wiring FORD MUSTANG 2003 Workshop Manual

z
No contact with side
glass. z
ADJUST the door glass.
z No contact with glass
runs at both ends of
belt line seal. z
ADJUST the belt line seal
or ADD foam at the seal
ends.
z Belt line seal damaged. zINSTALL a new seal.
z Air leak at outer
belt line z
Belt line seal installed
incorrectly on flange
(no glass contact). z
ADJUST the seal.
z Belt line seal does not
contact the glass. z
ADJUST the door glass.
z No contact with glass
runs at both ends of
belt line seal. z
ADJUST the belt line
seal/ADD foam at the seal
ends.
z Belt line seal damaged. zINSTALL a new seal.
z Draft at inner
door
handle/speaker
opening z
Hole in watershield. zSEAL the hole with a
suitable tape.
z Watershield
misaligned. z
REALIGN the watershield.
INSTALL a new
watershield if the pressure
sensitive adhesive fails.
z Exterior door handle
seal
misaligned/damaged. z
REALIGN or INSTALL a
new seal as necessary.
z Wind noise from
side view mirror z
Outside mirror housing
misaligned. z
REALIGN with the edges
shingled correctly and no
gaps.
z Mirror sail gasket
folded/misaligned. z
REINSTALL with the
gasket unfolded and
aligned correctly.
z Mirror housing trim cap
installed incorrectly. z
REINSTALL with the
edges shingled to the air
flow.
z Air leak through mirror
housing hinge. z
Fully ENGAGE the mirror
into its operating
position/USE foam to
block the air path through
the hinge.
z Inner sail trim installed
incorrectly. z
REINSTALL the sail
trim/ADJUST the door
trim.
z Inner sail gasket/barrier
installed incorrectly. z
REINSTALL the trim
cover with the
gasket/barrier aligned
correctly.
z Air path through wiring
bundle/fastener access
holes. z
BLOCK the air path(s)
with foam/tape.
z Exposed fastener
access hole on mirror
housing/sail. z
INSTALL a new cap if it is
missing.
z Air leak around
perimeter of fixed z
Gaps in the sealant
bead. z
APPLY approved sealant. Klj . 13 ba
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port. DISCARD the leaking
parts, and INSTALL a new
component.
z Vehicles with a
plastic intake
manifold. z
Acceptable condition. Some
plastic manifolds exhibit this
noise, which is the effect of
the plastic manifold.
z Automatic
transmission buzz or
hiss z
Incorrect
driveline
angles. z
CHECK for correct driveline
angles. REPAIR as
necessary. REFER to
Section 205 - 00 .
z Worn or
damaged main
control
solenoids or
valves. z
Using a transmission tester,
activate the solenoids to
duplicate sound. INSTALL
new components as
necessary. REFER to
Section 307 - 01 .
z Manual Transmission
Clutch throw- out
bearing whine. A
change in noise pitch
or loudness while
depressing the clutch
pedal z
Worn throw- out
bearing. z
INSTALL a new throw- out
bearing. REFER to Section 308 - 01 .
z Heating, vacuum and
air conditioning
(HVAC) system chirp
— most audible inside
the vehicle. Listen for
a change in noise
pitch or loudness
while changing the
HVAC system blower
speed z
Damaged or
worn HVAC
blower bearing. z
INSTALL a new blower
motor. REFER to Section 412 - 02 .
z Air conditioning (A/C)
clutch ticking —
occurs when the
compressor clutch
engages z
Acceptable
noise.
z Incorrect air
gap. z
LISTEN to the clutch to
determine if the noise occurs
with clutch engagement. A
small amount of noise is
acceptable. If the noise is
excessive, CHECK the A/C
clutch air gap. INSPECT the
A/C clutch for wear or
damage. INSTALL a new
clutch as necessary. REFER
to Section 412 - 03 .
z Intermittent rattle, or
scraping/rubbing
noise z
Loose exhaust
heat shield(s). z
INSPECT the exhaust
system for loose parts using
a glove or clamps to verify
cause. REPAIR as
necessary. REFER to
Section 309 - 00 .
z Wiring, hose or
other part
interfering with
accessory drive
belt or pulley. z
INSPECT accessory drive
system closely verifying
there is adequate clearance
to all rotating components.
REPAIR as necessary.
z Engine ticking or
knocking noise —
occurs during idle or z
Piston noise or
valvetrain noise
(bled down z
Go To Pinpoint Test G . Klj . 30 ba
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Pinpoint Tests
The pinpoint tests are a step-by-
step diagnostic process designed to determine the cause of a z
Bump—occurs
when shifting
from PARK to
a drive or
reverse
position.
Similar to
Clunk but with
no sound z
Initial gear
engagement. z
Acceptable condition.
z Buzz or hiss zIncorrect driveline
angles. z
CHECK for correct driveline
angles. REPAIR as
necessary. REFER to Section 205 - 00 .
z Worn or damaged
main control
solenoids or valves. z
Using a transmission tester,
ACTIVATE the solenoids to
duplicate sound. INSTALL
new components as
necessary. REFER to Section 307 - 01 .
z Vibration— a
high frequency
(20–80 Hz) that
is felt through
the seat or
gear shifter.
Changes with
engine speed z
Transmission cooler
lines grounded out. z
CHECK the transmission
cooler lines. REPAIR as
necessary.
z Flexplate to torque
converter nuts loose. z
CHECK the flexplate nuts.
TIGHTEN to specification.
REFER to Section 307 - 01 .
z Fluid filler tube
grounded out. z
CHECK the fluid filler tube.
REPAIR as necessary.
z Shift cable incorrectly
routed, grounded out
or loose. z
CHECK the shift cable.
REPAIR as necessary.
Section 307 - 05 .
z Shutter or
chatter—
occurs with
light to medium
acceleration
from low
speeds or a
stop z
Electrical
inputs/outputs.
z Vehicle wiring
harness.
z Incorrect
inputs/outputs from
the powertrain control
module (PCM), digital
transmission range
(TR) sensor, brake
pedal position (BPP)
sensor, throttle
position (TP) sensor,
transmission speed
sensor (TSS), output
speed shaft (OSS)
sensor or the torque
converter clutch
(TCC). z
CARRY OUT a Torque
Converter Clutch Operation
Test. RUN on- board
diagnostics or self- test.
REFER to Section 307 - 01 .
CLEAR the DTC's, ROAD
TEST and RERUN on- board
diagnostics or self- test. Klj . 47 ba
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DIAGNOSIS AND TESTING
Brake System
Refer to Wiring Diagrams Cell
60 , Instrument Cluster for schematic and connector information.
Refer to Wiring Diagrams Cell 97 , Daytime Running Lamps for schematic and connector information.
Inspection and Verification WARNING: Use of any other than the approved DOT 3 brake fluid will cause permanent
damage to brake components and will render the brakes inoperative.
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: Do not spill brake fluid onto painted surfaces. If spilled, wipe up immediately.
NOTE: Always check the fluid level in the brake master cylinder reservoir (2K478) before performing
the test procedures. If the fluid level is not at the correct level, add High Performance DOT 3 Brake
Fluid C6AZ- 19542-AB or equivalent DOT 3 fluid meeting Ford specification ESA- M6C25-A.
NOTE: Prior to performing any diagnosis, make sure the brake warning indicator is functional. For
additional information, refer to Section 413 - 01 .
The first indication that something may be wrong in the brake system is a change in the feeling through
the brake pedal (2455). The brake warning indicator in the instrument cluster and the brake fluid level SECTION 206-
00: Brake System — General Information 2003 Mustang Workshop Manual Special Tool(s)
73 Digital Multimeter
105-
R0051 or Equivalent ABS Brake and Pressure Test
Kit
107-
02350 or Equivalent Tire and Wheel Runout Gauge
Set
134-
00199 or Equivalent Klj . 1 ba
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in the brake master cylinder reservoir are also indicators of system concerns.
If a wheel is locked and the vehicle must be moved, open a bleeder screw at the locked wheel (1007)
to let out enough fluid to relieve the pressure. Close the bleeder screw. This bleeding operation may
release the brakes but will not correct the cause of trouble. If this does not relieve the locked wheel
condition, repair the locked components before proceeding.
Inspect all hoses and connections. All unused vacuum connectors should be capped. Make sure
hoses and their connections are correctly secured and in good condition with no holes, soft or
collapsed areas.
Non-
Pressure Leaks
The only part of the brake system that could have a brake fluid loss that does not appear when the
system is under pressure is the brake master cylinder reservoir area. Brake fluid loss can be caused
by a missing or poorly- fitted brake master cylinder filler cap (2162), a punctured or otherwise damaged
brake master cylinder reservoir, a missing or damaged brake master cylinder filler cap gasket, or by
missing, damaged or poorly- fitted sealing grommets between the brake master cylinder (2140) and the
brake master cylinder reservoir.
The brake master cylinder reservoir grommets are not separately serviceable and must be installed
new as part of a new brake master cylinder reservoir.
Install a new flexible brake hose if it shows signs of softening, cracking or other damage.
When installing a new brake hose, position the hose to avoid contact with other vehicle components.
Road Test
Perform a road test to compare actual vehicle braking performance with the performance standards
expected by the driver. The ability of the test driver to make valid comparisons and detect performance
deficiencies will depend on experience.
The driver should have a thorough knowledge of brake system operation and accepted general
performance guidelines in order to make good comparisons and detect performance problems.
Select a road that is reasonably smooth and level. Gravel or bumpy roads are not suitable because the
surface does not allow the tires to grip the road equally. Avoid crowned roads.
A key factor in evaluating brake concerns is the deceleration rate. This varies from vehicle to vehicle
and with changes in operating conditions. It is evident how well the brakes are working after just a few
applications.
Avoid locking the brakes. Locked brakes are not an indication of braking efficiency.
Visual Inspection Chart Mechanical Electrical
z
Brake master cylinder
z Brake caliper piston
z Brake discs
z Brake pads z
Parking brake switch
z Damaged or corroded wiring harness
z Brake master cylinder fluid level switch Klj . 2 ba
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DIAGNOSIS AND TESTING
Anti-
Lock Control
Refer to Wiring Diagrams Cell 42 , Anti-
Lock Brake for schematic and connector information.
Principles of Operation
The anti- lock brake control module receives wheel speed readings from each anti- lock brake sensor
and processes this information to determine if an ABS event is necessary. The anti- lock brake sensor
electrically senses each tooth of the anti- lock brake sensor indicators as it passes through the anti- lock
brake sensor's magnetic field.
The anti- lock brake control module continuously monitors and compares the rotational speed of each
wheel, and when it detects an impending wheel lock, modulates hydraulic brake pressure to the
appropriate brake caliper. This is accomplished by the anti- lock brake control module triggering the
hydraulic control unit (HCU) to open and close the appropriate solenoid valves. Once the affected
wheel returns to normal speed, the anti- lock brake control module returns the solenoid valves to their
normal position, and normal (base) braking resumes.
The anti- lock brake control module is self- monitoring. When the ignition switch is turned to the RUN
position, the anti- lock brake control module will do a preliminary electrical check, and at approximately
12 km/h (8 mph) the pump motor is turned on for approximately one half- second. Any malfunction of
the ABS will cause the ABS to shut off and the yellow ABS warning indicator to illuminate, however,
normal power assisted braking remains.
The ABS control module has the ability to store multiple DTCs in memory.
Inspection and Verification
1. Verify the customer concern by operating the system.
2. Visually inspect for obvious signs of mechanical and electrical damage.
SECTION 206-
09A: Anti-Lock Control — Rear 2003 Mustang Workshop Manual Special Tool(s)
Worldwide Diagnostic System
(WDS)
418-
F224,
New Generation STAR (NGS)
Tester
418- F052, or equivalent scan
tool 73 Digital Multimeter or
equivalent
105-
R0051 Klj . 1 ba
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Anti-Lock Brake Control Module Active Command Index
Symptom Chart ABSRF_I RF ABS Inlet Valve OFF---, OFFO--, OFF
-B-, OFF--G, OFFO- G, OFF-
BG, OFFOBG, ON---, ONO--, ON -B-, ON--G, ONO-
G, ON- BG, ONOBG ABSRF_O RF ABS Outlet Valve OFF---, OFFO--, OFF
-B-, OFF--G, OFFO- G, OFF-
BG, OFFOBG, ON---, ONO--, ON -B-, ON--G, ONO-
G, ON- BG, ONOBG ABSR_I Rear ABS Inlet Valve OFF---, OFFO--, OFF
-B-, OFF--G, OFFO- G, OFF-
BG, OFFOBG, ON---, ONO--, ON -B-, ON--G, ONO-
G, ON- BG, ONOBG ABSR_O Rear ABS Outlet Valve OFF---, OFFO--, OFF
-B-, OFF--G, OFFO- G, OFF-
BG, OFFOBG, ON---, ONO--, ON -B-, ON--G, ONO-
G, ON- BG, ONOBG
Anti-Lock Brake Control Module Active
Command Index Active Command Display Action
ABS OUTPUT CONTROL ABS POWER OFF, ON
DSBL TOG OFF, ON
LF INLET OFF, ON
LF OUTLET OFF, ON
RF INLET OFF, ON
RF OUTLET OFF, ON
R INLET OFF, ON
R OUTLET OFF, ON
Symptom Chart
NOTE: Refer to the Wiring Diagrams for connector numbers stated in the Pinpoint
tests. Condition
Possible Sources Action
z No communication with the anti-
lock brake control module z
CJB Fuse 29
(15A).
z Circuitry.
z Anti- lock brake
control module. z
Go To Pinpoint Test A .
z Unable to enter self- test. zAnti- lock brake
control module. z
Go To Pinpoint Test B .
z The yellow ABS warning
indicator does not self- check z
Circuitry.
z Anti- lock brake
control module.
z Instrument cluster. z
Go To Pinpoint Test J .
z Spongy brake pedal with no zAir in the brake zGo To Pinpoint Klj . 4 ba
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DIAGNOSIS AND TESTING
Anti-
Lock Control — Traction Control
Refer to Wiring Diagrams Cell 42 , Anti-
Lock Brake System for schematic and connector information.
Principles of Operation
The anti- lock-brake control module receives wheel speed readings from each anti- lock brake sensor
and processes this information to determine if an ABS event is necessary. The anti- lock brake sensor
electrically senses each tooth of the anti- lock brake sensor indicators as it passes through the anti- lock
brake sensor's magnetic field.
The anti- lock brake control module continuously monitors and compares the rotational speed of each
wheel and, when it detects an impending wheel lock, modulates brake pressure to the appropriate
brake caliper. This is accomplished by triggering the hydraulic control unit (HCU) to open and close the
appropriate solenoid valves. Once the affected wheel returns to normal speed, the anti- lock brake
control module returns the solenoid valves to their normal position, and normal (base) braking
resumes.
The anti- lock brake control module is self- monitoring. When the ignition switch is turned to the RUN
position, the anti- lock brake control module will do a preliminary electrical check, and at approximately
12 km/h (8 mph) the pump motor is turned on for approximately one half- second. Also during all
phases of operation the anti- lock brake control module (after the vehicle is in motion) checks for
correct operation of the anti- lock brake sensors. Any malfunction of the ABS will cause the ABS to shut
off and ABS warning indicator to illuminate; normal power assisted braking, however, remains.
The ABS control module has the ability to store multiple DTCs in memory.
The traction control system controls wheelspin by modulating the engine torque by communicating to
the powertrain control module (PCM) and by applying, then releasing, the appropriate brake to restore
traction when one or both drive wheels lose traction and begin to spin during acceleration.
The traction control system can be disabled by depressing the traction control switch. The traction
control system will reset and return to normal traction assist when the ignition switch is cycled or when
the traction control switch is depressed again. SECTION 206-
09B: Anti-Lock Control — Traction Control 2003 Mustang Workshop Manual Special Tool(s)
Worldwide Diagnostic System
(WDS)
418-
F224,
New Generation STAR (NGS)
Tester
418- F052, or equivalent scan
tool 73 Digital Multimeter or
equivalent
105-
R0051 Klj . 1 ba
202003 Mustang Workshop Manual
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Anti-Lock Brake Control Module Active Command Index
Symptom Chart Valve
RF_TC_S RF Traction Control Switching
Valve OFF, ON
LR_TC_S LR Traction Control Switching
Valve OFF, ON
RR_TC_S RR Traction Control Switching
Valve OFF, ON
T/ALVAL Left Traction Control Valve
Output State OFF---, OFFO--, OFF
-B-, OFF--G, OFFO- G, OFF-
BG, OFFOBG, ON---, ONO--, ON -B-, ON--G, ONO-
G, ON- BG, ONOBG T/ARVAL Right Traction Control Valve
Output State OFF---, OFFO--, OFF
-B-, OFF--G, OFFO- G, OFF-
BG, OFFOBG, ON---, ONO--, ON -B-, ON--G, ONO-
G, ON- BG, ONOBG
Anti-Lock Brake Control Module Active Command Index Active Command Display Action
ABS OUTPUT CONTROL ABS POWER OFF, ON
DSBL TOG OFF, ON
LF INLET OFF, ON
LF OUTLET OFF, ON
RF INLET OFF, ON
RF OUTLET OFF, ON
LR INLET OFF, ON
LR OUTLET OFF, ON
RR INLET OFF, ON
RR OUTLET OFF, ON
TRACTION CONTROL PRIMARY AND SWITCHING VALVE CONTROL LF TC PRV OFF, ON
LF TC SWV OFF, ON
RF TC PRV OFF, ON
RF TC SWV OFF, ON
LR TC PRV OFF, ON
LR TC SWV OFF, ON
RR TC PRV OFF, ON
RR TC SWV OFF, ON
Symptom Chart
NOTE: Refer to the wiring diagrams for connector numbers stated in the pinpoint Klj . 5 ba
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4 N805572-
S36 Air bag module retaining screws (2 req'd)
5 3L518 Steering wheel spoke cover
(2 req'd)
6 — Lock tabs
7 14A664 Clockspring
8 13318 Turn indicator cancel cam
9 3C610 Snap ring
10 3520 Bearing spring
11 3518 Upper bearing sleeve
12 3517 Upper bearing (small)
13 3517 Lower bearing (large)
14 3524 Shaft assembly
15 390345-
S36 Screw
16 13K359 Multi-
function switch 17 3E695 Lock cam
18 3F609 Tilt wheel handle
19 N806157 Lock cam pivot pin
20 3530 Lower shroud
21 55929 Shroud retaining screws
22 3D544 Release lever
23 3B661 Lock actuator lever (RH)
24 N805856 Lock actuator lever pin
25 3D653 Lock actuator lever (LH)
26 3B664 Lock lever spring (2 req'd)
27 14A099 Wiring shield
28 3D655 Lock lever spring return
29 3E715 Lock lever upper actuator
30 3E696 Lock spring (shaft)
31 11572 Ignition switch
32 N806423-
S56 Steering column mounting lower nuts
33 N806584 Screw
34 3E660 Mounting bracket
35 3D681 Bearing retaining
36 3518 Bearing sleeve
37 3517 Lower bearing
38 3L539 Lower bearing tolerance ring
39 3C131 Sensor ring
40 3520 Bearing spring
41 N808349 Bolt —
flange yoke 42 3N725 Coupling
43 3C611 Tube boot
44 3B676 Intermediate shaft Klj . 2 ba
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