window FORD MUSTANG 2003 Workshop Manual

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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glass
zAir traveling up
windshield molding
along A- pillar. z
INSTALL foam rope the
full length of the A- pillar.
z Windshield/backlite
misaligned or not
installed correctly. z
REINSTALL the
windshield/backlite.
z Rear hood seal at base
of windshield
misaligned/damaged. z
REALIGN or INSTALL a
new seal as necessary.
z Air leak at cowl zCowl gasket
misaligned/damaged. z
REALIGN or INSTALL a
new seal as necessary.
z Air leak around
liftgate perimeter z
Loose fit seal. zPINCH the seal carrier to
improve retention on the
seal flange or INSERT
foam in the carrier.
z Seal misaligned. zREINSTALL the seal.
z Liftgate misaligned. zREALIGN the liftgate.
CHECK the liftgate fit in
the body opening and
ADJUST as necessary.
z Scuff plate misaligned. zREINSTALL the scuff
plate.
z Seal or seal push pins
damaged. z
INSTALL a new seal.
z Air leak around
the liftgate flip
window
perimeter z
Loose fit seal. zPINCH the seal carrier to
improve the retention to
the seal flange.
z Seal misaligned. zREINSTALL the seal.
z Glass misaligned. zREALIGN the glass.
z Seal damaged. zINSTALL a new seal.
z Wind noise from
antenna z
Shape of antenna. zINSTALL an antenna boot
or a spiral antenna.
z Air leak around
antenna cable access
hole. z
INSPECT the antenna
access hole grommet.
REPAIR as necessary.
z Air leak from
closed roof
opening panel z
Seal installed
incorrectly. z
REINSTALL the seal.
z Roof opening panel
glass/door misaligned. z
REALIGN the roof
opening panel glass/door.
z Roof opening panel
damaged. z
INSTALL a new roof
opening panel.
z Buffeting from an
open roof
opening panel z
Wind deflector
inoperative/damaged. z
REPAIR or INSTALL a
new wind deflector as
necessary.
z Wind deflector height
incorrect. z
ADJUST the wind
deflector higher.
z Wind noise
created by
airflow over or
behind body
panels z
Fender splash shield
misaligned. z
REALIGN the fender
splash shield. Klj . 14 ba
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closing/opening
the window
z Squeak— heard
outside of vehicle
when
closing/opening
the door z
Exhaust shield
rubbing against
the chassis or
exhaust pipe. z
CHECK the exhaust system.
REPAIR as necessary. REFER
to Section 309 - 00 .
z Squeak— occurs
with initial brake
pedal application z
Disc brake pads. zUnder certain conditions,
asbestos free pads can
generate a squeak noise. This
noise is normal and does not
indicate a concern.
z Squeak— a
constant noise
that occurs with
brake pedal
applications z
Damaged or
worn disc brake
pads. z
INSPECT the pads for oil,
grease or brake fluid
contamination. CHECK for
glazed linings. A brake disc with
hard spots will also cause a
squeak type noise. REPAIR or
INSTALL new pads as
necessary. REFER to Section 206 - 03 for front disc brakes and
Section 206 - 04 for rear disc
brakes.
z Squeak— noise
occurs over
bumps or when
turning z
Worn control
arm bushings. z
INSPECT the control arm
bushings. Spray with lubricant
and CARRY OUT a "bounce
test" to determine which
bushing. REPAIR as necessary.
REFER to Section 204 - 01 .
z Worn or
damaged shock
absorber/strut. z
INSPECT the shock absorber
for damage. CARRY OUT a
"bounce test" to isolate the
noise. INSTALL a new shock
absorber/strut as necessary.
REFER to Section 204 - 01 for
the front shock absorber/strut or
Section 204 - 02 for the rear
shock absorber/strut.
z Rattle— heard
when
closing/opening
the door or
window z
Loose internal
door
mechanism,
bracket or
attachment. z
REPEAT the motion or CARRY
OUT a "tap test" to duplicate the
noise. INSPECT the door for
loose components. TIGHTEN
loose components or USE the
Rotunda Squeak and Rattle Kit
to isolate any rattling
components.
z Rattle — GT
models only,
noise occurs from
the rear of the
vehicle z
A loose or under
torqued shock
damper
attaching nut. z
VERIFY the torque on the
shock damper- to-axle nuts is 63
Nm (46 lb- ft). VERIFY the
torque for the shock damper- to-
rail bracket nuts is 90 Nm (66
lb- ft). Do not over torque.
TIGHTEN as necessary.
z Squeak or rattle—
heard inside the
vehicle over rough
roads/bumps z
Misaligned glove
compartment
door/hinge. z
ALIGN the glove compartment
door.
z Instrument panel
trim loose or z
INSPECT the instrument panel
trim for missing or loose clips or Klj . 32 ba
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B1405 Driver Power Window Down
Circuit Short to Battery GEM REFER to
Section 501 - 11 .
B1408 Driver Power Window Up
Circuit Short to Battery GEM REFER to
Section 501 - 11 .
B1410 Driver Power Window Motor
Circuit Failure GEM REFER to
Section 501 - 11 .
B1426 Lamp Safety Belt Circuit Short
to Battery GEM REFER to
Section 413 - 01 .
B1428 Lamp Safety Belt Circuit Failure GEM REFER to
Section 413 - 01 .
B1431 Wiper Brake/Run Relay Circuit
Failure GEM REFER to
Section 501 - 16 .
B1432 Wiper Brake/Run Relay Circuit
Short to Battery GEM REFER to
Section 501 - 16 .
B1434 Wiper Hi/Low Speed Relay Coil
Circuit Failure GEM REFER to
Section 501 - 16 .
B1436 Wiper Hi/Low Speed Relay Coil
Circuit Short to Battery GEM REFER to
Section 501 - 16 .
B1438 Wiper Mode Select Switch
Circuit Failure GEM REFER to
Section 501 - 16 .
B1441 Wiper Mode Select Switch
Circuit Short to Ground GEM REFER to
Section 501 - 16 .
B1446 Wiper Park Sense Circuit
Failure GEM REFER to
Section 501 - 16 .
B1448 Wiper Park Sense Circuit Short
to Battery GEM REFER to
Section 501 - 16 .
B1450 Wiper Wash/Delay Switch
Circuit Failure GEM REFER to
Section 501 - 16 .
B1453 Wiper Wash/Delay Switch
Circuit Short to Ground GEM REFER to
Section 501 - 16 .
B1458 Wiper Washer Pump Motor
Relay Circuit Failure GEM REFER to
Section 501 - 16 .
B1460 Wiper Washer Pump Motor
Relay Coil Circuit Short to Battery GEM REFER to
Section 501 - 16 .
B1462 Safety Belt Switch Circuit
Failure GEM REFER to
Section 413 - 09 .
B1466 Wiper Hi/Low Speed Not
Switching GEM REFER to
Section 501 - 16 .
B1473 Wiper Low Speed Circuit Motor
Failure GEM REFER to
Section 501 - 16 .
B1476 Wiper High Speed Circuit Motor
Failure GEM REFER to
Section 501 - 16 .
B1551 Decklid Release Circuit Failure GEM REFER to
Section 501 - 14B .
B1553 Decklid Release Circuit Short
to Battery GEM REFER to
Section 501 - 14B .
B1555 Ignition Run/Start Circuit
Failure GEM GO to
Pinpoint Test D .
B1687 Lamp Dome Input Circuit Short
to Battery GEM REFER to
Section 417 - 02 .
B2486 LF Side Repeater Lamp Output GEM REFER to
Section 417 - 01 . Klj . 3 ba
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Component Tests
Drive Belt Noise/Flutter
Drive belt chirp occurs due to pulley misalignment or excessive pulley runout. It can be the result of a
damaged pulley or an incorrectly aligned pulley.
To correct, determine the area where the noise comes from. Check each of the pulleys in that area
with a straightedge to the crankshaft pulley, looking for accessory pulleys out of position in the fore/aft
direction or at an angle to the straightedge.
Drive belt squeal is an intermittent noise that occurs when the drive belt slips on a pulley during certain
conditions, such as: engine start up, rapid engine acceleration, or A/C clutch engagement.
Drive belt squeal can occur:
zif any of the accessories are damaged, have a worn or damaged bearing, internal torsional
resistance above normal. All accessories should be rotatable by hand in the unloaded condition.
If not, inspect the accessory.
z if fluid gets on the drive belt. This includes power steering fluid, engine coolant, engine oil or air
conditioning system lubricant. If fluid does get on the drive belt during service, clean the drive
belt with soap and water and thoroughly rinse with clean water.
z NOTE: The drive belt tensioner arm should rotate freely without binding.
if the drive belt is too long. A drive belt that is too long will allow the drive belt tensioner arm to
go all the way to the arm travel stop under certain load conditions, which will release tension to
the drive belt. If the drive belt tensioner indicator is outside the installation wear range window,
install a new drive belt.
z if the drive belt tensioner is worn or damaged.
Belt Tension
NOTE: Drive belt tension is not adjustable.
The drive belt tensioner automatically adjusts drive belt tension. Symptom Chart Condition
Possible Sources Action
z Drive belt
noise, chirping,
flutter z
Defective/worn drive
belt.
z Misaligned pulley.
z Pulley runout.
z Damaged
accessories.
z Fluid contamination
of drive belt. z
GO to Component Tests, Drive
Belt, Noise/Flutter.
z Damaged or worn
drive belt tensioner. z
GO to Component Tests, Belt
Tensioner, Automatic.
z Premature
drive belt wear z
Defective drive belt.
z Misaligned pulley.
z Pulley runout.
z Damaged
accessories.
z Incorrectly installed
drive belt. z
GO to Component Tests, Drive
Belt Noise/Flutter and Drive
Belt Misalignment diagnosis. Klj . 2 ba
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System Air Flow Description
MAX A/C
When MAX A/C is selected:
zThe air inlet door vacuum control motor is at full vacuum, closing off outside air and admitting
only recirculated air.
z The panel/defrost door vacuum control motor is at full vacuum and the panel/floor door vacuum
control motor is at no vacuum, directing airflow to the instrument panel A/C registers. A small
amount of airflow from the side window demisters will be present.
z Blended air temperature is available.
z The A/C compressor will operate if the outside temperature is above approximately 6°C (43°F).
z The blower motor is on.
NORM A/C
When NORM A/C is selected:
zThe air inlet door vacuum control motor is at no vacuum, admitting only outside air into the
passenger compartment. 9 19D990 A/C evaporator core orifice
10 19860 A/C evaporator core
11 — Low pressure vapor
12 — High pressure vapor
13 — Low pressure liquid
14 — High pressure liquid Klj . 6 ba
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z
The panel/defrost door vacuum control motor is at full vacuum and the panel/floor door vacuum
control motor is at no vacuum, directing airflow to the instrument panel A/C registers. A small
amount of airflow from the side window demisters will be present.
z Blended air temperature is available.
z The A/C compressor will operate if the outside air temperature is above approximately 6°C (43°
F).
z The blower motor is on.
PANEL
When PANEL is selected:
zThe air inlet door vacuum control motor is at no vacuum, admitting only outside air into the
passenger compartment.
z The panel/defrost door vacuum control motor is at full vacuum and the panel/floor door vacuum
control motor is at no vacuum, directing airflow to the instrument panel A/C registers. A small
amount of airflow from the side window demisters will be present.
z The temperature can be adjusted to heat the air, but the air cannot be cooled below the outside
temperature.
z The A/C compressor will not operate.
z The blower motor is on.
OFF
When OFF is selected:
zThe air inlet door vacuum control motor is at full vacuum, closing off outside air from entering
the passenger compartment.
z The panel/floor door vacuum control motor is at full vacuum and the panel/defrost door vacuum Klj . 7 ba
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control motor is at no vacuum, closing off airflow to the defrost duct, side window demisters,
floor duct and instrument panel A/C registers.
z The A/C compressor will not operate.
z The blower motor is off.
FLOOR
When FLOOR is selected:
zThe air inlet door vacuum control motor is at no vacuum, admitting only outside air into the
passenger compartment.
z The panel/floor door vacuum control motor is at full vacuum and the panel/defrost door vacuum
control motor is at no vacuum, directing airflow to the floor duct. A small amount of airflow from
the side window demisters will be present.
z The temperature can be adjusted to heat the air, but the air cannot be cooled below the outside
temperature.
z The A/C compressor will not operate.
z The blower motor is on.
FLOOR/DEFROST
When FLOOR/DEFROST is selected:
zThe air inlet door vacuum control motor is at no vacuum, admitting only outside air into the
passenger compartment.
z The panel/floor door vacuum control motor is at partial vacuum and the panel/defrost door
vacuum control motor is at no vacuum, directing airflow to the floor duct, the defroster duct, and
the side window demisters.
z The temperature can be adjusted to heat or cool the air below the outside temperature. Klj . 8 ba
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z
The A/C compressor will operate if the outside air temperature is above approximately 6°C (43°
F).
z The blower motor is on.
DEFROST
When DEFROST is selected:
zThe air inlet door vacuum control motor is at no vacuum, admitting only outside air into the
passenger compartment.
z The panel/floor door and panel/defrost door vacuum control motors are at no vacuum, directing
airflow to the defroster duct and the side window demisters.
z The temperature can be adjusted to heat or cool the air below the outside temperature.
z The A/C compressor will operate if the outside air temperature is above approximately 6°C (43°
F).
z The blower motor is on. Electrical Components Klj . 9 ba
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Item Part Number Description
1 18A318 Vacuum control motor, panel/defrost door
2 18A478 Panel/defrost door (full vacuum position)
3 — Defrost airflow
4 — Side window demister airflow
5 18B545 Temperature blend door (full heat position)
6 19860 A/C evaporator core
7 19A813 Air inlet door (full vacuum position)
8 — Outside air inlet
9 18A318 Vacuum control motor—
air inlet door 10 — Recirculated air inlet
11 19805 Blower motor
12 — Vacuum from the engine intake manifold
13 19A563 A/C vacuum check valve
14 19A566 A/C vacuum reservoir tank and bracket
15 19B888 A/C-
heater function selector switch Klj . 3 ba
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