pinpoint FORD MUSTANG 2003 Workshop Manual

·
No end clearance ·
Inspect converter and install a new or remanufactured torque
converter as required. ·
Piston plate damaged or stuck
to cover ·
If cover is heat- stained, install a new converter and determine
the cause of the overheat condition.
Torque Converter Clutch Operation Concerns: Cycling/Shudder/Chatter Possible Component Reference/Action
242 —
ELECTRICAL ROUTINE Powertrain Control System
·
Electrical inputs/outputs, vehicle
wiring harnesses, PCM, torque
converter clutch (TCC) solenoid,
OSS ·
Carry out Self-Test. Refer to the Powertrain
Control/Emissions Diagnosis (PC/ED) manual for
diagnosis and testing of the Powertrain Control System.
Go To Pinpoint Test E . Repair as required. Clear
DTCs, road test and repeat Self- Test. ·
Speed control equipped vehicles ·
Evaluate with speed control off. 342 —
HYDRAULIC/MECHANICAL ROUTINE Fluid
·
Condition ·
Inspect fluid condition. If burnt, drain fluid and converter.
Install a new fluid and filter assembly. Bring vehicle to
normal operating temperature. Carry out Transmission
Drive Cycle Test. Carry out Transmission Self- Test. If
condition still exists, continue diagnostics. Main Controls
·
Solenoid pressure regulator valve,
No. 7 check ball, bypass clutch
control valve and plunger, converter
pressure limit valve stuck, damaged
or assembled incorrectly ·
Inspect for damage. Repair as required. ·
Bolts not tightened to specifications ·
Tighten bolts to specifications. ·
Solenoid screen blocked or damaged ·
Clean or install a new screen. ·
TCC solenoid malfunction ·
Activate solenoid using scan tool. If solenoid operation
cannot be felt when placing hand on solenoid, install a
new solenoid. Inspect O- rings for damage. Repair as
required. ·
Gaskets damaged ·
Inspect for damage and install a new gasket. Pump Assembly
·
Bolts not tightened to specification ·
Tighten bolts to specification. ·
Porosity/cross leaks, missing balls or
leaking ·
Inspect for porosity/leaks or missing balls. Install a new
pump as required. ·
Gaskets damaged ·
Inspect for damage and install a new gasket. Input Shaft
·
Seals damaged ·
Inspect for damage. Repair as required. Torque Converter
·
Excessive end clearance ·
Inspect converter. Install a new or re- manufactured
torque converter as required.
Other Concerns: No Engine Braking In Manual 2nd Or Manual 1st Position Klj . 25 ba
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mechanism damaged
Main Controls
·
Manual valve stuck or
damaged ·
Inspect for damage. Repair as required. ·
Bolts not tightened to
specifications ·
Tighten bolts to specifications.
Other Concerns: External Leaks Possible Component Reference/Action
252 —
ELECTRICAL ROUTINE Powertrain Control System
·
Electrical inputs/outputs, sensor
seals leaking (digital TR, OSS,
vehicle speed sensor VSS, if
equipped, or transmission connector) ·
Inspect for leakage and repair as required. 352 —
HYDRAULIC/MECHANICAL ROUTINE Case
·
Case vent, case porosity, case
cracked ·
Check the vent for free breathing. Check the fluid level.
Check the transmission for overheat conditions. Repair
as required. Seals/Gaskets
·
Leakage at gaskets, seals, etc. (refer
to external sealing illustration for
potential leak locations) ·
Remove all traces of lubricant on exposed surfaces of
the transmission. Check the vent for free breathing.
Operate the transmission at normal temperatures and
perform fluid leakage check. Repair as required. Other
·
Cooler fitting, cooler lines pressure
tap, converter drain plug, band
anchor pins ·
Locate the source of the leak. Repair as required.
Other Concerns: Poor Vehicle Performance Possible Component Reference/Action
253 —
ELECTRICAL ROUTINE Powertrain Control System
·
Electrical inputs/outputs, vehicle
wiring harnesses, shift solenoids,
digital TR sensor, torque
converter clutch (TCC) solenoid,
transmission fluid temperature
(TFT) sensor ·
Carry out Self-Test. Refer to the Powertrain
Control/Emissions Diagnosis (PC/ED) manual for diagnosis
and testing of the Powertrain Control System. Go To Pinpoint Test A ,
Go To Pinpoint Test B or
Go To Pinpoint Test C . Repair as required. Clear codes, road test and
repeat Self- Test. Also refer to Routines 241/341 Torque
Converter Operation Concern: Always Applied. ·
Engine driveability concerns ·
Inspect air intake/air filter system. Check the fuel system
and fuel pressure. Refer to the Powertrain
Control/Emissions Diagnosis (PC/ED) manual. Inspect the
exhaust system for restriction. Refer to Section 309 - 00 .
353 —
HYDRAULIC/MECHANICAL ROUTINE Shift Linkage, Digital TR Sensor Klj . 27 ba
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12 o'clock position
„ Friction elements ·
3rd Gear:
„ Torque converter
„ Case to planet support spring
„ Friction elements ·
4th Gear:
„ Gear set
„ Friction elements
„ Torque converter ·
Reverse:
„ Gear set
„ Friction elements ·
Output shaft splines worn or damaged Other Noises/Vibrations
·
Main controls, valve resonance ·
Shift cable:
„ Vibration
„ Grounding
„ Cooler lines
„ Grounding ·
Locate source of disturbance and repair as
required.
Other Concerns: Engine Will Not Crank Possible Component Reference/Action
255 —
ELECTRICAL ROUTINE Powertrain Control System
·
Electrical inputs/outputs,
vehicle wiring harnesses,
engine starting system
hardware, digital TR sensor ·
Carry out Self- Test. Refer to the Powertrain Control/Emissions
Diagnosis (PC/ED) manual for diagnosis and testing of the
Powertrain Control System. Go To Pinpoint Test C . Repair and
adjust as required. 355 —
HYDRAULIC/MECHANICAL ROUTINE 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.
Other Concerns: No Park (P) Range Possible Component Reference/Action
256 —
ELECTRICAL ROUTINE ·
No Electrical Concerns 356 —
HYDRAULIC/MECHANICAL ROUTINE Klj . 29 ba
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DIAGNOSIS AND TESTING
External Controls
Refer to Wiring Diagrams Cell
37 , Shift Lock for schematic and connector information.
Refer to Wiring Diagrams Cell 29 , Transmission Control for schematic and connector information.
Inspection and Verification 1. Verify the customer concern by operating the transmission external control.
2. Visually inspect for obvious signs of mechanical and electrical damage; refer to the following chart:
3. If the concern is not visually evident, determine the symptom. GO to Symptom Chart .
Symptom Chart SECTION 307-
05: Automatic Transaxle/Transmission External Controls 2003 Mustang Workshop Manual Special Tool(s)
73 Digital Multimeter
105-
R0051 or equivalent
Visual Inspection Chart Mechanical Electrical
z
Shift control linkage binding.
z Shift lock actuator.
z Shift control cable.
z Interlock cable. z
Circuitry.
z Central junction box (CJB) fuse:
„17 (15A)
„ 28 (15A)
„ 35 (15A)
z Brake pedal position (BPP) switch.
z Wiring harness.
z Loose or corroded connections.
z Bulb.
SYMPTOM CHART Condition
Possible Sources Action
z The shift interlock
system does not
release/lock correctly z
Circuitry.
z CJB Fuse 17 (15A)
or Fuse 35 (15A).
z Shift lock actuator.
z Brake pedal position
(BPP) switch. z
Go To Pinpoint Test A . Klj . 1 ba
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Pinpoint Tests
PINPOINT TEST A: THE SHIFT INTERLOCK SYSTEM DOES NOT
RELEASE/LOCK CORRECTLY z
The shift control is
out of correct gear
relationship z
Transmission shift
cable and bracket.
z Retainer bracket.
z Shift control linkage
out of adjustment. z
Go To Pinpoint Test B .
z Transmission range
indicator does not
correspond to the
gear z
Transmission shift
cable bracket. z
TIGHTEN the bolts
holding transmission
shift cable bracket.
z Transmission shift
cable loose from the
transmission
retainer bracket. z
TIGHTEN the bolts.
z Shift linkage. zVERIFY digital
transmission range
(DTR) sensor range for
correct adjustment.
REFER to Section 307 -
01 .
z The Transmission
Control Switch (TCS)
Is Inoperative z
CJB Fuse 28 (15A).
z TCS.
z TCS not cycled
during self- test.
z Powertrain control
module (PCM).
z Circuitry. z
Go To Pinpoint Test C .
z The Transmission
Control Indicator
Lamp (TCIL) Is Not
Operating Correctly z
Bulb.
z Instrument cluster.
z Powertrain control
module. z
REFER to Section 413 -
01 .
z Excessive Shift Effort zTransmission shift
cable. z
INSTALL a new
transmission shift cable.
z Cable bracket. zADJUST the cable.
TIGHTEN the screws.
z Transmission Range
Selector Lever Will
Not Shift z
Transmission shift
cable. z
INSTALL a new
transmission shift cable.
z Broken transmission
shift cable. z
INSTALL a new
transmission shift cable. Test Step Result / Action to Take
A1 TEST THE BRAKE LIGHTS
z
Key in ON position.
z Apply the brake pedal and observe the stoplamps.
z Do the stoplamps illuminate? Yes
GO to
A2 .
No
REFER to Section 417 -Klj . 2 ba
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PINPOINT TEST B: THE SHIFT CONTROL IS OUT OF CORRECT
GEAR RELATIONSHIP 01 .
A2 CHECK CIRCUIT 511 (LG) FOR AN OPEN
z
Key in OFF position.
z Disconnect: Shift Lock Actuator C2127.
z Measure the voltage between the shift lock actuator C2127- 3,
Circuit 511 (LG), harness side and ground while depressing
and releasing the brake pedal.
z Is the voltage greater than 10 volts with the brake pedal
depressed and 0 volts with the brake pedal released? Yes
GO to
A3 .
No
REPAIR the circuit. TEST
the system for normal
operation. A3 CHECK CIRCUIT 294 (WH/LB) FOR AN OPEN
z
Key in ON position.
z Measure the voltage between shift lock actuator C2127- 1,
Circuit 294 (WH/LB), harness side and ground.
z Is the voltage greater than 10 volts? Yes
GO to
A4 .
No
REPAIR the circuit. TEST
the system for normal
operation. A4 TEST CIRCUIT 1205 (BK) FOR AN OPEN
z
Measure the resistance between shift lock actuator C2127- 2,
Circuit 1205 (BK), harness side and ground.
z Is the resistance less than 5 ohms? Yes
INSTALL a new shift lock
actuator. REFER to
Brake Shift Interlock Actuator .
TEST the system for
normal operation.
No
REPAIR the circuit. TEST
the system for normal
operation. Klj . 3 ba
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PINPOINT TEST C: THE TRANSMISSION CONTROL SWITCH (TCS)
IS INOPERATIVE Test Step Result / Action to Take
B1 CHECK THE SHIFT
CONTROL LINKAGE z
Key in ON position.
z Apply the brake pedal.
z Actuate the transmission
range selector lever in all
ranges.
z Observe the shift control
linkage during operation.
z Is the shift control linkage
OK? Yes
GO to
B2 .
No
REPAIR as necessary. TEST the system for normal
operation. B2 CHECK THE TRANSMISSION
SHIFT CABLE z
Check the transmission shift
cable and bracket installation
and tightness.
z Is the transmission shift
cable correctly installed
and adjusted? Yes
GO to
B3 .
No
REPAIR as necessary. TEST the system for normal
operation. B3 CHECK THE
LINKAGE/CABLE FOR CORRECT
GEAR RELATIONSHIP z
Apply the brake pedal.
z Actuate the transmission
range selector lever in all
ranges.
z Does the indicator match
the gear selection? Yes
VERIFY the correct adjustment of the digital transmission
range (DTR) sensor. REFER to
Section 307 - 01 . Adjust the
digital DTR sensor if necessary. TEST the system for
normal operation.
No
ADJUST the transmission shift cable. REFER to Cable Adjustment . TEST the system for normal operation.
Test Step Result / Action to Take
C1 CHECK THE VOLTAGE TO THE TRANSMISSION CONTROL
SWITCH z
Key in OFF position.
z Disconnect: Transmission Control Switch C279.
z Key in ON position.
z Measure the voltage between TCS C279- 3, Circuit 911
(WH/LG), harness side and ground. Yes
GO to
C2 .
No
REPAIR the circuit. TEST
the system for normal
operation. Klj . 4 ba
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DIAGNOSIS AND TESTING
Manual Transmission and Clutch
Inspection and Verification
It is important to get an accurate description of the concern before any diagnosis can be carried out.
Ask questions as to whether it occurs when hot or cold, during shifting, driving at a particular speed or
in a particular gear. If possible, have the customer demonstrate the concern.
zWith the vehicle at a complete stop, shift through all the gears and evaluate the noise at
different engine rpm. Check for any noises in NEUTRAL at different engine rpm.
Symptom Chart SECTION 308-
00: Manual Transaxle/Transmission and Clutch — General
Information 2003 Mustang Workshop
Manual Symptom Chart
Condition
Possible Sources Action
z Clutch slippage zClutch pedal
sticking.
z Pressure plate
diaphragm
spring damaged
or weakened.
z Clutch pressure
plate damaged.
z Clutch disc
facing damaged
or worn
excessively.
z Clutch disc
facing surface
hardened or oil-
coated.
z Clutch release
hub and bearing
binding.
z Flywheel glazed
or damaged.
z loose pressure
plate to flywheel
bolts z
Go To Pinpoint Test A .
z Clutch chatter or shudder zLoose or worn
engine mount.
z Loose pressure
plate to flywheel
bolts
z Oil on clutch
disc facing.
z Clutch pressure
plate damaged z
Go To Pinpoint Test B . Klj . 1 ba
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or excessive
runout.
z Clutch disc
facing surface
hardened or
damaged.
z Flywheel
surface glazed
or damaged.
z Transmission
input shaft
eccentric or not
perpendicular.
z Clutch drag zClutch drag.
z Cable release
linkage outside
the flywheel
housing worn,
cracked, bent.
z Excessive
runout or
damaged clutch
disc.
z Clutch disc
splines rusted or
worn.
z Loose pressure
plate to flywheel
bolts. z
Go To Pinpoint Test C .
z Clutch pedal pulsation zClutch disc
damaged or
worn.
z Excessive
flywheel runout.
z Loose pressure
plate to flywheel
bolts.
z Improperly
assembled
release lever to
pivot stud. z
Go To Pinpoint Test D .
z Clutch related vibrations zEngine
component
grounding
against frame.
z Loose flywheel
bolts.
z Excessive
flywheel runout.
z Imbalanced
clutch pressure
plate.
z Accessory drive
belt loose or
damaged. z
Go To Pinpoint Test E .
z Hard shifting zManual
transmission
concern.
z Loose pressure
plate to flywheel
bolts. z
Go To Pinpoint Test F . Klj . 2 ba
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z
Excessive noise zPilot bearing
worn or
damaged.
z Excessive
crankshaft end
play. z
Go To Pinpoint Test G .
z Transmission difficult to
shift z
Lubricant. zADD or DRAIN AND
FILL with specified
lubricant.
z Internal shift
mechanism. z
CHECK the internal shift
mechanism for smooth
operation. REPAIR or
INSTALL a new
mechanism as
necessary.
z Sliding gears,
synchronizers. z
CHECK for free
movement of gears and
synchronizers. REPAIR
or INSTALL new
components as
necessary.
z Housings, shaft. zCHECK for binding
condition between the
input shaft and the
engine crankshaft pilot
bearing or bushing.
REPAIR or INSTALL
new components as
necessary. REFER to
Section 308 - 03A or
Section 308 - 03B .
z Loose pressure
plate to flywheel
bolts. z
CHECK for loose bolts
at the pressure plate.
INSTALL new
components as
necessary. REFER to
Section 308 - 01 .
z NOTE: While verifying
the condition, determine
whether the noise is gear
rollover noise, release
bearing rub or some
other transmission-
related noise. Gear
rollover noise, inherent in
manual transmissions, is
caused by the constant
mesh gears turning at the
engine idle speed while
the clutch is engaged and
the transmission is in
NEUTRAL. Release
bearing rub is sometimes
mistaken for mainshaft
bearing noise. Gear
rollover noise will
disappear when the
clutch is disengaged or
when the transmission is
engaged in gear. z
Lubricant. zADD or DRAIN AND
FILL with specified
lubricant. Klj . 3 ba
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