECK
the bolts for damage.
z Clutch squeaking
noise— noise is heard
when the clutch is
operated. Vehicle
moves slowly or
creeps when the clutch
is disengaged. Can
also be difficult to shift
into first and reverse
gear z
Pilot bearing seized
or damaged. z
INSTALL a new pilot
bearing. REFER to
Section 308 - 01 .
z Clutch squeaking
noise— occurs with
clutch pedal
depressed/released z
Worn clutch pedal
shaft or bushings. z
INSPECT the clutch
pedal for wear or
damage. REPAIR as
necessary. REFER to
Section 308 - 02 .
z Clutch whirring/rattle
noise— occurs when
clutch pedal is
depressed z
Worn, damaged or
misaligned clutch
release bearing. z
INSTALL a new clutch
release bearing.
REFER to Section 308 -
01 .
z Clutch grating/grinding
noise— occurs when
clutch pedal is
depressed z
Clutch pressure
plate fingers bent or
worn. z
INSPECT the clutch
pressure plate release
fingers. INSTALL a new
pressure plate as
necessary. REFER to
Section 308 - 01 .
z Contact surface of
clutch release
bearing worn or
damaged. z
INSTALL a new clutch
release bearing.
REFER to Section 308 -
01 .
z Clutch chatter— a
small amount of noise
when clutch pedal is
released at initial take-
off z
Clutch engagement. zAcceptable operating
condition.
z Clutch chatter/grabs—
in some cases a
shudder is felt. Occurs
with clutch pedal
depressed/released z
Damaged or worn
powertrain/driveline
mounts. z
INSPECT the
powertrain/drivetrain
mounts. INSTALL new
mounts as necessary.
REFER to Section 303 -
01A for 3.8L engines or
Section 303 - 01B for
4.6L (2V) engines.
z Binding or dragging
plunger of the clutch
master cylinder or
slave cylinder. z
CHECK the master and
slave cylinder
operation. INSPECT
the components for
damage or wear.
INSTALL a new master
or slave cylinder as
necessary. REFER to Klj . 40 ba
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Section 308 - 02 .
z Grease or oil on the
clutch disc facing. z
CHECK the input shaft
seal and rear main oil
seal. REPAIR as
necessary. INSTALL a
new clutch disc.
REFER to Section 308 -
03A for T50D
transmissions or
Section 308 - 03B for
TR3650 transmissions.
z Clutch disc surface
glazed or damaged. z
INSPECT the clutch
disc surface for a
glazed, hardened or
damage condition.
CARRY OUT a disc
check. INSTALL a new
clutch disc as
necessary. REFER to
Section 308 - 01 .
z Damaged or worn
clutch pressure
plate. z
INSPECT the clutch
pressure plate for wear
or damage. INSTALL a
new clutch pressure
plate as necessary.
REFER to Section 308 -
01 .
z Flywheel surface
damaged or glazed. z
INSPECT the flywheel
for damage or wear.
CARRY OUT a
flywheel runout check.
INSTALL a new
flywheel as necessary.
REFER to Section 303 -
01A for 3.8L engines or
Section 303 - 01B for
4.6L (2V) engines.
z Clutch chatter noise—
noise when clutch
pedal is released at
initial take- off. Clutch is
hard to engage and
disengage z
Pilot bearing worn,
damaged or not
correctly aligned in
bore. z
INSPECT the clutch
pressure plate release
fingers for uneven
wear, clutch
components burnt or a
seized pilot bearing.
INSTALL a new pilot
bearing as necessary.
REFER to Section 308 -
01 .
z Clutch vibration zLoose flywheel
bolts.
z Damaged or loose
clutch pressure
plate.
z Excessive flywheel
runout. z
Go To Pinpoint Test L .
z Transmission
rattling/clattering
noise— noise at idle or
on light acceleration
from a stop. Gear
selection difficult z
Gearshift lever joint
worn or damaged. z
INSTALL a new
gearshift lever. REFER
to Section 308 - 03A for
T50D transmissions or
Section 308 - 03B for
TR3650 transmissions. Klj . 41 ba
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PINPOINT TEST B: ENGINE TICKING NOISE No
INSPECT the wheel
bearings. ADJUST or
REPAIR as necessary.
TEST the system for
normal operation.
A6 CHECK THE FRONT SUSPENSION
z
Check the front suspension for:
zBroken or loose bolts.
z Damaged springs.
z Worn or damaged upper and lower control arm
bushings.
z Loose or rough front bearings.
z Uneven tire wear.
z Are all the suspension components in satisfactory
condition? Yes
GO to
A7 .
No
REPAIR or INSTALL
new components as
necessary. TEST the
system for normal
operation. A7 RESURFACE THE FRONT BRAKE DISCS
z
CAUTION: Do not use a bench lathe to machine brake
discs.
z NOTE: Follow the manufacturer's instructions to machine the
brake discs. After machining, make sure the brake disc meets
the thickness specification.
z Refer to Brake Disc Machining in this section. Resurface the
front brake discs. Road test the vehicle.
z Is the vibration/shudder present? Yes
GO to
A8 .
No
Vehicle is OK. A8 CHECK THE REAR SUSPENSION
z
Check the rear suspension for:
zBroken or loose bolts.
z Damaged or worn springs or spring bushings.
z Worn or damaged upper and lower control arm
bushings.
z Worn or damaged trailing arms.
z Loose or rough rear bearings.
z Uneven tire wear.
z Are all the suspension components in satisfactory
condition? Yes
GO to
A9 .
No
REPAIR or INSTALL
new components as
necessary. TEST the
system for normal
operation. A9 RESURFACE THE REAR BRAKE DISC OR DRUM
z
CAUTION: Do not use a bench lathe to machine brake
discs.
z NOTE: Follow the manufacturers instructions to machine the
brake discs. After machining, make sure the brake disc meets
the thickness specification.
z Refer to Brake Disc Machining in this section. Resurface the
rear brake discs or drums. Road test the vehicle.
z Is the vibration/shudder present? Yes
CHECK the front
suspension for wear or
damage. RESURFACE
the front brake discs.
TEST the system for
normal operation.
No
Vehicle is OK.
Test Step Result / Action to Take
B1 CHECK FOR TICKING NOISE AT THE FUEL
RAIL z
Disconnect the first fuel line clip. Yes Klj . 49 ba
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PINPOINT TEST J: WHEEL AND TIRE I1 ROAD TEST THE VEHICLE
z
Test drive the vehicle.
z NOTE: An assistant will be needed for this road test.
z During the road test, drive the vehicle over a rough road.
Using ChassisEARs, determine from which
area/component the noise is originating.
z Is there a squeak, creak or rattle noise? Yes
GO to
I2 .
No
The suspension system is
OK. Conduct a diagnosis on
other suspect systems. I2 REAR SHOCK ABSORBER/STRUT CHECK
z
WARNING: The electrical power to the air
suspension system must be shut off prior to hoisting,
jacking or towing an air suspension vehicle. This can
be accomplished by turning off the air suspension
switch. Failure to do so can result in unexpected
inflation or deflation of the air springs, which can result
in shifting of the vehicle during these operations.
z Raise and support the vehicle.
z Check the rear shock absorber/strut mounts for loose bolts
or nuts.
z Check the rear shock absorbers/struts for damage. Carry
out a shock absorber check.
z Are the rear shock absorbers/struts loose or damaged? Yes
TIGHTEN to specifications if
loose. INSTALL new rear
shock absorbers/struts if
damaged. TEST the system
for normal operation.
No
GO to
I3 .
I3 CHECK THE REAR SPRINGS
z
Check the rear springs and rear spring mounts/brackets for
wear or damage.
z Are the rear springs or spring mounts/brackets worn or
damaged? Yes
REPAIR or INSTALL new
components as necessary.
TEST the system for normal
operation.
No
GO to
I4 .
I4 CHECK THE CONTROL ARMS/TRAILING ARMS
z
Inspect the control arm/trailing arm bushings for wear or
damage. Check for loose control arm/trailing arm bolts.
z Inspect for twisted or bent control arm/trailing arms.
z Are the control arm/trailing arms loose, damaged or
worn? Yes
REPAIR or INSTALL new
components as necessary.
TEST the system for normal
operation.
No
GO to
I5 .
I5 CHECK THE STABILIZER BAR/TRACK BAR
z
Check the stabilizer bar/track bar bushings and links for
damage or wear.
z Check the stabilizer bar/track bar for damage.
z Check for loose or damaged stabilizer bar isolators or
brackets.
z Are the stabilizer bar/track bar components loose, worn
or damaged? Yes
REPAIR or INSTALL new
components as necessary.
TEST the system for normal
operation.
No
Suspension system OK.
CONDUCT diagnosis on
other suspect systems.
Test Step
Result / Action to Klj . 55 ba
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PINPOINT TEST L: CLUTCH VIBRATION appropriate workshop manual for the service procedures.
z Secure the brake drums (if so equipped), by installing wheel
hub bolt nuts, reversed.
z Carefully accelerate the drivetrain while checking for vibration.
z Is the vibration present? assemblies as necessary.
TEST the system for
normal operation.
Test Step Result / Action to Take
L1 CHECK ENGINE COMPONENTS FOR GROUNDING
z
NOTE: Make sure the clutch is the cause of the
vibration concern. The vibration should occur during
clutch operation. The clutch can also be difficult to
engage or disengage. Eliminate all related systems
before checking the clutch components.
z NOTE: Check the driveline angles and driveshaft
runout before disassembling the clutch system. Refer
to Section 205 - 00 for the correct driveline angle
specifications.
z Check the powertrain/drivetrain mounts, exhaust
manifolds or other engine components for grounding
on the chassis.
z Are any mounts or engine components
grounded? Yes
REPAIR as necessary. TEST the
system for normal operation.
No
GO to
L2 .
L2 CHECK THE ACCESSORY DRIVE
z
Remove the accessory drive belt.
z Does the vibration stop with the accessory drive
belt removed? Yes
DIAGNOSE the accessory drive
components.
No
GO to
L3 .
L3 CHECK FOR LOOSE CLUTCH PRESSURE PLATE
BOLTS z
Check for loose clutch pressure plate bolts. Inspect
the clutch pressure plate for damage or for material
between the pressure plate and flywheel.
z Are there any loose bolts or damage? Yes
TIGHTEN the bolts to
specifications or if damaged,
INSTALL a new clutch pressure
plate. REFER to
Section 308 - 01 .
TEST the system for normal
operation.
No
GO to L4 .
L4 CHECK THE CLUTCH DISC SPRINGS
z
Check for worn, broken or loose clutch disc springs.
z Are the clutch springs worn, broken or loose? Yes
INSTALL a new clutch disc.
REFER to
Section 308 - 01 . TEST
the system for normal operation.
No
GO to L5 .
L5 CHECK THE CLUTCH DISC SPLINES
z
Inspect the clutch disc splines for damage or wear.
z Is there damage or wear? Yes
INSTALL a new clutch disc.
REFER to
Section 308 - 01 . TEST Klj . 61 ba
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PINPOINT TEST M: TRANSFER CASE VIBRATION the system for normal operation.
No
GO to
L6 .
L6 CHECK THE FLYWHEEL BOLTS
z
Check for loose flywheel bolts.
z Are the bolts loose? Yes
TIGHTEN the bolts to
specifications. REFER to
Section 308 - 01 . TEST the system for
normal operation.
No
GO to L7 .
L7 CHECK THE FLYWHEEL SURFACE
z
Inspect the flywheel surface for wear or damage.
Check the flywheel runout.
z Is there any damage or excessive wear? Yes
INSTALL a new flywheel. TEST
the system for normal operation.
No
Clutch system normal. CONDUCT
a diagnosis on other suspect
systems.
Test Step Result / Action to Take
M1 INSPECT THE TRANSFER CASE
z
WARNING: The electrical power to the air suspension
system must be shut off prior to hoisting, jacking or towing
an air suspension vehicle. This can be accomplished by
turning off the air suspension switch. Failure to do so can
result in unexpected inflation or deflation of the air springs,
which can result in shifting of the vehicle during these
operations.
z Inspect the transfer case for loose or missing mounting bolts.
Check for fluid seepage between the transfer case and the
transmission.
z Are the mounting bolts missing or loose? Yes
TIGHTEN to
specifications or
INSTALL new bolts as
necessary. TEST the
system for normal
operation.
No
GO to
M2 .
M2 INSPECT THE REAR DRIVESHAFT
z
NOTE: Verify that the driveshaft and pinion flange index marks
are aligned.
z Inspect the driveshaft for missing weights, damage or
undercoating.
z Inspect the U- joints for freedom of movement.
z Check driveshaft runout and, if necessary, check the pinion
flange runout.
z Is the driveshaft or U- joints worn or damaged or
misaligned? Yes
REPAIR or INSTALL a
new driveshaft as
necessary. TEST the
system for normal
operation.
No
GO to
M3 .
M3 CHECK THE DRIVELINE ANGLES
z
Measure the rear driveshaft and pinion angles. Refer to Section 205 - 00 .
z Measure the front driveshaft and pinion angles. Refer to Section 205 - 00 .
z Are the driveline angles incorrect? Yes
REPAIR as necessary.
TEST the system for
normal operation.
No Klj . 62 ba
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SPECIFICATIONS
SECTION 204-
02: Rear Suspension 2003 Mustang Workshop Manual Torque Specifications
Description Nm lb-
ft lb-
in Mustang
Rear shock absorber (upper attachment) 40 30 —
Rear shock absorber (lower attachment) 80 59 —
Shock absorber clevis bracket-to-
axle nut 108 80 —
Upper arm-
to-frame bolt 97 72 —
Upper arm-
to-axle bolt 111 82 —
Lower arm-
to-body attachment bolt 150 111 —
Lower arm-
to-axle bolt 150 111 —
Stabilizer bar-
to-lower arm bolt 55 41 —
Parking brake cable bracket 55 41 —
Axle damper front bolt 90 66 —
Axle damper rear nut 90 66 —
Axle damper bracket-
to-frame bolt 80 59 —
Pinion bumper mount-
to-body bolts 14 10 —
Bracket assembly-
to-differential housing bolt 48 35 —
Wheel nuts 129 95 —
Cobra
Subframe-to-
body bolts 103 76 —
Subframe-to-
rear bracket bolts 103 76 —
Subframe rear bracket-
to-body bolts 80 59 —
Shock absorber-
to-lower arm and bushing bolts 133 98 —
Shock absorber-
to-body nuts 40 30 —
Upper arm and bushing-
to-subframe nuts 90 66 —
Upper arm and bushing-
to-knuckle nut 90 66 —
Lower arm and bushing-
to-subframe bolts 250 184 —
Lower arm and bushing-
to-knuckle nut 115 85 —
Toe link-
to-subframe nut 48 35 —
Toe link-
to-knuckle nut 48 35 —
Stabilizer bar bracket bolt 55 41 —
Stabilizer bar link nuts 48 35 —
Rear axle differential rear insulator-
to-axle housing bolts 103 76 —
Rear brake disc dust shield-
to-knuckle bolts 10 — 89
Brake line-
to-rear brake caliper bolt 40 30 —
Parking brake cable bracket-
to-lower arm and bushing bolt 15 11 —
ABS sensor bolt 23 17 — Klj . 1 ba
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