cooling FORD MUSTANG 2003 Workshop Manual

CAUTION: The use of any other type of transmission fluid than specified could result in
transmission failure.
If fluid needs to be added, add fluid in 0.25L (1/2 pint) increments through the filler tube. Do not overfill
the fluid. For fluid type, refer to the specification chart.
Fluid Condition Check
1. Check the fluid level.
2. Observe the color and the odor. The color under normal circumstances should be dark reddish, not brown or black or have a burnt odor.
3. Hold the fluid level indicator over a white facial tissue and allow the fluid to drip onto the facial tissue and examine the stain.
4. If evidence of solid material is found, the transmission fluid pan should be removed for further inspection.
5. If the stain is a foamy pink color this may indicate coolant in the transmission. The engine cooling system should also be inspected at this time.
6. If fluid contamination or transmission failure is confirmed by the sediment in the bottom of the fluid pan, the transmission must be disassembled and completely cleaned. This includes the
torque converter and cooler tubes. The oil- to-air cooler will need to be installed.
7. Carry out diagnostic checks and adjustments. Refer to Diagnosis By Symptom in this section. Klj . 3 ba
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following areas of possible leakage should also be checked to determine if engine oil leakage is
causing the concern.
a. Leakage at the engine valve cover gasket may allow oil to flow over the torque converter housing or seep down between the torque converter housing and cylinder block causing oil to
be present in or at the bottom of the torque converter housing.
b. Oil galley plug leaks will allow oil to flow down the rear face of the cylinder block to the bottom of the torque converter housing.
c. Leakage at the crankshaft rear oil seal will work back to the flexplate, and then into the torque converter housing.
d. Leakage at engine oil pressure sensor.
Leak Check Test 1. Remove the fluid level indicator and note the color of the fluid. Original factory fill fluid is dyed red to aid in determining if leakage is from the engine or transmission. Unless a considerable
amount of makeup fluid has been added or the fluid has been changed, the red color should
assist in pinpointing the leak.
2. Remove the torque converter housing cover. Clean off any fluid from the top and bottom of the torque converter housing, front of the case and rear face of the engine and oil pan. Clean the
torque converter area by washing with a suitable nonflammable solvent and blow dry with
compressed air.
3. Wash out the torque converter housing, the front of the flexplate and the converter drain plugs. The torque converter housing may be washed out using cleaning solvent and a squirt- type oil
can. Blow all washed areas dry with compressed air.
4. Start and run the engine until the transmission reaches its normal operating temperature. Observe the back of the cylinder block and top of the torque converter housing for evidence of
fluid leakage. Raise the vehicle on a hoist; refer to Section 100 - 02 and run the engine at fast
idle, then at engine idle, occasionally shifting to the Overdrive and Reverse ranges to increase
pressure within the transmission. Observe the front of the flexplate, back of the cylinder block
(in as far as possible), and inside the torque converter housing and front of the case. Run the
engine until fluid leakage is evident and the probable source of leakage can be determined.
Leak Check Test With Black Light Used With 12 Volt Master UV Diagnostic Inspection Kit
Oil soluble aniline or fluorescent dyes premixed at the rate of 2.5ml (1/2 teaspoon) of dye powder to
0.235L (1/2 pint) of transmission fluid have proved helpful in locating the source of fluid leakage. Such
dyes may be used to determine whether an engine oil or transmission fluid leak is present, or if the
fluid in the fluid cooler leaks into the engine cooling system. A black light must be used with the
fluorescent dye solution. Klj . 4 ba
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DIAGNOSIS AND TESTING
Transmission Fluid Cooler
CAUTION: Whenever a transmission has been disassembled to install new parts, the
cooler bypass valve (CBV), all transmission fluid coolers (in tank and auxiliary) and
transmission fluid cooler lines must be cleaned and backflushed. Use a suitable the torque
converter/fluid cooler cleaner.
NOTE: Cleaning and backflushing the transmission fluid cooling system along with following all the
normal cleaning and inspection procedures in this section during disassembly and reassembly will
keep contamination from reentering the transmission and causing a repeat repair.
When internal wear or damage has occurred in the transmission, metal particles, clutch plate material,
or band material may have been carried into the torque converter and transmission fluid cooler. These
contaminants are a major cause of recurring transmission troubles and must be removed from the
system before the transmission is put back into use.
Transmission Fluid Cooler Flow Test
NOTE: The transmission linkage/cable adjustment, fluid level and line pressure must be within
specification before carrying out this test. Refer to Section 307 - 05 for adjustments.
1. Remove fluid level indicator from fluid filler tube.
2. Place funnel in fluid filler tube.
3. Position the vehicle on a hoist. For additional information, refer to Section 100 - 02 .
4. Remove the cooler return line (top fitting) from the fitting on the transmission case.
5. Connect one end of a hose to the cooler return line and route other end of the hose up to a point where it can be inserted into the funnel at the fluid filler tube.
6. Remove the safety stands and lower the vehicle. Insert end of hose into the funnel.
7. Start the engine and run it at idle with the transmission in NEUTRAL.
8. When fluid flows from the hose in a steady stream, a liberal amount of fluid should be observed. "Liberal" is about 1 liter (1 quart) delivered in 15 seconds. If a liberal flow is observed, the test is
complete.
9. If the flow is not liberal, stop the engine. Disconnect the hose from the cooler return line and connect it to the converter outlet fitting (bottom fitting) on the transmission case.
10. Repeat steps 6 and 7. If flow is now approximately 1 liter (1 quart) in 15 seconds, refer to Transmission Fluid Cooler — Backflushing and Cleaning in this section. If the flow is still not
approximately 1 liter (1 quart) in 15 seconds, repair or install pump and or converter.
For the installation of new transmission fluid cooler or tubes, refer to Section 307 - 02 .
SECTION 307-
01: Automatic Transaxle/Transmission 2003 Mustang Workshop Manual Klj . 1 ba
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Shift Linkage, Digital TR Sensor
·
Damaged or incorrectly adjusted ·
Inspect and repair as required. Verify transmission shift
cable adjustment; refer to Section 307 - 05 . Adjust
transmission shift cable as necessary. After repairing
transmission shift cable, verify that the digital TR sensor
is correctly adjusted. Adjust the digital TR sensor as
necessary. Park Mechanism
·
Output shaft ring, parking brake pawl,
parking pawl return spring, park rod
guide cup, parking pawl shaft,
parking pawl actuating rod, manual
lever detent spring damaged or
assembled incorrectly ·
Inspect for damage or incorrect assembly and repair as
required.
Other Concerns: Overheating Possible Component Reference/Action
257 —
ELECTRICAL ROUTINE Refer to Routine 240/340, Torque Converter Operation Concern: No Apply
357 —
HYDRAULIC/MECHANICAL ROUTINE Fluid
·
Incorrect level ·
Adjust fluid to correct level. ·
Condition ·
Inspect condition of fluid. Other
·
Damaged, blocked or reversed cooler lines or
restriction in the transmission oil cooler ·
Inspect for damage and correct
installation. Repair as required. Vehicle Concerns Causing Engine Overheating
·
Refer to the appropriate engine
cooling section. Main Controls
·
Drain back valve, torque clutch control valve, converter
limit valve stuck, damaged or assembled incorrectly ·
Inspect for damage and repair as
required. Torque Converter Clutch
·
No apply ·
Refer to Routine 240/340. Klj . 30 ba
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DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES
Torque Converter Cleaning And Inspection
1. If a new torque converter is being installed, continue with Substep 2 of Step 2.
2. If a new torque converter is not being installed, the following procedures must be performed: 1. The torque converter must be thoroughly cleaned.
„Torque converters with drain plugs can be cleaned by using a suitable torque
converter/fluid cooler cleaner.
„ Torque converters without drain plugs can be cleaned by hand. Partially fill the
torque converter using only recommended transmission fluid for the applicable
transmission. Hand agitate the torque converter and then thoroughly drain the
fluid. Refill the torque converter with clean automatic transmission fluid specified
for transmission, and reinstall.
2. All in- tank and auxiliary coolers must be thoroughly cleaned by forward and backward
flushing. For additional information, refer to Transmission Fluid Cooler — Backflushing
and Cleaning in this section.
3. All cooler lines must be thoroughly cleaned by backward and forward flushing. For additional information, refer to Transmission Fluid Cooler — Backflushing and Cleaning
in this section.
4. All Cooler Bypass Valves (CBV), if equipped, must be thoroughly cleaned.
5. Carry out the Transmission Fluid Cooler Flow Test. For additional information, refer to
Transmission Fluid Cooler — Backflushing and Cleaning in this section.
6. If the transmission cooling system fails the Transmission Fluid Cooler Flow Test, a new fluid cooler, cooler bypass valve, and/or cooler lines must be installed. For additional
information, refer to Section 307 - 02 .
7. If new coolers are to be installed, use only factory approved service parts.
SECTION 307-
01: Automatic Transaxle/Transmission 2003 Mustang Workshop Manual Material
Item Specification
MERCON® V Automatic
Transmission Fluid
XT
-5-QM, XT -5-DM MERCON® V Klj . 1 ba
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SPECIFICATIONS
SECTION 307-
02: Transaxle/Transmission Cooling 2003 Mustang Workshop Manual General Specifications
Item Specification
Fluid
MERCON® V Automatic Transmission Fluid XT
-5-QM MERCON® V
Torque Specifications Description Nm lb-
ft Fluid cooler tube nut at radiator 32 24
Cooler line bracket to engine nut 48 35
Fluid cooler tube nut at transmission 21 15 Klj . 1 ba
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DESCRIPTION AND OPERATION
Transmission Cooling —
Integral
This vehicle with an automatic transmission is equipped with an integral transmission fluid cooler. The
cooler is contained inside of the radiator outlet tank and cannot be serviced separately. The cooler
transfers heat from the transmission fluid to the engine coolant.
For transmission fluid cooler flow test, refer to Section 307 - 01 .
For transmmission fluid cooler backflushing and cleaning, refer to Section 307 - 01 .
Transmission Fluid Cooler Tubes SECTION 307-
02: Transaxle/Transmission Cooling 2003 Mustang Workshop Manual Item Part Number Description
1 — Fluid cooler inlet tube
2 — Fluid cooler outlet tube
3 7005 Transmission case
4 — Transmission case fittings Klj . 1 ba
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DIAGNOSIS AND TESTING
Transmission Cooling
Inspection and Verification
WARNING: Never remove the radiator cap under any conditions while the engine is
operating. Failure to follow these instructions could result in personal injury and/or damage to
the cooling system or engine. To avoid having scalding hot coolant or steam blow out of the
radiator, use extreme care when removing the radiator cap from a hot radiator. Wait until the
engine has cooled, then wrap a thick cloth around the radiator cap and turn it slowly to the first
stop. Step back while the pressure is released from the cooling system. When you are certain
all the pressure has been released, press down on the radiator cap (with a cloth), turn and
remove.
The transmission fluid cooler is integral to the radiator (8005). Whenever leaks or damage to the
radiator are found, install an entire new radiator. For additional information, refer to Section 303 - 03A or
Section 303 - 03B .
Symptom Chart SECTION 307-
02: Transaxle/Transmission Cooling 2003 Mustang Workshop Manual SYMPTOM CHART
Condition
Possible Sources Action
z Transmission
Overheating z
Damaged radiator. zREPAIR or install a new
radiator. For additional
information, REFER to
Section 303 - 03A or
Section 303 - 03B .
z System leaks. zINSPECT for leaks. REPAIR
as necessary.
z Incorrect fluid level. zADJUST to proper level.
z Fluid condition. zINSPECT according to
instructions under Fluid
Condition Check. REFER to
Section 307 - 01 .
z Damaged, blocked,
reversed, leaking or
restricted cooler lines
or cooler tubes. z
INSPECT cooler lines and
tubes. REPAIR or flush as
necessary.
z Engine concerns
causing transmission
to overheat. z
INSPECT engine cooling
system. For additional
information, REFER to
Section 303 - 03A or
Section 303 - 03B .
z Excessive towing
loads. z
CHECK gross vehicle weight.
z Incorrect idle or
performance. z
REFER to the Powertrain
Control/Emissions Diagnosis
(PC/ED) manual. Klj . 1 ba
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REMOVAL AND INSTALLATION
Transmission Fluid Cooler Tubes
Removal
1. Disconnect the battery cables.
2. Raise and support the vehicle. For additional information, refer to Section 100 - 02 .
3. Remove the nuts.
4. Remove the fluid cooler tube bracket at the engine.
5. NOTE: Use a backup wrench to hold the case fitting secure.
Remove the fluid cooler tubes at the transmission. Installation SECTION 307-
02: Transaxle/Transmission Cooling 2003 Mustang Workshop Manual Klj . 1 ba
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z
Refrigerant R- 134a must not be mixed with air for leak testing or used with air for any
other purpose above atmospheric pressure. R- 134a is combustible when mixed with high
concentrations of air and higher pressures.
z A number of manufacturers are producing alternative refrigerant products that are
designed to be used instead of R- 134a refrigerant. The use of any unauthorized
substitute refrigerant can severely damage the A/C components. If repair is required, use
only new or recycled refrigerant R- 134a.
CAUTION: To avoid contamination of the A/C system, always observe the following:
z Keep service tools and the work area clean.
z Never open or loosen a connection before discharging the system.
z When loosening a connection, if any residual pressure is evident, allow it to leak out
before opening the fitting.
z Evacuate a system that has been opened to install a new component or one that has
been discharged through leakage before charging.
z Seal an open fitting with a cap or plug immediately after disconnecting a component
from the system.
z Clean the outside of the fittings thoroughly before disconnecting a component from the
system.
z Do not remove the sealing caps from a new component until ready to install.
z Refrigerant oil will absorb moisture from the atmosphere if left uncapped. Do not open
an oil container until ready to use, and install the cap immediately after using. Store the
oil in a clean, moisture- free container.
z Install a new O- ring seal before connecting an open fitting. Coat the fitting and the O- ring
seal with refrigerant oil before connecting.
z When installing a refrigerant line, avoid sharp bends. Position the line away from the
exhaust or any sharp edges that can chafe the line.
z Do not open a refrigerant system or uncap a new component unless it is as close as
possible to room temperature. This will prevent condensation from forming inside a
component that is cooler than the surrounding air.
The manual climate control system heats or cools the vehicle depending on the function selector
switch position and the temperature selected.
zThe function selector switch position determines heating or cooling and air distribution.
z The temperature control setting determines the air temperature.
z The heater blower motor switch (18578) varies the blower motor speed.
Principles of Operation
There are four main principles involved with the basic theory of operation:
zheat transfer
z latent heat of vaporization
z relative humidity
z effects of pressure Heat Transfer Klj . 2 ba
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